Innovative Wickeltechnologien für Statorspulen zur Erhöhung des Füllfaktors und Reduzierung der Beanspruchungen im Wickelprozess

In this thesis several technologies for manufacturing stator windings are developed and investigated and an analysis of these processes is performed. The needle winding with supporting winding caps as a modification of the conventional needle winding allows improved fill factors by a modified winding path of the winding needle, supported by specially adapted winding heads. Based on experimental feasibility studies, design recommendations are derived. The winding process with preheated wire allows reduced cavities under non-circular stator windings resulting in an improved thermal conductivity while allowing for reduced wire tensions. Therefor the wire is heated during the winding process, so that a softening of the copper as well as the reversible thermal expansion can be utilized. In the field of simulation of winding processes the impact of element sizes as well as the variation of material properties on the accuracy of simulation results is investigated and evaluated.