Pub Date : 2022-11-29DOI: 10.1109/EDPC56367.2022.10019739
A. Kampker, H. Heimes, Benjamin Dorn, F. Brans
Due to the increasing demand and the transformation of the automotive industry, immense capacities for the production of electric drives have been built up in recent years. When building up these capacities, manufacturing companies are facing enormous time pressure, which is intensified by the fact that planners often only have little experiences with the used technologies. As a result, entire production lines or larger sections of production lines are assigned to machine suppliers in so-called closed tenders. Those tenders are more product-oriented than process-oriented, so that the machine supplier has the process responsibility. From the point of view of manufacturing companies, the reason for this approach lies primarily in the reduction of risk and interfaces. Production systems are handed over to the manufacturing companies ready for use after planning and installation. This results in the risk of the manufacturing company, as system operator, becoming technologically dependent on the machine supplier in some cases. In addition, market dynamics mean that individual technologies are continuously being developed further. This raises the question of how to ensure that changes to existing production systems can be implemented in the most time- and cost-efficient way possible, taking into account the conditions in the industry, such as a lack of experience on the operator side, the dynamics in the availability of new technologies and the multilateral project constitution consisting of machine suppliers and operators. For that purpose, this paper presents a framework that can be used to systematically identify and assess the risks related with the substitution of individual technologies in a disruptive environment. In addition, measures for risk reduction for technology substitutions are derived, considering the lack of experiential knowledge. The framework is presented at the example of hairpin stator production.
{"title":"Framework for Integration and Substitution of Process Technologies in Existing Production Systems Under Consideration of Limited Technology Experiences","authors":"A. Kampker, H. Heimes, Benjamin Dorn, F. Brans","doi":"10.1109/EDPC56367.2022.10019739","DOIUrl":"https://doi.org/10.1109/EDPC56367.2022.10019739","url":null,"abstract":"Due to the increasing demand and the transformation of the automotive industry, immense capacities for the production of electric drives have been built up in recent years. When building up these capacities, manufacturing companies are facing enormous time pressure, which is intensified by the fact that planners often only have little experiences with the used technologies. As a result, entire production lines or larger sections of production lines are assigned to machine suppliers in so-called closed tenders. Those tenders are more product-oriented than process-oriented, so that the machine supplier has the process responsibility. From the point of view of manufacturing companies, the reason for this approach lies primarily in the reduction of risk and interfaces. Production systems are handed over to the manufacturing companies ready for use after planning and installation. This results in the risk of the manufacturing company, as system operator, becoming technologically dependent on the machine supplier in some cases. In addition, market dynamics mean that individual technologies are continuously being developed further. This raises the question of how to ensure that changes to existing production systems can be implemented in the most time- and cost-efficient way possible, taking into account the conditions in the industry, such as a lack of experience on the operator side, the dynamics in the availability of new technologies and the multilateral project constitution consisting of machine suppliers and operators. For that purpose, this paper presents a framework that can be used to systematically identify and assess the risks related with the substitution of individual technologies in a disruptive environment. In addition, measures for risk reduction for technology substitutions are derived, considering the lack of experiential knowledge. The framework is presented at the example of hairpin stator production.","PeriodicalId":297228,"journal":{"name":"2022 12th International Electric Drives Production Conference (EDPC)","volume":"141 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-11-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"134032542","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 : 2022-11-29DOI: 10.1109/EDPC56367.2022.10019736
A. Vogel, Andreas Morello, A. Mahr, J. Franke, A. Kühl
Especially in the production of electric drives, highly efficient drives in new use cases are needed to reach global climate targets. To obtain maximum motor power with minimal motor weight, it is necessary to fill the stator slots with a maximum of copper. In the past, the round wire has been the state of the art. However, with increasing efficiency expectations, round wires cannot reach the performance targets anymore. Form coils, also known as hairpins, are one common technology with higher fill factors. In addition, winding processes with endless flat or rectangle wires are currently in development and could fulfill the demand for electric drives in the future. Accompanied by new joining solutions, this technology could lower the production cost on the one hand and reduce the contacting spots with potentially increased contacting resistance on the other hand. One challenge in the automation of their winding and joining is a fully automated process chain, starting with the winding process and ending with end-of-line testing. One thing, all process steps have in common is the requirement to detect the position of the wires with high precision. This detection is fundamental to subsequent steps, performed by smart robot-based machines.
{"title":"Challenges in Cost-effective Automated Detection of Enameled Flat Wires in the Context of Robot-based Stator Manipulation","authors":"A. Vogel, Andreas Morello, A. Mahr, J. Franke, A. Kühl","doi":"10.1109/EDPC56367.2022.10019736","DOIUrl":"https://doi.org/10.1109/EDPC56367.2022.10019736","url":null,"abstract":"Especially in the production of electric drives, highly efficient drives in new use cases are needed to reach global climate targets. To obtain maximum motor power with minimal motor weight, it is necessary to fill the stator slots with a maximum of copper. In the past, the round wire has been the state of the art. However, with increasing efficiency expectations, round wires cannot reach the performance targets anymore. Form coils, also known as hairpins, are one common technology with higher fill factors. In addition, winding processes with endless flat or rectangle wires are currently in development and could fulfill the demand for electric drives in the future. Accompanied by new joining solutions, this technology could lower the production cost on the one hand and reduce the contacting spots with potentially increased contacting resistance on the other hand. One challenge in the automation of their winding and joining is a fully automated process chain, starting with the winding process and ending with end-of-line testing. One thing, all process steps have in common is the requirement to detect the position of the wires with high precision. This detection is fundamental to subsequent steps, performed by smart robot-based machines.","PeriodicalId":297228,"journal":{"name":"2022 12th International Electric Drives Production Conference (EDPC)","volume":"32 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-11-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"114271567","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 : 2022-11-29DOI: 10.1109/EDPC56367.2022.10019745
Markus Omlor, J. Reith, A. Breitbarth, C. Hake, K. Dilger
Due to the electrification of the drive train, hairpin technology for stators has established itself in the automotive industry. Hairpins are rectangular copper wires connected to full stator coils using laser beam welding. The welding results depend on the preliminary processes and tolerances of the welding system. The quality of the connection is defined by its cross-sectional area that is influenced by porosity. Another quality characteristic are spatters. The quantification of the cross-sectional area and porosity of the welding seams is usually carried out post-process using X-Ray computed tomography (CT). This paper investigates spatters using high-speed camera-based image processing and airborne sound using an optical microphone. By varying influencing factors of the welding result (position deviations, maximum laser power, focal position shift, stripping quality), different quality levels of the welding joints are generated. With the developed method for in-process evaluation of high-speed camera images, a spatter detection and quantification of their number and size is enabled. The method shows an accuracy of 84%. In addition, the characteristics of the recorded airborne sound during the process allows conclusions to be drawn about the welding results. Deviations in maximum laser power, height offset, focal position shift and stripping quality can be detected. Both methods provide a reliable inline monitoring of the welding process as well as its quantitative quality assessment.
{"title":"Inline Process Monitoring of Hairpin Welding Using Optical and Acoustic Quality Metrics","authors":"Markus Omlor, J. Reith, A. Breitbarth, C. Hake, K. Dilger","doi":"10.1109/EDPC56367.2022.10019745","DOIUrl":"https://doi.org/10.1109/EDPC56367.2022.10019745","url":null,"abstract":"Due to the electrification of the drive train, hairpin technology for stators has established itself in the automotive industry. Hairpins are rectangular copper wires connected to full stator coils using laser beam welding. The welding results depend on the preliminary processes and tolerances of the welding system. The quality of the connection is defined by its cross-sectional area that is influenced by porosity. Another quality characteristic are spatters. The quantification of the cross-sectional area and porosity of the welding seams is usually carried out post-process using X-Ray computed tomography (CT). This paper investigates spatters using high-speed camera-based image processing and airborne sound using an optical microphone. By varying influencing factors of the welding result (position deviations, maximum laser power, focal position shift, stripping quality), different quality levels of the welding joints are generated. With the developed method for in-process evaluation of high-speed camera images, a spatter detection and quantification of their number and size is enabled. The method shows an accuracy of 84%. In addition, the characteristics of the recorded airborne sound during the process allows conclusions to be drawn about the welding results. Deviations in maximum laser power, height offset, focal position shift and stripping quality can be detected. Both methods provide a reliable inline monitoring of the welding process as well as its quantitative quality assessment.","PeriodicalId":297228,"journal":{"name":"2022 12th International Electric Drives Production Conference (EDPC)","volume":"24 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-11-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"128488569","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 : 2022-11-29DOI: 10.1109/EDPC56367.2022.10019747
A. Riedel, A. Kühl, J. Franke, Rolf Gräf, T. Hubert, David Bauer
The increasing demand of electric drives in the mobility sector leads to continuous innovations in the development and production of electric machines. Currently, it can be seen that hairpin technology is well established in the automotive industry for traction drives. In addition to the high level of automation of the process, the reasons therefore are the achievable copper filling factors, which result from the flat conductors used and thus increase the power density of the electrical machine. However, at higher frequencies, as a result of higher driving speeds, large conductor dimensions, especially the height of the conductor, lead to undesirable aspects in the form of eddy current losses. These negative effects can be reduced by replacing the solid rectangular conductor with a stranded conductor. Therefore, the substitution of the conductor material in the field of hairpin technology can be classified as the next innovation stage. The base material is a twisted stranded conductor compacted into a rectangular shape. In this paper, a novel process chain for the manufacturing of a stranded hairpin stator is presented, individual process steps are analyzed and potential improvement measures are explained. Subsequently, an evaluation is made on the basis of an assembled and electrotechnically measured stator with stranded hairpins.
{"title":"Experimental Investigation of a New Manufacturing Technology for Hairpin Stators with Litz Wires","authors":"A. Riedel, A. Kühl, J. Franke, Rolf Gräf, T. Hubert, David Bauer","doi":"10.1109/EDPC56367.2022.10019747","DOIUrl":"https://doi.org/10.1109/EDPC56367.2022.10019747","url":null,"abstract":"The increasing demand of electric drives in the mobility sector leads to continuous innovations in the development and production of electric machines. Currently, it can be seen that hairpin technology is well established in the automotive industry for traction drives. In addition to the high level of automation of the process, the reasons therefore are the achievable copper filling factors, which result from the flat conductors used and thus increase the power density of the electrical machine. However, at higher frequencies, as a result of higher driving speeds, large conductor dimensions, especially the height of the conductor, lead to undesirable aspects in the form of eddy current losses. These negative effects can be reduced by replacing the solid rectangular conductor with a stranded conductor. Therefore, the substitution of the conductor material in the field of hairpin technology can be classified as the next innovation stage. The base material is a twisted stranded conductor compacted into a rectangular shape. In this paper, a novel process chain for the manufacturing of a stranded hairpin stator is presented, individual process steps are analyzed and potential improvement measures are explained. Subsequently, an evaluation is made on the basis of an assembled and electrotechnically measured stator with stranded hairpins.","PeriodicalId":297228,"journal":{"name":"2022 12th International Electric Drives Production Conference (EDPC)","volume":"26 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-11-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"117301112","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 : 2022-11-29DOI: 10.1109/EDPC56367.2022.10019758
M. Hoffmann, Marius Siekmann
Synchronous reluctance machines (SynRM) characterize a sinusoidal magnetic air gap field. They are deployed in a variety of applications and operated by a frequency inverter. When implementing an optimized control method, its efficiency meets the requirements of the IE4 class and higher. Therefore, the SynRM are alternatives to induction machines due to its robust structure and its low costs when employed as variable speed drive in powertrains. The paper compares two different efficiency-optimized methods for the field-oriented control of a SynRM.
{"title":"Efficiency-optimized control of variable speed reluctance machines","authors":"M. Hoffmann, Marius Siekmann","doi":"10.1109/EDPC56367.2022.10019758","DOIUrl":"https://doi.org/10.1109/EDPC56367.2022.10019758","url":null,"abstract":"Synchronous reluctance machines (SynRM) characterize a sinusoidal magnetic air gap field. They are deployed in a variety of applications and operated by a frequency inverter. When implementing an optimized control method, its efficiency meets the requirements of the IE4 class and higher. Therefore, the SynRM are alternatives to induction machines due to its robust structure and its low costs when employed as variable speed drive in powertrains. The paper compares two different efficiency-optimized methods for the field-oriented control of a SynRM.","PeriodicalId":297228,"journal":{"name":"2022 12th International Electric Drives Production Conference (EDPC)","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-11-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"129031481","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 : 2022-11-29DOI: 10.1109/EDPC56367.2022.10019752
M. Ziegler, F. Brandl, J. Franke, A. Kühl
Soft magnetic cores in electric machines conduct and enhance the magnetic flux. The magnetic properties of the single sheets are mainly influenced by the alloying elements, the microstructure and the rolling and annealing process. To reduce eddy current losses during operation, soft magnetic cores are laminated. However, all manufacturing processes and the further assembling steps, like mounting of the stator, change the magnetic properties of the stack. Laser welding is a common method for producing lamination stacks, as very thin sheets can be welded automatically with high velocities. However, the weld seams are electrically conductive connections, which lead to an increase in eddy current losses. Furthermore, the microstructure in the heat-affected zone is impaired, which leads to a higher demand for magnetization and increased hysteresis losses. A main reason for this is the magneto-mechanical effect, as mechanical stresses influence the magnetic properties. For improvement, the process parameters must be adapted to the specific material system and the requirements. In this paper, a numerical simulation model for visualizing and optimizing the heat distribution in welded electrical steel laminations is presented. The main objective is the analysis of the weld dimension for different welding parameters. For this purpose, a transient thermal analysis is carried out with Ansys Workbench. The welding process is mapped in a simplified way with a moving heat source for different conditions. To validate the results, a comparison to experimental tests is applied. In this way, the simulation results are verified and potential sources of errors are identified.
{"title":"Numerical Simulation of the Laser Welding Process for Electrical Steel Laminations","authors":"M. Ziegler, F. Brandl, J. Franke, A. Kühl","doi":"10.1109/EDPC56367.2022.10019752","DOIUrl":"https://doi.org/10.1109/EDPC56367.2022.10019752","url":null,"abstract":"Soft magnetic cores in electric machines conduct and enhance the magnetic flux. The magnetic properties of the single sheets are mainly influenced by the alloying elements, the microstructure and the rolling and annealing process. To reduce eddy current losses during operation, soft magnetic cores are laminated. However, all manufacturing processes and the further assembling steps, like mounting of the stator, change the magnetic properties of the stack. Laser welding is a common method for producing lamination stacks, as very thin sheets can be welded automatically with high velocities. However, the weld seams are electrically conductive connections, which lead to an increase in eddy current losses. Furthermore, the microstructure in the heat-affected zone is impaired, which leads to a higher demand for magnetization and increased hysteresis losses. A main reason for this is the magneto-mechanical effect, as mechanical stresses influence the magnetic properties. For improvement, the process parameters must be adapted to the specific material system and the requirements. In this paper, a numerical simulation model for visualizing and optimizing the heat distribution in welded electrical steel laminations is presented. The main objective is the analysis of the weld dimension for different welding parameters. For this purpose, a transient thermal analysis is carried out with Ansys Workbench. The welding process is mapped in a simplified way with a moving heat source for different conditions. To validate the results, a comparison to experimental tests is applied. In this way, the simulation results are verified and potential sources of errors are identified.","PeriodicalId":297228,"journal":{"name":"2022 12th International Electric Drives Production Conference (EDPC)","volume":"27 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-11-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"121190293","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 : 2022-11-29DOI: 10.1109/EDPC56367.2022.10019767
Christian Wachter, Fenja Haller, Florian Liebetrau
With additive manufacturing, copper windings and even whole coils can be manufactured in a new, totally different approach than with common manufacturing methods. The coil design is no longer bound to the limitations given by the wires bend radius or the geometric capabilities of winding machines. Therefore, additive manufacturing offers new degrees of freedom for the design of copper windings and thus the design of electric machines. However, the electric properties of printed copper material must be known exactly and should be comparable to solid copper wire. This paper examines the impedance characteristics of additive manufactured copper conductors of two different copper alloys with varying print density and two different cross-section areas. Additionally, copper conductors consisting of multiple twisted subprofiles are examined, emulating stranded conductors. The measurement results are set in relation to an extruded copper profile to ensure comparability. The influence of the skin effect is examined by performing the investigations over a wide frequency range. Furthermore, the effect of different print densities on the effective resistance can be shown clearly. Besides the measurement results, an evaluation of the possible field of application and the limitations is given.
{"title":"Additive Manufactured Copper Conductors: Impedance Characteristics of Samples with Varying Density and Cross-section profile","authors":"Christian Wachter, Fenja Haller, Florian Liebetrau","doi":"10.1109/EDPC56367.2022.10019767","DOIUrl":"https://doi.org/10.1109/EDPC56367.2022.10019767","url":null,"abstract":"With additive manufacturing, copper windings and even whole coils can be manufactured in a new, totally different approach than with common manufacturing methods. The coil design is no longer bound to the limitations given by the wires bend radius or the geometric capabilities of winding machines. Therefore, additive manufacturing offers new degrees of freedom for the design of copper windings and thus the design of electric machines. However, the electric properties of printed copper material must be known exactly and should be comparable to solid copper wire. This paper examines the impedance characteristics of additive manufactured copper conductors of two different copper alloys with varying print density and two different cross-section areas. Additionally, copper conductors consisting of multiple twisted subprofiles are examined, emulating stranded conductors. The measurement results are set in relation to an extruded copper profile to ensure comparability. The influence of the skin effect is examined by performing the investigations over a wide frequency range. Furthermore, the effect of different print densities on the effective resistance can be shown clearly. Besides the measurement results, an evaluation of the possible field of application and the limitations is given.","PeriodicalId":297228,"journal":{"name":"2022 12th International Electric Drives Production Conference (EDPC)","volume":"38 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-11-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"129919330","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 : 2022-11-29DOI: 10.1109/EDPC56367.2022.10019746
Henrik Christoph Born, F. Blanc, Volkmar Platte, A. Kampker, H. Heimes, Benjamin Dorn, F. Brans, David Drexler, Fabian Oehler, Andrea zu Münster, Sebastian Reising
In the field of automotive electric traction machines, the hairpin stator technology has become one of the established standards. This uses rigid, solid rectangular insulated copper wires instead of flexible round enameled wires. This technology is associated with higher efficiencies on the product side due to high slot fill factors and replaces rather stochastic winding processes on the process side with deterministic automated manufacturing and assembly processes. At higher-frequency operating points of electrical machines, however, rectangular copper wires are at a disadvantage compared with high frequency litz wires, because the AC losses are exceeding the DC losses. Against this background, the formed litz wire technology represents one of the next innovations in electric motor production. The starting material is a high frequency litz wire, which is profiled, compressed and afterwards formed to replace rectangular copper wires in hairpin stator production. From the changed starting material, challenges arise from the necessary adaptation of the individual production processes. This paper describes a general process chain of formed litz wire winding technology and the deriving challenges in production.
{"title":"Development of a Production Process for Formed Litz Wire Stator Windings","authors":"Henrik Christoph Born, F. Blanc, Volkmar Platte, A. Kampker, H. Heimes, Benjamin Dorn, F. Brans, David Drexler, Fabian Oehler, Andrea zu Münster, Sebastian Reising","doi":"10.1109/EDPC56367.2022.10019746","DOIUrl":"https://doi.org/10.1109/EDPC56367.2022.10019746","url":null,"abstract":"In the field of automotive electric traction machines, the hairpin stator technology has become one of the established standards. This uses rigid, solid rectangular insulated copper wires instead of flexible round enameled wires. This technology is associated with higher efficiencies on the product side due to high slot fill factors and replaces rather stochastic winding processes on the process side with deterministic automated manufacturing and assembly processes. At higher-frequency operating points of electrical machines, however, rectangular copper wires are at a disadvantage compared with high frequency litz wires, because the AC losses are exceeding the DC losses. Against this background, the formed litz wire technology represents one of the next innovations in electric motor production. The starting material is a high frequency litz wire, which is profiled, compressed and afterwards formed to replace rectangular copper wires in hairpin stator production. From the changed starting material, challenges arise from the necessary adaptation of the individual production processes. This paper describes a general process chain of formed litz wire winding technology and the deriving challenges in production.","PeriodicalId":297228,"journal":{"name":"2022 12th International Electric Drives Production Conference (EDPC)","volume":"48 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-11-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"134351785","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 : 2022-11-29DOI: 10.1109/EDPC56367.2022.10019750
Ben Hunt, Anburaja Muruganandam, Dezhi Li, P. Franciosa
This paper explores the weldability of 1xxx and 6xxx series aluminium (Al) round wire welded to a range of Al and copper (Cu) plates to represent busbar and terminals for remote laser welding (RLW) and ultrasonic welding (USW), respectively. The motivations for materials are discussed and evaluated from a performance and high-volume manufacturing perspective for low-cost traction motors. The welding processes are assessed for their suited winding schemes. This paper proposes a novel approach of using USW to weld multiple thicker conductors with the aim of producing stranded wire terminations, similar to that commonly used for wire harnesses. The paper also proposes an alternative weld configuration as the main contribution for RLW. This utilises an axially focused laser beam direct to the interface between the wire and busbar. The aim is that this will improve the weldability of the Al-to-Cu specimens without the use of filler wire, commonly adopted in these scenarios, in addition to simplifying manufacturability. Lastly, the paper reviews the results of the proposed methods and discusses the manufacturing implications.
{"title":"Weldability Study of Round Aluminium Magnet Wires for Lightweight Low-Cost Traction Electric Motor Applications","authors":"Ben Hunt, Anburaja Muruganandam, Dezhi Li, P. Franciosa","doi":"10.1109/EDPC56367.2022.10019750","DOIUrl":"https://doi.org/10.1109/EDPC56367.2022.10019750","url":null,"abstract":"This paper explores the weldability of 1xxx and 6xxx series aluminium (Al) round wire welded to a range of Al and copper (Cu) plates to represent busbar and terminals for remote laser welding (RLW) and ultrasonic welding (USW), respectively. The motivations for materials are discussed and evaluated from a performance and high-volume manufacturing perspective for low-cost traction motors. The welding processes are assessed for their suited winding schemes. This paper proposes a novel approach of using USW to weld multiple thicker conductors with the aim of producing stranded wire terminations, similar to that commonly used for wire harnesses. The paper also proposes an alternative weld configuration as the main contribution for RLW. This utilises an axially focused laser beam direct to the interface between the wire and busbar. The aim is that this will improve the weldability of the Al-to-Cu specimens without the use of filler wire, commonly adopted in these scenarios, in addition to simplifying manufacturability. Lastly, the paper reviews the results of the proposed methods and discusses the manufacturing implications.","PeriodicalId":297228,"journal":{"name":"2022 12th International Electric Drives Production Conference (EDPC)","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-11-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"133574967","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 : 2022-11-29DOI: 10.1109/EDPC56367.2022.10019760
L. Hausmann, F. Wirth, J. Fleischer
In recent years, the hairpin technology has become the most relevant process chain for manufacturing of stator windings applied in electric traction motors. However, there are still limitations with regard to flexibility and the economic production of small quantities - especially due to the tool-bound process steps. Resulting from the complex machine kinematics and a stator-specific tooling for the simultaneous forming of several hundred open coil endings, the twisting process of the subsequently welded winding head of hairpin stators is critical in particular. Against this background, a robot-based approach for a flexible twisting process is presented in this paper as an alternative to conventionally used machine configurations. In this way, both an economical small series production of stators and accelerated prototyping should be enabled. In the beginning, this paper covers the general process sequence as well as the developed machine and tooling concept. To compensate the increased effort for start-up and control required for sequential kinematic wire forming, the basic framework of a dedicated simulation environment for rapid offline planning is introduced. Finally, the prototype of the developed machine set-up is presented and additionally used for an experimental proof of concept.
{"title":"Flexible Twisting Process of Stators with Hairpin Winding","authors":"L. Hausmann, F. Wirth, J. Fleischer","doi":"10.1109/EDPC56367.2022.10019760","DOIUrl":"https://doi.org/10.1109/EDPC56367.2022.10019760","url":null,"abstract":"In recent years, the hairpin technology has become the most relevant process chain for manufacturing of stator windings applied in electric traction motors. However, there are still limitations with regard to flexibility and the economic production of small quantities - especially due to the tool-bound process steps. Resulting from the complex machine kinematics and a stator-specific tooling for the simultaneous forming of several hundred open coil endings, the twisting process of the subsequently welded winding head of hairpin stators is critical in particular. Against this background, a robot-based approach for a flexible twisting process is presented in this paper as an alternative to conventionally used machine configurations. In this way, both an economical small series production of stators and accelerated prototyping should be enabled. In the beginning, this paper covers the general process sequence as well as the developed machine and tooling concept. To compensate the increased effort for start-up and control required for sequential kinematic wire forming, the basic framework of a dedicated simulation environment for rapid offline planning is introduced. Finally, the prototype of the developed machine set-up is presented and additionally used for an experimental proof of concept.","PeriodicalId":297228,"journal":{"name":"2022 12th International Electric Drives Production Conference (EDPC)","volume":"112 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-11-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"116440924","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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