Simulation of orthocyclic windings using the linear winding technique
Simulation of orthocyclic windings using the linear winding technique
复制标题
使用线性绕组技术模拟正循环绕组
DOI：
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发表时间：
2015
期刊：
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通讯作者：
J. Franke
中科院分区：
文献类型：
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作者：
J. Bonig;B. Bickel;M. Spahr;C. Fischer;J. Franke
自过去几年以来，德国的电动汽车许可数量不断增加。为了经济高效地生产一流质量和足够数量的电机，了解线圈绕制过程是必不可少的。因此，线行为的预测是关键挑战之一。因此，建立了一个详细的模型来研究线性缠绕过程中的线材行为。基于有限元的仿真工具 LS-DYNA 用作显式动力学工具。该工具采用显式时间积分方法来实现时间离散化。为了表示该模拟中缠绕的高动态过程，可以定义动态影响，例如线圈体的旋转速度或加速度。在过程模拟中，给定的边界条件应用于模型。线材的非线性材料特性通过拉伸测试和先前研究工作中数据表中的值进行严格验证。本文介绍了使用线性绕组技术的正交循环绕组的仿真结果。以导丝器后倾角为参考参数，通过实验验证了动态仿真模型。在第一层缠绕过程中主销倾角上升，直到钢丝跳到下一层。因此，可以确定最大后倾角并将模拟值与实验值进行匹配。导线器的行进轮廓被认为对于产生正循环缠绕极其重要。另一个重要部分是电线固定或几何形状，以支撑第一绕组从绕组一到绕组二的偏移。对线圈体表面有凹槽和没有凹槽的正循环绕组的结果进行了仿真，并证明了凹槽对准确的正循环绕组图像的积极影响。
A continuously rising number of electric vehicle licensing is mentioned since the last few years in Germany. For a cost-efficient production of electrical engines in first-class quality and in sufficient quantity, it is indispensable to understand the process of coil winding. Thereby, the prediction of wire behavior is one of the key challenges. Therefore, a detailed model is built to investigate wire behavior during the linear winding process. The finite element based simulation tool LS-DYNA serves as explicit dynamics tool. The tool works with an explicit time integration method for time discretization. To represent the high dynamic process of winding within this simulation, dynamic influences such as rotational speed or acceleration of the coil body are definable. Within process simulation, the given boundary conditions are applied to the model. The non-linear material properties of the wire are validated under scrutiny by a tensile test and by values out of datasheets in previous research work. Simulation results of orthocyclic windings using the linear winding technique are presented within this paper. The dynamic simulation model is validated by experiments using the caster angle of the wire guide as reference parameter. The caster angel rises during the winding process of the first layer until the wire jumps to the next layer. Hence, it is possible to identify the maximum caster angle and match the simulation value against the experiment value. The travel profile of the wire guide is identified as extremely important to generate an orthocyclic winding. Another substantial part is the wire fixation respectively the geometry to support the first winding offset from winding one to winding two. Results of orthocyclic windings are simulated with and without grooves on the coil body surface and demonstrate the positive influence of grooves for an accurate orthocyclic winding picture.