Challenges and Solutions for Contacting Insulated Litz Wire Structures in the Context of Electromechanical Engineering

Seefried, Johannes; Riedel, Andreas; Kühl, Alexander; Franke, Jörg

doi:10.1007/978-3-030-78424-9_52

Cited by 8 publications

(6 citation statements)

References 9 publications

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“…Welding technologies, both traditional and laser, require prior removal of insulation from the contact area [3]. During the resistance welding process, force and current are…”

Section: Weldingmentioning

confidence: 99%

Section: Weldingmentioning

confidence: 99%

“…Welding technologies, both traditional and laser, require prior removal of insulation from the contact area [3]. During the resistance welding process, force and current are applied to the bundle of Litz wire to compact it into a solid that then gets welded to the contact terminal placed on the lower electrode [3]. Tungsten Inert Gas welding is another example of a welding process that requires strict standards such as ISO10042 [16] to ensure the desired quality standards.…”

Section: Weldingmentioning

confidence: 99%

“…However, joining Litz wires is challenging due to the requirement of enamel (wire insulation layer) removal from every individual thin strand, followed by making an electrical connection between them. Recently, Seefried et al [3] have compared and reviewed the challenges in various joining techniques for insulated Litz wires. The joining can be divided into two main process steps.…”

Section: Introductionmentioning

confidence: 99%

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Inspection of Enamel Removal Using Infrared Thermal Imaging and Machine Learning Techniques

Tiwari

Miller

Farnsworth

et al. 2023

Sensors

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Within aerospace and automotive manufacturing, the majority of quality assurance is through inspection or tests at various steps during manufacturing and assembly. Such tests do not tend to capture or make use of process data for in-process inspection and certification at the point of manufacture. Inspection of the product during manufacturing can potentially detect defects, thus allowing consistent product quality and reducing scrappage. However, a review of the literature has revealed a lack of any significant research in the area of inspection during the manufacturing of terminations. This work utilises infrared thermal imaging and machine learning techniques for inspection of the enamel removal process on Litz wire, typically used for aerospace and automotive applications. Infrared thermal imaging was utilised to inspect bundles of Litz wire containing those with and without enamel. The temperature profiles of the wires with or without enamel were recorded and then machine learning techniques were utilised for automated inspection of enamel removal. The feasibility of various classifier models for identifying the remaining enamel on a set of enamelled copper wires was evaluated. A comparison of the performance of classifier models in terms of classification accuracy is presented. The best model for enamel classification accuracy was the Gaussian Mixture Model with expectation maximisation; it achieved a training accuracy of 85% and enamel classification accuracy of 100% with the fastest evaluation time of 1.05 s. The support vector classification model achieved both the training and enamel classification accuracy of more than 82%; however, it suffered the drawback of a higher evaluation time of 134 s.

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“…Welding technologies, both traditional and laser, require prior removal of insulation from the contact area [3]. During the resistance welding process, force and current are…”

Section: Weldingmentioning

confidence: 99%

Section: Weldingmentioning

confidence: 99%

Section: Weldingmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Inspection of Enamel Removal Using Infrared Thermal Imaging and Machine Learning Techniques

Tiwari

Miller

Farnsworth

et al. 2023

Sensors

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show abstract

“…The compacted high-frequency litz wire can subsequently be welded onto contact terminals using the ultrasonic welding process. A direct welding of high-frequency litz wires with terminals is rather difficult to implement since the primary insulation hinders the welding process [23].…”

Section: Contacting Technologiesmentioning

confidence: 99%

Production Concepts for Inductive Power Transfer Systems for Vehicles

et al. 2022

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The option of wireless energy transmission in electric vehicles can become the main market driver for electric vehicles due to its distinct advantages, such as range, weight, or costs, over conventional conductive charging solutions. In addition to the great potential, which different research work and realized systems have already shown, there are new requirements for the associated production networks in the automotive industry which must be addressed at an early stage. Furthermore, no solutions currently exist for the industrial production of these components. This paper presents the main components for the feasibility of wireless power transmission in electric vehicles. In addition, the required value chains and processes for the new components of the inductive power transfer systems, and the final assembly for induction coils, which has been developed at the FAU, will be presented. These include the developing of a winding process on a 15-axis special machine, ultrasonic crimping of the litz wire ends, and vacuum potting.

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Challenges of Contacting Processes for Thin Copper Flat Wires in the Context of Electromechanical Engineering

Seefried

Mahr

Weigelt

et al. 2021

2021 11th International Electric Drives Production Conference (EDPC)

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Challenges and Solutions for Contacting Insulated Litz Wire Structures in the Context of Electromechanical Engineering

Cited by 8 publications

References 9 publications

Inspection of Enamel Removal Using Infrared Thermal Imaging and Machine Learning Techniques

Inspection of Enamel Removal Using Infrared Thermal Imaging and Machine Learning Techniques

Production Concepts for Inductive Power Transfer Systems for Vehicles

Challenges of Contacting Processes for Thin Copper Flat Wires in the Context of Electromechanical Engineering

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