Pub Date : 2019-12-01DOI: 10.1109/EDPC48408.2019.9011973
N. Urban, Lukas Bauch, Rouven Armbruster, J. Franke
The electromagnetic properties of soft magnetic materials are of decisive importance for the efficiency, running characteristics and performance of electric motors. To fulfil the target criteria as favorably as possible, high requirements are placed on the processing techniques of soft magnetic materials with regard to accuracy, reproducibility and quality. Through continuous improvements, novel additive manufacturing processes are also able to meet these requirements. They can already be a pragmatic alternative, where conventional processes reach their technological or economical limits. Laser beam melting of metals in a powder bed is one of the processes in which a workpiece is created from shapeless metal powder. Due to its generative character, new design elements can be utilized to build lightweight motors or to manufacture them economically in small quantities. However, the process does not allow the production of a laminated soft magnetic part, which leads to increased eddy current losses. To counteract these, a material with a high specific electrical resistance has to be used. This publication presents the selection of a material suitable for this application, taking into account the state of the art and the procedure for qualifying the material in the laser beam melting process. This enables potential users of additive manufacturing to estimate the effort for the qualification of a tailor-made alloy and to use it for their own applications.
{"title":"Evaluation of Soft Magnetic Ferrosilicon FeSi 6.5 for Laser Beam Melting","authors":"N. Urban, Lukas Bauch, Rouven Armbruster, J. Franke","doi":"10.1109/EDPC48408.2019.9011973","DOIUrl":"https://doi.org/10.1109/EDPC48408.2019.9011973","url":null,"abstract":"The electromagnetic properties of soft magnetic materials are of decisive importance for the efficiency, running characteristics and performance of electric motors. To fulfil the target criteria as favorably as possible, high requirements are placed on the processing techniques of soft magnetic materials with regard to accuracy, reproducibility and quality. Through continuous improvements, novel additive manufacturing processes are also able to meet these requirements. They can already be a pragmatic alternative, where conventional processes reach their technological or economical limits. Laser beam melting of metals in a powder bed is one of the processes in which a workpiece is created from shapeless metal powder. Due to its generative character, new design elements can be utilized to build lightweight motors or to manufacture them economically in small quantities. However, the process does not allow the production of a laminated soft magnetic part, which leads to increased eddy current losses. To counteract these, a material with a high specific electrical resistance has to be used. This publication presents the selection of a material suitable for this application, taking into account the state of the art and the procedure for qualifying the material in the laser beam melting process. This enables potential users of additive manufacturing to estimate the effort for the qualification of a tailor-made alloy and to use it for their own applications.","PeriodicalId":119895,"journal":{"name":"2019 9th International Electric Drives Production Conference (EDPC)","volume":"465 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"122893872","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2019-12-01DOI: 10.1109/EDPC48408.2019.9012012
Christina Ketterer, Timo Benzel, A. Möckel
Defining an operating point of an existing drive system depends on the exact knowledge and modeling of the system and its corresponding degrees of freedom. To optimize the operating point, the individual adjustment to the needs of the user has to be part of the design process as well. The proposed approach is based on a stationary loss model consisting of equivalent circuits and characteristic diagrams of the drive system components parametrized with measurement data. Fixed input values are the desired torque and speed. A better comprehension of the system leads to a simple analytical model in the rotor-oriented dq-reference frame considering saturation effects and losses. Furthermore, the obtained current operating points depending on the user profile serve as input values for the existing current controller. The examined system contains an electronically commutated permanent magnet synchronous machine, a gearbox and a lithium-ion battery. Simulations and analyses on the test bench indicate that the deduced model representation and the adaption of the operating points as basis for the control algorithm are very effective. The results show a reduced model error of torque magnitude by up to 3% and an efficiency enhancement of up to 2%.
{"title":"User-oriented control of a drive system over the whole operating range","authors":"Christina Ketterer, Timo Benzel, A. Möckel","doi":"10.1109/EDPC48408.2019.9012012","DOIUrl":"https://doi.org/10.1109/EDPC48408.2019.9012012","url":null,"abstract":"Defining an operating point of an existing drive system depends on the exact knowledge and modeling of the system and its corresponding degrees of freedom. To optimize the operating point, the individual adjustment to the needs of the user has to be part of the design process as well. The proposed approach is based on a stationary loss model consisting of equivalent circuits and characteristic diagrams of the drive system components parametrized with measurement data. Fixed input values are the desired torque and speed. A better comprehension of the system leads to a simple analytical model in the rotor-oriented dq-reference frame considering saturation effects and losses. Furthermore, the obtained current operating points depending on the user profile serve as input values for the existing current controller. The examined system contains an electronically commutated permanent magnet synchronous machine, a gearbox and a lithium-ion battery. Simulations and analyses on the test bench indicate that the deduced model representation and the adaption of the operating points as basis for the control algorithm are very effective. The results show a reduced model error of torque magnitude by up to 3% and an efficiency enhancement of up to 2%.","PeriodicalId":119895,"journal":{"name":"2019 9th International Electric Drives Production Conference (EDPC)","volume":"30 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"121348994","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2019-12-01DOI: 10.1109/EDPC48408.2019.9011834
Wilken Wößner, Emily Uhl, J. Hofmann, J. Fleischer
An increased range of electric vehicles not only sets high demand to the chosen concept for energy storage but also implies that electric motors with high power-to-weight ratio need to be employed. A possible approach for weight reduction in a permanent magnet synchronous machine is an intelligent assembly of the rotor components followed by a positive balancing process. This approach allows to predict and minimize the rotor unbalance, resulting in a reduction in size of balancing discs that can account for up to 10% of the rotor mass. A higher potential in reduction of the rotor mass lies in the ability to dispense entirely with balancing discs and the subsequent balancing process. This paper analyses whether a balancing grade of G 2.5 can be achieved through intelligent assembly. In a first step, the required measuring and mounting steps are presented. Possible measuring and mounting uncertainties are identified and quantified through literature, simulation and experimental results, allowing a sensitivity analysis of the entire process chain. The results of this analysis are used to identify the measuring and mounting steps with the highest influence on the deviation between an expected and measured rotor unbalance. For magnet assembly, a good model validity is achieved. Errors in perpendicularity between lamination stacks and shafts are found to have a high influence on the reachable rotor unbalance and therefore offer room for further improvement of the approach.
{"title":"Sensitivity Analysis and Validation of the Intelligent Assembly Process for Permanent Magnet Rotors with the Balancing Grade G 2.5","authors":"Wilken Wößner, Emily Uhl, J. Hofmann, J. Fleischer","doi":"10.1109/EDPC48408.2019.9011834","DOIUrl":"https://doi.org/10.1109/EDPC48408.2019.9011834","url":null,"abstract":"An increased range of electric vehicles not only sets high demand to the chosen concept for energy storage but also implies that electric motors with high power-to-weight ratio need to be employed. A possible approach for weight reduction in a permanent magnet synchronous machine is an intelligent assembly of the rotor components followed by a positive balancing process. This approach allows to predict and minimize the rotor unbalance, resulting in a reduction in size of balancing discs that can account for up to 10% of the rotor mass. A higher potential in reduction of the rotor mass lies in the ability to dispense entirely with balancing discs and the subsequent balancing process. This paper analyses whether a balancing grade of G 2.5 can be achieved through intelligent assembly. In a first step, the required measuring and mounting steps are presented. Possible measuring and mounting uncertainties are identified and quantified through literature, simulation and experimental results, allowing a sensitivity analysis of the entire process chain. The results of this analysis are used to identify the measuring and mounting steps with the highest influence on the deviation between an expected and measured rotor unbalance. For magnet assembly, a good model validity is achieved. Errors in perpendicularity between lamination stacks and shafts are found to have a high influence on the reachable rotor unbalance and therefore offer room for further improvement of the approach.","PeriodicalId":119895,"journal":{"name":"2019 9th International Electric Drives Production Conference (EDPC)","volume":"2 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"128346801","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2019-12-01DOI: 10.1109/EDPC48408.2019.9011826
Yufeng Guo, J. Soulard, D. Greenwood
Thermal performance of electric machines strongly depends on their insulation system and the corresponding impregnation process. A series of experiments was carried out on individual stator segments with concentrated winding to study thermal behavior and impregnation goodness. Variables include different impregnation processes, resins, and slot liner materials. A custom-made thermal test rig was used to measure the thermal conductance of each segment. Unexpected results led to further characterisation including cross-section microscopy and CT-scanning of the internal structure of the segments. Air pockets in the gap between the inner layer of winding and the tooth were observed. Their influence was investigated by calibrating a Lumped Parameter Thermal Network (LPTN) model at steady state operation. The simulations explained why the segments without slot liners showed increased thermal conductance. It also showed why varying the slot liner materials, the resins or the impregnation processes had limited influence on the thermal conductance. This paper highlights that repeatable positioning of conductors in the slots as close to the tooth as possible and high impregnation goodness around the slot liners are key manufacturing challenges for high stator thermal performance.
{"title":"Challenges in Electric Machine Stator Manufacturing and Their Influences on Thermal Performance","authors":"Yufeng Guo, J. Soulard, D. Greenwood","doi":"10.1109/EDPC48408.2019.9011826","DOIUrl":"https://doi.org/10.1109/EDPC48408.2019.9011826","url":null,"abstract":"Thermal performance of electric machines strongly depends on their insulation system and the corresponding impregnation process. A series of experiments was carried out on individual stator segments with concentrated winding to study thermal behavior and impregnation goodness. Variables include different impregnation processes, resins, and slot liner materials. A custom-made thermal test rig was used to measure the thermal conductance of each segment. Unexpected results led to further characterisation including cross-section microscopy and CT-scanning of the internal structure of the segments. Air pockets in the gap between the inner layer of winding and the tooth were observed. Their influence was investigated by calibrating a Lumped Parameter Thermal Network (LPTN) model at steady state operation. The simulations explained why the segments without slot liners showed increased thermal conductance. It also showed why varying the slot liner materials, the resins or the impregnation processes had limited influence on the thermal conductance. This paper highlights that repeatable positioning of conductors in the slots as close to the tooth as possible and high impregnation goodness around the slot liners are key manufacturing challenges for high stator thermal performance.","PeriodicalId":119895,"journal":{"name":"2019 9th International Electric Drives Production Conference (EDPC)","volume":"104 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"134489881","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2019-12-01DOI: 10.1109/EDPC48408.2019.9011844
A. Kampker, R. Pandey, José Gómez, Saskia Wessel, Patrick Treichel, Ibrahim Malatyali
Medium and heavy-duty vehicles form the backbone of logistic industry. However, the increase in the amount of freight as well as stringent emission norms are putting enormous pressure on the fleet operators. Additionally, due to the lack of industry standards the manufacturers are also not committing their fortunes over an evolving technology. Therefore, before we achieve a well-established and standardized methodology for the design of electric drivetrains for logistic vehicles, a sub-optimal, short term and still cost effective solution need to be devised that will serve as a precursor for the future of the industry. In general, electro- mobility is subject to high cost pressure due to the additional costs of the battery. In this case, the reduction of costs of other parts of the drivetrain plays an important role for the viability of this technology. This paper focuses on the identification of the cost- effective drivetrain variant for medium-heavy duty trucks. For this purpose, an appropriate method is required for the cost calculation during the stages of product development and production. Therefore, during this phase of technology evolution of electro-mobility, an innovative manufacturer-oriented cost calculation method is developed, evaluated and used to investigate the research question of which drivetrain variant is the most economical overall, considering the development and production cycle in a given scenario. The market of medium-heavy duty trucks is energy cost driven, but from the manufacturers perspective significant savings can be made by implementing an optimal drivetrain methodology. For this analysis, the suitable drivetrain concepts are compared based on the empirical data obtained from available industry standards. The results are also derived from a research project currently being undertaken at the Institute PEM of RWTH Aachen University and financed by the Federal Ministry for the Environment, Nature Conservation, and Nuclear Safety.
{"title":"Cost Optimal Design Strategy of Electric Drivetrains for Medium Heavy-Duty Vehicles Based on Product Development and Production Costs","authors":"A. Kampker, R. Pandey, José Gómez, Saskia Wessel, Patrick Treichel, Ibrahim Malatyali","doi":"10.1109/EDPC48408.2019.9011844","DOIUrl":"https://doi.org/10.1109/EDPC48408.2019.9011844","url":null,"abstract":"Medium and heavy-duty vehicles form the backbone of logistic industry. However, the increase in the amount of freight as well as stringent emission norms are putting enormous pressure on the fleet operators. Additionally, due to the lack of industry standards the manufacturers are also not committing their fortunes over an evolving technology. Therefore, before we achieve a well-established and standardized methodology for the design of electric drivetrains for logistic vehicles, a sub-optimal, short term and still cost effective solution need to be devised that will serve as a precursor for the future of the industry. In general, electro- mobility is subject to high cost pressure due to the additional costs of the battery. In this case, the reduction of costs of other parts of the drivetrain plays an important role for the viability of this technology. This paper focuses on the identification of the cost- effective drivetrain variant for medium-heavy duty trucks. For this purpose, an appropriate method is required for the cost calculation during the stages of product development and production. Therefore, during this phase of technology evolution of electro-mobility, an innovative manufacturer-oriented cost calculation method is developed, evaluated and used to investigate the research question of which drivetrain variant is the most economical overall, considering the development and production cycle in a given scenario. The market of medium-heavy duty trucks is energy cost driven, but from the manufacturers perspective significant savings can be made by implementing an optimal drivetrain methodology. For this analysis, the suitable drivetrain concepts are compared based on the empirical data obtained from available industry standards. The results are also derived from a research project currently being undertaken at the Institute PEM of RWTH Aachen University and financed by the Federal Ministry for the Environment, Nature Conservation, and Nuclear Safety.","PeriodicalId":119895,"journal":{"name":"2019 9th International Electric Drives Production Conference (EDPC)","volume":"41 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"124106241","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2019-12-01DOI: 10.1109/edpc48408.2019.9011856
{"title":"Copyright","authors":"","doi":"10.1109/edpc48408.2019.9011856","DOIUrl":"https://doi.org/10.1109/edpc48408.2019.9011856","url":null,"abstract":"","PeriodicalId":119895,"journal":{"name":"2019 9th International Electric Drives Production Conference (EDPC)","volume":"110 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"121152434","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2019-12-01DOI: 10.1109/EDPC48408.2019.9011857
M. Weigelt, J. Kink, A. Mayr, J. V. Lindenfels, A. Kühl, J. Franke
Linear winding is one of several process alternatives in coil production. Due to its simplicity and robustness, it is used in various applications. At the Institute for Factory Automation and Production Systems at the Friedrich-Alexander- University Erlangen-Nuremberg, simulation tools are used to validate and evaluate various winding process alternatives. In this context, this paper describes a finite element (FE) analysis of the linear winding process. First, an overview of the linear winding technique and its special features is given. The configuration of the FE simulation model and the applied material model is presented in detail and necessary simplifications are described. After executing the simulation, the simulation results are validated against the experimental data. The validated simulation is used to identify significant influencing variables. Based on the simulation, it can be deduced that an increase of the wire tensile force as well as a reduction of the wire diameter in the tolerance window leads to a smaller overall circumference of the coil. Furthermore, the caster angle could be determined as an influence on the coil diameter.
{"title":"Digital Twin of the Linear Winding Process Based on Explicit Finite Element Method","authors":"M. Weigelt, J. Kink, A. Mayr, J. V. Lindenfels, A. Kühl, J. Franke","doi":"10.1109/EDPC48408.2019.9011857","DOIUrl":"https://doi.org/10.1109/EDPC48408.2019.9011857","url":null,"abstract":"Linear winding is one of several process alternatives in coil production. Due to its simplicity and robustness, it is used in various applications. At the Institute for Factory Automation and Production Systems at the Friedrich-Alexander- University Erlangen-Nuremberg, simulation tools are used to validate and evaluate various winding process alternatives. In this context, this paper describes a finite element (FE) analysis of the linear winding process. First, an overview of the linear winding technique and its special features is given. The configuration of the FE simulation model and the applied material model is presented in detail and necessary simplifications are described. After executing the simulation, the simulation results are validated against the experimental data. The validated simulation is used to identify significant influencing variables. Based on the simulation, it can be deduced that an increase of the wire tensile force as well as a reduction of the wire diameter in the tolerance window leads to a smaller overall circumference of the coil. Furthermore, the caster angle could be determined as an influence on the coil diameter.","PeriodicalId":119895,"journal":{"name":"2019 9th International Electric Drives Production Conference (EDPC)","volume":"5 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"116813845","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2019-12-01DOI: 10.1109/EDPC48408.2019.9011859
A. Reinap
This article explores four preselected permanent magnet synchronous machine (PMSM) topologies suitable for direct mounting on low pressure spool in a turbo fan engine. The challenge of contributing to More Electric Engine (MEE) development is that the electrical machine needs to operate over wide speed range, take advantage of available space that forces to use a high number of poles and last but not least a high-power density is anticipated. The initialization of these PMSM topologies fulfills the space requirements, evaluates and compares different core materials, FeCo and FeSi, and addresses mechanical load and cooling integration aspects. The design goal is to find affordable and rational set of materials and manufacturing methods in combination with machine characteristics that suits the best for the mission. It is found that PMSM with FeCo core with distributed winding and Halbach magnet arrangement would meet best the low ripple, high efficiency and power requirement while concentrated winding machine would provide appealing option of individually controlled direct cooled hollow conductor coils for better thermal management.
{"title":"Aerospace Electric Generator Design Considerations","authors":"A. Reinap","doi":"10.1109/EDPC48408.2019.9011859","DOIUrl":"https://doi.org/10.1109/EDPC48408.2019.9011859","url":null,"abstract":"This article explores four preselected permanent magnet synchronous machine (PMSM) topologies suitable for direct mounting on low pressure spool in a turbo fan engine. The challenge of contributing to More Electric Engine (MEE) development is that the electrical machine needs to operate over wide speed range, take advantage of available space that forces to use a high number of poles and last but not least a high-power density is anticipated. The initialization of these PMSM topologies fulfills the space requirements, evaluates and compares different core materials, FeCo and FeSi, and addresses mechanical load and cooling integration aspects. The design goal is to find affordable and rational set of materials and manufacturing methods in combination with machine characteristics that suits the best for the mission. It is found that PMSM with FeCo core with distributed winding and Halbach magnet arrangement would meet best the low ripple, high efficiency and power requirement while concentrated winding machine would provide appealing option of individually controlled direct cooled hollow conductor coils for better thermal management.","PeriodicalId":119895,"journal":{"name":"2019 9th International Electric Drives Production Conference (EDPC)","volume":"19 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"133817091","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2019-12-01DOI: 10.1109/EDPC48408.2019.9011918
M. Ziegler, A. Mayr, J. Seefried, A. Kuehl, J. Franke
The increasing demand for highly efficient electric motors for traction applications leads to novel challenges for electric motor manufacturers. With the use of more advanced motor designs and materials, production processes need to be adapted or even reinvented. To reduce iron losses in ferromagnetic components, the stator and rotor core is laminated into thin electrical steel laminations. Depending on the requirements, different joining processes are used for fixing the shape of the lamination stack. As the stators of large traction drives are subject to high mechanical loads, welding processes are mainly used for this process step. In addition to conventional TIG welding, laser beam welding is gaining more and more importance for the processing of electrical steel laminations. The high level of automation, good seam stability and the possibility to weld thin sheets are reasons for using laser welding in this application domain. However, due to the complexity of the laser process and the multitude of influencing variables, it is quite challenging to find optimal process parameters. Furthermore, it must be ensured that the high welding quality once achieved is maintained over time. In this paper, the influence of different welding strategies is investigated and potentials of different process monitoring methods are analyzed.
{"title":"Potentials of Process Monitoring During Laser Welding of Electrical Steel Laminations","authors":"M. Ziegler, A. Mayr, J. Seefried, A. Kuehl, J. Franke","doi":"10.1109/EDPC48408.2019.9011918","DOIUrl":"https://doi.org/10.1109/EDPC48408.2019.9011918","url":null,"abstract":"The increasing demand for highly efficient electric motors for traction applications leads to novel challenges for electric motor manufacturers. With the use of more advanced motor designs and materials, production processes need to be adapted or even reinvented. To reduce iron losses in ferromagnetic components, the stator and rotor core is laminated into thin electrical steel laminations. Depending on the requirements, different joining processes are used for fixing the shape of the lamination stack. As the stators of large traction drives are subject to high mechanical loads, welding processes are mainly used for this process step. In addition to conventional TIG welding, laser beam welding is gaining more and more importance for the processing of electrical steel laminations. The high level of automation, good seam stability and the possibility to weld thin sheets are reasons for using laser welding in this application domain. However, due to the complexity of the laser process and the multitude of influencing variables, it is quite challenging to find optimal process parameters. Furthermore, it must be ensured that the high welding quality once achieved is maintained over time. In this paper, the influence of different welding strategies is investigated and potentials of different process monitoring methods are analyzed.","PeriodicalId":119895,"journal":{"name":"2019 9th International Electric Drives Production Conference (EDPC)","volume":"92 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"125857247","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2019-12-01DOI: 10.1109/EDPC48408.2019.9011847
Johannes Wanner, M. Weeber, K. Birke, A. Sauer
The useful life and durability of battery systems strongly depend on the high and uniform quality of the manufactured battery cells. However, heterogeneous information infrastructures in manufacturing still limit the knowledge on cause and effect relationships between process and product quality parameters. Based on a literature review, the prospects of soft sensoring and sensor fusion in the data-driven modelling and prediction of product quality in battery cell manufacturing is analyzed. It is suggested that soft sensoring and sensor fusion is able to improve the accuracy of product quality models by overcoming the restrictions imposed by a limited number of hardware sensors. Besides, a general lack of data availability along the process chain in battery cell manufacturing is identified, which can be addressed by a new method to detect, correct and process deficits in battery cell manufacturing with missing hardware sensors.
{"title":"Quality Modelling in Battery Cell Manufacturing Using Soft Sensoring and Sensor Fusion - A Review","authors":"Johannes Wanner, M. Weeber, K. Birke, A. Sauer","doi":"10.1109/EDPC48408.2019.9011847","DOIUrl":"https://doi.org/10.1109/EDPC48408.2019.9011847","url":null,"abstract":"The useful life and durability of battery systems strongly depend on the high and uniform quality of the manufactured battery cells. However, heterogeneous information infrastructures in manufacturing still limit the knowledge on cause and effect relationships between process and product quality parameters. Based on a literature review, the prospects of soft sensoring and sensor fusion in the data-driven modelling and prediction of product quality in battery cell manufacturing is analyzed. It is suggested that soft sensoring and sensor fusion is able to improve the accuracy of product quality models by overcoming the restrictions imposed by a limited number of hardware sensors. Besides, a general lack of data availability along the process chain in battery cell manufacturing is identified, which can be addressed by a new method to detect, correct and process deficits in battery cell manufacturing with missing hardware sensors.","PeriodicalId":119895,"journal":{"name":"2019 9th International Electric Drives Production Conference (EDPC)","volume":"5 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2019-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"129832479","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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