Process modeling of linear coil winding processes with a subsequent deformation model

电驱动器的绕组对其性能具有决定性作用，因此必须满足其制造方面的更高要求。对于混合动力汽车应用，集中绕组，也称为齿线圈，是技术状态。它们被设计为具有非圆形线圈体，该线圈体被铜线连续地缠绕。高效绕组的主要挑战是在定义的绕组方案之后的层结构，即齐平绕组，其导致高铜填充系数。为了确保适当的可操作性，必须防止电线绝缘的损坏或线规的减小，这将导致更高的电阻。线性缠绕工艺作为直接缠绕工艺，能够实现高生产率的导线敏感缠绕。目前，工艺设计以及可实现的线圈质量参数是在经验实验的基础上确定的。这是由于半成品和过程的未知参数交叉相互作用。特别地，线的影响及其变形行为和效果，如由于强应变、冷硬化或在将线放置到线圈主体上时的回弹行为而导致的规格减小，对于线性缠绕过程是未知的。这导致生产率降低和卷绕质量参数降低。推导出的科学目标是一个基于变形的过程模型，该模型将这些不同的影响联系起来，以确定生产过程中和最终产品中线材的应力-应变状态。新获得的过程知识将被用作新的焊丝振荡控制的输入模型。通过对变形效果的特殊使用，通过优化工艺框架参数也可以实现更好的缠绕效果。不同的变形效果将通过单独的实验进行研究，然后加入到一个一致的绝缘铜线材料模型。缠绕过程中不同效应的联系将在发生位置使用FEM和演示线圈模型进行建模。特别感兴趣的是当将线放置在线圈主体边缘周围时的线负载条件、所产生的线行为和线张力的感应波动。由于大多数影响无法在过程中测量，因此将开发多体动态模拟来确定焊线负载条件。该过程模拟将与早期导出的材料模型相关联，以包括变形框架条件下的线材弯曲扭矩的依赖性。

The winding of electric drives is a decisive for the its performance and thus has to meet stronger demands regarding its manufacturing. For hybrid electric vehicle applications concentrated windings, also called tooth coils, are state of technology. They are design with a noncircular coil body which is being wound continuously with a copper wire. The major challenge for efficient windings is the layer structure after a defined winding scheme, a flush winding, which results in a high copper fill factor. In order to ensure a proper operability a damage of wire insulation or a reduction of the wire gauge, which would lead to a higher electric resistance, must be prevented. The linear winding process, as a direct winding process, enables a wire sensitive winding with a high productivity. Currently, the process design as well as the achievable coil quality parameters are determined on empiric experimental bases. This is due to the unknown parameter cross-interaction of semi-manufactured goods and the process. In particular, the influence of the wire and its deformation behavior and effects, like a gauge reduction due to strong straining, cold hardening or the spring back behavior while placing the wire onto the coil body, are unknown for the linear winding process. This results in decreased productivity and lower winding quality parameters. The deduced scientific objective is a deformation based process model which interlinks theses different effects in order to determine stress-strain-states of the wire within the production process and the in the final product. The new gained process knowledge will be used as an input model for a new wire oscillation control. With the specific use of deformation effects a better winding result can be achieved as well by optimizing the process frame parameters. Different deformation effects will be investigated by separate experiments and then joined into a consistent material model for insulated copper wire. The link of the different effects during the winding process will be modeled at the place of occurrence using FEM with a demonstrator coil dummy. Of particular interest are the wire load conditions while placing the wire around the coil body edges, the resulting wire behavior and induced fluctuations of the wire tensions. Since most effects cannot be measured within the process, a multi body dynamic simulation will be developed to determine the wire load conditions. This process simulation will be linked with the earlier derived material model in order to include the dependencies of the wire bending torque from the deformation frame conditions.