Explicit dynamics process simulation of linear coil winding for electric drives production
Explicit dynamics process simulation of linear coil winding for electric drives production
复制标题
用于电驱动生产的线性线圈绕组的显式动力学过程仿真
DOI：
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发表时间：
2014
期刊：
影响因子：
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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
越来越多的电动汽车缓慢而稳步地进入消费市场。为了经济高效地生产出质量一流、数量充足的电机，了解线圈缠绕的过程是必不可少的。因此，对线材性能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绕过程中的导线行为。基于有限元的仿真工具LS-DYNA作为显式动力学工具。为了在模拟中表现绕组的高动态过程，必须进行一些初始调整。这意味着，动态影响，如线圈体的转速或加速度是可定义的。在过程仿真中，将给定的边界条件应用于模型。钢丝的材料性能通过拉伸试验和先前研究数据表中的值进行验证。为了达到最佳收敛，针对不同的接触行为选择了不同的接触算法。此外，为了获得显著的结果，需要对网格进行特定的调整。最先进的线圈绕组是一个实验程序，它提供了足够的工艺参数，因此，在绕组技术的专业知识。然而，有很多不同的、相互作用的参数，这些参数必须根据边界条件进行优化。在绕线过程的仿真模型中，可以对不同的参数进行优化以获得最优的绕线结果，这是该领域值得深入研究的问题。生成的模型使用户不仅可以影响工艺参数，还可以修改绕组体的几何形状。为了使仿真更加科学合理，通过前人的实验和仿真对仿真结果进行了验证
Slowly but steadily, more and more electric vehicles push onto the consumer market. 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 the 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. To represent the high dynamic process of winding within this simulation, some first adaptions have to be made. This means, that 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 material properties of the wire under scrutiny are validated by a tensile test and by the values out of datasheets in previous research. In order to achieve the best convergence, different contact algorithms are selected for each individual contact behavior. Furthermore, specific adjustments to the mesh are necessary to gain significant results. State of the art in coil winding is an experimental procedure, which delivers adequate process parameters and, thus, expertise in winding technology. Nevertheless, there are a lot of different, interacting parameters, which have to be optimized in terms of boundary conditions. The simulation model of winding process, in which varying parameters can be optimized pertaining to the optimal winding result, calls for extensive research in this field. The generated model enables the user not only to influence the process parameters but also to modify the geometry of a winding body. To make the simulation scientifically sound, it is validated by previous experiments and simulations