Feasibility Study for Enameled Round Copper Wire Compression within Slots of Electrical Machines

Investigation of the Forming Behavior of Copper Wires for the Compaction of Windings for Electric Machines

“…This simplification leads to the fact that no statements can be made about the insulation layer and the surface layer of the copper wires. Experimental investigations were carried out for this purpose [4]. Setup of Simulation.…”

“…The technological and scientific state of the art for the compression of windings of electrical machines can be found in a past publication of the authors [4], in which also experimental studies were carried out. For this work, approaches with numerical analysis of round wire windings are listed in detail.…”

“…The underlined control parameters are used as factors in the simulation study described in the following chapters. Based on the preliminary investigations [4] and the resulting prior knowledge, the experimental design is to be limited to three main factors with three levels each for the simplified simulation model. The aim was to create an impact analysis of these main factors with a full factorial design.…”

“…Aim of the compact winding process is the forming of a defined layer structure of round wires to predefined cross-sections, for example rectangular shapes. For this purpose, experimental test series have already been carried out by the authors, especially with regard to the electrical behavior and the associated practical feasibility for electric machines [4]. Since it is very timeconsuming to determine the relationships between the forming step and the resulting winding shape in an experimental matter, a simplified model was implemented in the present work using the explicit finite element method (FEM) for basic investigations.…”