Pub Date : 2019-12-01DOI: 10.1109/EDPC48408.2019.9011969
D. Wüterich, M. Liewald, M. Kopp
Against the background of rising electro mobility concepts for vehicles, corresponding demands on electric machines with regard to their efficiency and power density remarkably influence stator production of such machines in terms of required power output. Here, fundamental parameters that must be considered when designing stators are magnetic properties of the stator core and the electric properties of the winding. Furthermore, the performance of stators is influenced by geometrical properties such as copper filling of the stator grooves and the inner radius of the stator core. In order to increase copper fill factors within the stator body, several stator production technologies have recently been developed and investigated, e.g. hairpin, flyer winding and insertion technology. In addition to those technologies, the so called flatpack bending process constitutes a new process for stator production in which the pre-bent winding is first inserted into a flat, comb like shaped stator core. This assembly is subsequently rounded in a multi-stage rotary draw bending process, obtaining high copper filling ratios. However, the main challenge for this bending and subsequent springback procedure arises from the roundness deviations occurring along current process chains. For this reason, a simulation model has been created in the framework of a collaborative research project between SEG Automotive and the Institute for Metal Forming Technology, Stuttgart, aiming to better understand and to improve this stator flatpack bending process. For an extensive validation of this model, various parameters need to be examined and their influence to be evaluated. In this study, simulations were performed using this numerical model, in which levels of yield strength of the material to be formed were varied in order to calculate their influences on the outer radius. For validation objectives of simulation results, bending experiments were subsequently conducted, so samples obtained were evaluated using 3D scan technology. As a result, only a maximum difference of 0.3 mm of bent stator core was observed by comparing the numerically calculated results and the results measured during the experiments.
{"title":"Validation of Bending Simulation Models Based on Yield Strength Influences of Electrical Steel Sheets on Stator Core Radius","authors":"D. Wüterich, M. Liewald, M. Kopp","doi":"10.1109/EDPC48408.2019.9011969","DOIUrl":"https://doi.org/10.1109/EDPC48408.2019.9011969","url":null,"abstract":"Against the background of rising electro mobility concepts for vehicles, corresponding demands on electric machines with regard to their efficiency and power density remarkably influence stator production of such machines in terms of required power output. Here, fundamental parameters that must be considered when designing stators are magnetic properties of the stator core and the electric properties of the winding. Furthermore, the performance of stators is influenced by geometrical properties such as copper filling of the stator grooves and the inner radius of the stator core. In order to increase copper fill factors within the stator body, several stator production technologies have recently been developed and investigated, e.g. hairpin, flyer winding and insertion technology. In addition to those technologies, the so called flatpack bending process constitutes a new process for stator production in which the pre-bent winding is first inserted into a flat, comb like shaped stator core. This assembly is subsequently rounded in a multi-stage rotary draw bending process, obtaining high copper filling ratios. However, the main challenge for this bending and subsequent springback procedure arises from the roundness deviations occurring along current process chains. For this reason, a simulation model has been created in the framework of a collaborative research project between SEG Automotive and the Institute for Metal Forming Technology, Stuttgart, aiming to better understand and to improve this stator flatpack bending process. For an extensive validation of this model, various parameters need to be examined and their influence to be evaluated. In this study, simulations were performed using this numerical model, in which levels of yield strength of the material to be formed were varied in order to calculate their influences on the outer radius. For validation objectives of simulation results, bending experiments were subsequently conducted, so samples obtained were evaluated using 3D scan technology. As a result, only a maximum difference of 0.3 mm of bent stator core was observed by comparing the numerically calculated results and the results measured during the experiments.","PeriodicalId":119895,"journal":{"name":"2019 9th International Electric Drives Production Conference (EDPC)","volume":"111 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":"123195548","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/EDPC48408.2019.9011935
D. Mayer, L. Hausmann, Nathalie Maul, Lino Reinschmidt, J. Hofmann, J. Fleischer
Due to the increasing electrification of the automotive drive train, production systems for electric motors grow in importance. In order to produce the required quantities at reasonable costs there is a particular need for developing new stator production plants. A trend towards using shaped coils in stators, so called hairpins, is emerging as this technology promises great automation potentials as well as high copper fill factors. Due to the axial insertion of the hairpins into the lamination stack the requirements for the slot liner shape change in contrast to the widely used winding technologies. Thus, new slot liner shapes, such as ‘B’-, ‘O’- or ‘S’-shapes, can be used. The shapes replace the previous ‘U’- shaped slot liner as well as the slot cover. In order to maintain a high fill factor, the shapes have to fit closely to the lamination stack. For this purpose, the insulation paper must be grooved and then folded into the desired shape. To map the new slot liner shapes, the grooving process and its influence on slot insulation must be understood in detail. In this paper the grooving process and its effect on breakdown voltage of the slot liner are examined. First, an overview about different insulation materials for slot liners is given. Second, a test rig setup to adjust different depths and widths of grooving is introduced. Additionally, a further test rig setup for conducting breakdown voltage tests on slot liners is presented. Based on these test rigs, experiments are carried out to determine how the grooving process parameters affect the breakdown voltage of the slot liners. As a result of the investigation a characterization of the grooving process regarding the breakdown voltage for the examined insulation paper is presented.
由于汽车传动系统的电气化程度越来越高，电动机的生产系统变得越来越重要。为了以合理的成本生产所需的数量，特别需要开发新的定子生产工厂。在定子中使用形状线圈的趋势，即所谓的发夹，正在出现，因为这种技术承诺了巨大的自动化潜力以及高铜填充系数。由于发夹轴向插入到层压堆栈中，与广泛使用的缠绕技术相比，对槽线形状的要求发生了变化。因此，可以使用新的槽衬形状，例如' B ' -， ' O ' -或' S ' -形状。这些形状取代了以前的“U”形槽内衬以及槽盖。为了保持高填充系数，形状必须紧密贴合层压堆叠。为此，绝缘纸必须开槽，然后折叠成所需的形状。为了绘制新的槽衬形状，必须详细了解开槽过程及其对槽绝缘的影响。本文研究了开槽过程及其对槽衬击穿电压的影响。首先，对不同的槽衬保温材料进行了概述。其次，介绍了一种可调节不同槽深和宽度的试验台装置。此外，还介绍了一种用于槽管击穿电压测试的试验台装置。在这些试验台的基础上，进行了开槽工艺参数对槽衬击穿电压的影响试验。作为调查的结果，沟槽过程的表征有关击穿电压的检查绝缘纸提出。
{"title":"Systematic Investigation of the Grooving Process and its Influence on Slot Insulation of Stators with Hairpin Technology","authors":"D. Mayer, L. Hausmann, Nathalie Maul, Lino Reinschmidt, J. Hofmann, J. Fleischer","doi":"10.1109/EDPC48408.2019.9011935","DOIUrl":"https://doi.org/10.1109/EDPC48408.2019.9011935","url":null,"abstract":"Due to the increasing electrification of the automotive drive train, production systems for electric motors grow in importance. In order to produce the required quantities at reasonable costs there is a particular need for developing new stator production plants. A trend towards using shaped coils in stators, so called hairpins, is emerging as this technology promises great automation potentials as well as high copper fill factors. Due to the axial insertion of the hairpins into the lamination stack the requirements for the slot liner shape change in contrast to the widely used winding technologies. Thus, new slot liner shapes, such as ‘B’-, ‘O’- or ‘S’-shapes, can be used. The shapes replace the previous ‘U’- shaped slot liner as well as the slot cover. In order to maintain a high fill factor, the shapes have to fit closely to the lamination stack. For this purpose, the insulation paper must be grooved and then folded into the desired shape. To map the new slot liner shapes, the grooving process and its influence on slot insulation must be understood in detail. In this paper the grooving process and its effect on breakdown voltage of the slot liner are examined. First, an overview about different insulation materials for slot liners is given. Second, a test rig setup to adjust different depths and widths of grooving is introduced. Additionally, a further test rig setup for conducting breakdown voltage tests on slot liners is presented. Based on these test rigs, experiments are carried out to determine how the grooving process parameters affect the breakdown voltage of the slot liners. As a result of the investigation a characterization of the grooving process regarding the breakdown voltage for the examined insulation paper is presented.","PeriodicalId":119895,"journal":{"name":"2019 9th International Electric Drives Production Conference (EDPC)","volume":"26 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":"120840929","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/EDPC48408.2019.9011866
M. Regnet, A. Kremser, M. Reinlein, P. Szary, Ulrich Abele
In this paper, the influence of cutting tool wear on the core losses and magnetizing demand of electrical steel sheets and the possible effects in electrical machine production are illustrated. Test strips with dimensions of 7.5 mm × 300 mm are punched with a sharp industrial cutting tool from four different electrical steel sheet types. Afterwards a total of 200 000 punch strokes are performed by using 8 tons of one type of electrical steel sheet. Every 10 000 strokes the punching process is interrupted and measurement test strips are punched by the four different types of electrical steel sheets in rolling direction and transverse to rolling direction. Measurements of the magnetic properties are carried out with a single sheet tester at 50 Hz with a defined sinusoidal waveform of the magnetic polarization. For displaying a trend over constant polarization an averaging over the results of the four electrical steel sheets is done as well as a moving average of the measurement points. The magnetizing demand of test strips shows a continuous increasing up to the last punched test strips. It is shown that the cutting tool reaches a level of wear at about 75 000 punch strokes. From there specific core losses almost have a constant deviation.
本文阐述了刀具磨损对电工钢板铁芯损耗和磁化需求的影响，以及在电机生产中可能产生的影响。测试条的尺寸为7.5 mm × 300 mm，用四种不同的电工钢板类型的锋利工业切削工具打孔。然后，使用8吨一种类型的电工钢板，总共进行了20万次冲孔。每10000次冲孔过程中断一次，由四种不同类型的电工钢板沿轧制方向和横向向轧制方向冲孔测量试条。磁性能的测量是用单片测试仪进行的，频率为50赫兹，具有确定的磁极化正弦波形。为了显示恒定极化的趋势，对四个电钢板的结果进行平均，并对测量点进行移动平均。试纸的充磁需求在最后一次打孔前呈连续增长趋势。结果表明，切削刀具在约75000冲程时达到磨损水平。从那里，特定的磁芯损耗几乎有恒定的偏差。
{"title":"Influence of Cutting Tool Wear on Core Losses and Magnetizing Demand of Electrical Steel Sheets","authors":"M. Regnet, A. Kremser, M. Reinlein, P. Szary, Ulrich Abele","doi":"10.1109/EDPC48408.2019.9011866","DOIUrl":"https://doi.org/10.1109/EDPC48408.2019.9011866","url":null,"abstract":"In this paper, the influence of cutting tool wear on the core losses and magnetizing demand of electrical steel sheets and the possible effects in electrical machine production are illustrated. Test strips with dimensions of 7.5 mm × 300 mm are punched with a sharp industrial cutting tool from four different electrical steel sheet types. Afterwards a total of 200 000 punch strokes are performed by using 8 tons of one type of electrical steel sheet. Every 10 000 strokes the punching process is interrupted and measurement test strips are punched by the four different types of electrical steel sheets in rolling direction and transverse to rolling direction. Measurements of the magnetic properties are carried out with a single sheet tester at 50 Hz with a defined sinusoidal waveform of the magnetic polarization. For displaying a trend over constant polarization an averaging over the results of the four electrical steel sheets is done as well as a moving average of the measurement points. The magnetizing demand of test strips shows a continuous increasing up to the last punched test strips. It is shown that the cutting tool reaches a level of wear at about 75 000 punch strokes. From there specific core losses almost have a constant deviation.","PeriodicalId":119895,"journal":{"name":"2019 9th International Electric Drives Production Conference (EDPC)","volume":"40 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":"128704878","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/EDPC48408.2019.9011914
P. Schwarz, A. Möckel
Because of the constant progress regarding calculation methods, materials and production technologies, new opportunities for alternative machine concepts are offered, such as the concept of axial flux machines, which is under investigation in current research projects. Axial flux machines are well suited for applications, in which high torque densities are required in combination with a low axial motor length. To reduce costs of powerful axial flux machines, mostly used rare earth magnets could be replaced with alternative solutions, e.g. excitation coils. This paper deals with the elaboration of advantages and disadvantages of field coils in axial flux machines and the influence of the air gap size with different types of excitation.
{"title":"Air gap influence in axial flux machines with different excitation","authors":"P. Schwarz, A. Möckel","doi":"10.1109/EDPC48408.2019.9011914","DOIUrl":"https://doi.org/10.1109/EDPC48408.2019.9011914","url":null,"abstract":"Because of the constant progress regarding calculation methods, materials and production technologies, new opportunities for alternative machine concepts are offered, such as the concept of axial flux machines, which is under investigation in current research projects. Axial flux machines are well suited for applications, in which high torque densities are required in combination with a low axial motor length. To reduce costs of powerful axial flux machines, mostly used rare earth magnets could be replaced with alternative solutions, e.g. excitation coils. This paper deals with the elaboration of advantages and disadvantages of field coils in axial flux machines and the influence of the air gap size with different types of excitation.","PeriodicalId":119895,"journal":{"name":"2019 9th International Electric Drives Production Conference (EDPC)","volume":"28 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":"126828604","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/EDPC48408.2019.9011999
F. Wirth, J. Fleischer
Due to the increasing sales of electric vehicles, new production technologies must be developed for meeting the growing demand for high productivity and quality in electric drives manufacturing. In comparison to conventional winding technologies, the hairpin technology provides significant advantages regarding the ability for automation, the productivity as well as the attainable filling factors, but also exhibits technological weaknesses concerning the process reliability. Since the shaping of hairpin coils represents the initial core process of the winding production by hairpin technology, geometric tolerances of the hairpin contour after shaping have a major impact on the downstream manufacturing processes. Especially the insertion of the coils into the stator slots as well as the twisting and contacting of the open coil sides are highly affected by variations in the positioning and orientation of the hairpin legs. Besides the process-based deviations caused by vibrations and tool displacements, the tolerances of hairpin contours are frequently induced by fluctuations of the geometric and material properties of the wire - like the dimensions and radii as well as the Young's modulus and flow curve. In this paper, a holistic analysis of geometric and material tolerances of flat wires and their effect on the accuracy of hairpin shaping processes is shown. For this purpose, essential material properties of flat winding wires are characterized by means of tensile tests at first and subsequently used as boundary conditions for a numerical sensitivity analysis of a tool-bound hairpin shaping process. The FE-based analyses are carried out in Abaqus FEA using a fully parametrized simulation model that is validated by means of CT measurements. The derived knowledge about interdependencies between fluctuations of wire properties and the reliability of hairpin shaping processes enables the cost-effective definition of wire tolerances in compliance with quality specifications.
{"title":"Influence of Wire Tolerances on Hairpin Shaping Processes","authors":"F. Wirth, J. Fleischer","doi":"10.1109/EDPC48408.2019.9011999","DOIUrl":"https://doi.org/10.1109/EDPC48408.2019.9011999","url":null,"abstract":"Due to the increasing sales of electric vehicles, new production technologies must be developed for meeting the growing demand for high productivity and quality in electric drives manufacturing. In comparison to conventional winding technologies, the hairpin technology provides significant advantages regarding the ability for automation, the productivity as well as the attainable filling factors, but also exhibits technological weaknesses concerning the process reliability. Since the shaping of hairpin coils represents the initial core process of the winding production by hairpin technology, geometric tolerances of the hairpin contour after shaping have a major impact on the downstream manufacturing processes. Especially the insertion of the coils into the stator slots as well as the twisting and contacting of the open coil sides are highly affected by variations in the positioning and orientation of the hairpin legs. Besides the process-based deviations caused by vibrations and tool displacements, the tolerances of hairpin contours are frequently induced by fluctuations of the geometric and material properties of the wire - like the dimensions and radii as well as the Young's modulus and flow curve. In this paper, a holistic analysis of geometric and material tolerances of flat wires and their effect on the accuracy of hairpin shaping processes is shown. For this purpose, essential material properties of flat winding wires are characterized by means of tensile tests at first and subsequently used as boundary conditions for a numerical sensitivity analysis of a tool-bound hairpin shaping process. The FE-based analyses are carried out in Abaqus FEA using a fully parametrized simulation model that is validated by means of CT measurements. The derived knowledge about interdependencies between fluctuations of wire properties and the reliability of hairpin shaping processes enables the cost-effective definition of wire tolerances in compliance with quality specifications.","PeriodicalId":119895,"journal":{"name":"2019 9th International Electric Drives Production Conference (EDPC)","volume":"1 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":"125377748","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/EDPC48408.2019.9011827
Moritz Meiners, A. Mayr, T. Lechler, J. Franke
With the increasing demand for electric cars, automobile manufacturers and suppliers are ramping up more and more plants for the production of electric traction motors. In the development of new plants, Industry 4.0 aspects are usually already considered, resulting in a large number of integrated sensors and thus a relatively high data availability. These process data in turn contain implicit knowledge that can be used to accelerate the ramp-up phase and to optimise the later series production. Especially in times characterised by frequent process adaptations and continuous learning, increasing knowledge can bring competitive advantages. This particularly applies to the automotive production of electric traction motors, which is currently confronted with ever changing product concepts, low production experience and uncertain quantities. Therefore, this paper presents a method for a simple, holistic visualisation of process chain interrelationships, which can already be used during series ramp-up and the associated limited data amount. By using suitable visualisation and clustering methods, process knowledge can be increased, ramp-up times be shortened and production be improved in the long run.
{"title":"Accelerated Production Ramp-Up Utilising Clustering and Visualisation of Process Chain Interrelationships","authors":"Moritz Meiners, A. Mayr, T. Lechler, J. Franke","doi":"10.1109/EDPC48408.2019.9011827","DOIUrl":"https://doi.org/10.1109/EDPC48408.2019.9011827","url":null,"abstract":"With the increasing demand for electric cars, automobile manufacturers and suppliers are ramping up more and more plants for the production of electric traction motors. In the development of new plants, Industry 4.0 aspects are usually already considered, resulting in a large number of integrated sensors and thus a relatively high data availability. These process data in turn contain implicit knowledge that can be used to accelerate the ramp-up phase and to optimise the later series production. Especially in times characterised by frequent process adaptations and continuous learning, increasing knowledge can bring competitive advantages. This particularly applies to the automotive production of electric traction motors, which is currently confronted with ever changing product concepts, low production experience and uncertain quantities. Therefore, this paper presents a method for a simple, holistic visualisation of process chain interrelationships, which can already be used during series ramp-up and the associated limited data amount. By using suitable visualisation and clustering methods, process knowledge can be increased, ramp-up times be shortened and production be improved in the long run.","PeriodicalId":119895,"journal":{"name":"2019 9th International Electric Drives Production Conference (EDPC)","volume":"60 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":"129802667","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/EDPC48408.2019.9012039
F. Pauli, Michael Schröder, K. Hameyer
The high copper fill factor of electrical machines with preformed coils allows for high torque and power densities. However, due to the manufacturing process, completely new challenges arise for the insulation system of machines with such preformed coils. Due to the complex geometry of the coil, conventional enameling processes, which are used in wire wound machines, are not suitable. Therefore, forming of enameled wire, as well as powder coating of already formed bare copper coils, are studied in this work as alternatives.
{"title":"Design and Evaluation Methodology for Insulation Systems of Low Voltage Drives with Preformed Coils","authors":"F. Pauli, Michael Schröder, K. Hameyer","doi":"10.1109/EDPC48408.2019.9012039","DOIUrl":"https://doi.org/10.1109/EDPC48408.2019.9012039","url":null,"abstract":"The high copper fill factor of electrical machines with preformed coils allows for high torque and power densities. However, due to the manufacturing process, completely new challenges arise for the insulation system of machines with such preformed coils. Due to the complex geometry of the coil, conventional enameling processes, which are used in wire wound machines, are not suitable. Therefore, forming of enameled wire, as well as powder coating of already formed bare copper coils, are studied in this work as alternatives.","PeriodicalId":119895,"journal":{"name":"2019 9th International Electric Drives Production Conference (EDPC)","volume":"17 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":"126120522","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/EDPC48408.2019.9012059
Andreas Greifelt, G. Dajaku, D. Gerling, J. Gerold, Arber Daiaku, Weibin Yang
This paper describes the series production challenges of high-efficient Flux Barrier technology used in permanent magnet synchronous machines. Within the paper the Flux Barrier technology is described and how it can be used in a beneficial way concerning efficiency or torque increase as well as cost saving element. Furthermore, challenges and beneficial effects are influenced within production. This effects are mentioned, underpinned with “lessons learned” from the first productions of Flux Barrier machines. The experiences of three different motor designs are described: a small fan motor, a medium power e-bike motor and a high torque steering drive. A consideration of cooling within Flux barriers is also mentioned in paper. Included are the measured facts about the sensitivity analysis and the prototype measurements with the comparison with the original machines as well as the summary and perspective of future work.
{"title":"Series Production Challenges of High-Efficient Flux Barrier Permanent Magnet Machines (FB-PMSM)","authors":"Andreas Greifelt, G. Dajaku, D. Gerling, J. Gerold, Arber Daiaku, Weibin Yang","doi":"10.1109/EDPC48408.2019.9012059","DOIUrl":"https://doi.org/10.1109/EDPC48408.2019.9012059","url":null,"abstract":"This paper describes the series production challenges of high-efficient Flux Barrier technology used in permanent magnet synchronous machines. Within the paper the Flux Barrier technology is described and how it can be used in a beneficial way concerning efficiency or torque increase as well as cost saving element. Furthermore, challenges and beneficial effects are influenced within production. This effects are mentioned, underpinned with “lessons learned” from the first productions of Flux Barrier machines. The experiences of three different motor designs are described: a small fan motor, a medium power e-bike motor and a high torque steering drive. A consideration of cooling within Flux barriers is also mentioned in paper. Included are the measured facts about the sensitivity analysis and the prototype measurements with the comparison with the original machines as well as the summary and perspective of future work.","PeriodicalId":119895,"journal":{"name":"2019 9th International Electric Drives Production Conference (EDPC)","volume":"37 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":"134115124","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/EDPC48408.2019.9011953
J. Niemann, A. Schlegel, M. Putz
Market growth and technological uncertainties characterize the electro-mobility. High emission standards, fossil fuel scarcity, environmental protection, and political initiatives promote this development. Besides, factors such as customer behavior, infrastructure, new competitors, and technological developments induce high volatility in forecasted market volumes. Due to these uncertainties, production systems of electrified vehicles require a combination of changeable production systems and flexibility measures. The production capacity of changeable production systems is currently determined by a conventional capacity planning method, which does not integrate the degrees of freedom conferred by changeability. In this publication, we present a new capacity planning method of changeable production systems in electro-mobility. Changeability comprises pre-defined measures that change either the capacity or the technological spectrum of productions by an investment. A total of five changeability drivers exist, thereof we consider scalability and universality. Scalability in this context refers to the technical, local, and personnel possibilities to expand and reduce factory elements and production systems. Universality focuses on technological production properties, in particular, the ability to meet different production and technology requirements. We define specific changeability options for both drivers. Moreover, we integrate these in production capacity planning, which leads to various production configurations. Additionally, we evaluate the monetary impact and the resulting flexibility of each configuration at any time within the observation period using the real options approach. We choose this approach to integrate market uncertainties in the decision- making process. Further, a Monte Carlo simulation validates all configurations showing positive option values, and we determine a final capacity plan. We apply the method to a production system for electric drives. Our results show that an early investment in scalability and universality options improve the financial performance and flexibility of a production system in an uncertain market environment.
{"title":"Method for Capacity Planning of Changeable Production Systems in the Electric Drives Production","authors":"J. Niemann, A. Schlegel, M. Putz","doi":"10.1109/EDPC48408.2019.9011953","DOIUrl":"https://doi.org/10.1109/EDPC48408.2019.9011953","url":null,"abstract":"Market growth and technological uncertainties characterize the electro-mobility. High emission standards, fossil fuel scarcity, environmental protection, and political initiatives promote this development. Besides, factors such as customer behavior, infrastructure, new competitors, and technological developments induce high volatility in forecasted market volumes. Due to these uncertainties, production systems of electrified vehicles require a combination of changeable production systems and flexibility measures. The production capacity of changeable production systems is currently determined by a conventional capacity planning method, which does not integrate the degrees of freedom conferred by changeability. In this publication, we present a new capacity planning method of changeable production systems in electro-mobility. Changeability comprises pre-defined measures that change either the capacity or the technological spectrum of productions by an investment. A total of five changeability drivers exist, thereof we consider scalability and universality. Scalability in this context refers to the technical, local, and personnel possibilities to expand and reduce factory elements and production systems. Universality focuses on technological production properties, in particular, the ability to meet different production and technology requirements. We define specific changeability options for both drivers. Moreover, we integrate these in production capacity planning, which leads to various production configurations. Additionally, we evaluate the monetary impact and the resulting flexibility of each configuration at any time within the observation period using the real options approach. We choose this approach to integrate market uncertainties in the decision- making process. Further, a Monte Carlo simulation validates all configurations showing positive option values, and we determine a final capacity plan. We apply the method to a production system for electric drives. Our results show that an early investment in scalability and universality options improve the financial performance and flexibility of a production system in an uncertain market environment.","PeriodicalId":119895,"journal":{"name":"2019 9th International Electric Drives Production Conference (EDPC)","volume":"1 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":"116615862","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/EDPC48408.2019.9011874
A. Mayr, Sebastian Dietze, T. Herzog, Eike Schäffer, Franziska Schäfer, Jochen Bauer, Jonathan Fuchs, J. Franke
The interest in artificial intelligence (AI) and its use in industrial production is growing steadily. The increasingly known machine learning, however, is only one of several AI technologies emerging from basic research. Another subarea of AI represent the so-called semantic technologies, which play a decisive role especially in knowledge management. They allow knowledge to be structured and processed in such a way that it can be used for targeted support in complex, knowledge-intensive tasks. Especially during the design of production systems, such technologies have the potential to reduce planning efforts by providing existing expert knowledge. For electric motor manufactures, designing a proper production system remains a challenge due to low standards and numerous alternative manufacturing processes. Accordingly, this paper provides an overview of semantic technologies and outlines their fundamental potential in the conceptual design of production systems. Finally, a pragmatic approach is presented to improve the future knowledge work at electric motor manufacturers.
{"title":"Knowledge-based Support of the Production System Design by Semantic Technologies Using the Example of the Electric Motor Production","authors":"A. Mayr, Sebastian Dietze, T. Herzog, Eike Schäffer, Franziska Schäfer, Jochen Bauer, Jonathan Fuchs, J. Franke","doi":"10.1109/EDPC48408.2019.9011874","DOIUrl":"https://doi.org/10.1109/EDPC48408.2019.9011874","url":null,"abstract":"The interest in artificial intelligence (AI) and its use in industrial production is growing steadily. The increasingly known machine learning, however, is only one of several AI technologies emerging from basic research. Another subarea of AI represent the so-called semantic technologies, which play a decisive role especially in knowledge management. They allow knowledge to be structured and processed in such a way that it can be used for targeted support in complex, knowledge-intensive tasks. Especially during the design of production systems, such technologies have the potential to reduce planning efforts by providing existing expert knowledge. For electric motor manufactures, designing a proper production system remains a challenge due to low standards and numerous alternative manufacturing processes. Accordingly, this paper provides an overview of semantic technologies and outlines their fundamental potential in the conceptual design of production systems. Finally, a pragmatic approach is presented to improve the future knowledge work at electric motor manufacturers.","PeriodicalId":119895,"journal":{"name":"2019 9th International Electric Drives Production Conference (EDPC)","volume":"47 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":"123097186","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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