Development of a Production Process for Formed Litz Wire Stator Windings
Development of a Production Process for Formed Litz Wire Stator Windings
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成型利兹线定子绕组生产工艺的开发
DOI：
10.1109/edpc56367.2022.10019746
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发表时间：
2022
期刊：
影响因子：
--
通讯作者：
Sebastian Reising
中科院分区：
文献类型：
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作者：
Henrik Christoph Born;F. Blanc;Volkmar Platte;A. Kampker;H. Heimes;Benjamin Dorn;Florian Brans;David Drexler;Fabian Oehler;Andrea zu Münster;Sebastian Reising
在汽车电力牵引机领域，发夹定子技术已成为既定标准之一。它使用刚性实心矩形绝缘铜线而不是柔性圆形漆包线。由于槽填充系数高，该技术与产品方面的更高效率相关，并用确定性的自动化制造和装配工艺取代了工艺方面相当随机的缠绕工艺。然而，在电机的较高频率工作点，矩形铜线与高频利兹线相比处于劣势，因为交流损耗超过直流损耗。在此背景下，成型利兹线技术代表了电动机生产的下一个创新之一。起始材料是高频利兹线，经过异形、压缩和成型，以取代发夹定子生产中的矩形铜线。由于起始材料的变化，各个生产工艺的必要调整带来了挑战。本文描述了成形利兹线缠绕技术的一般工艺链以及生产中面临的挑战。
In the field of automotive electric traction machines, the hairpin stator technology has become one of the established standards. This uses rigid, solid rectangular insulated copper wires instead of flexible round enameled wires. This technology is associated with higher efficiencies on the product side due to high slot fill factors and replaces rather stochastic winding processes on the process side with deterministic automated manufacturing and assembly processes. At higher-frequency operating points of electrical machines, however, rectangular copper wires are at a disadvantage compared with high frequency litz wires, because the AC losses are exceeding the DC losses. Against this background, the formed litz wire technology represents one of the next innovations in electric motor production. The starting material is a high frequency litz wire, which is profiled, compressed and afterwards formed to replace rectangular copper wires in hairpin stator production. From the changed starting material, challenges arise from the necessary adaptation of the individual production processes. This paper describes a general process chain of formed litz wire winding technology and the deriving challenges in production.