René Siebert, R. Baumann, E. Beyer, P. Herwig, A. Wetzig
{"title":"Laser manufacturing of electrical machines","authors":"René Siebert, R. Baumann, E. Beyer, P. Herwig, A. Wetzig","doi":"10.1109/EDPC.2014.6984389","DOIUrl":"https://doi.org/10.1109/EDPC.2014.6984389","url":null,"abstract":"Laser remote cutting for electrical machine application and a new surface treatment method in order to heal manufacturing related magnetic degradation will be presented and discussed. In comparison to the state of the art laser remote cutting utilizes a brilliant high power solid-state laser producing less thermal and magnetic degradation in the processed part. A process integrated surface treatment additionally reduces the manufacturing related magnetic degradation by up to ten percent. Matter under consideration will be the control of cycle time of exemplary stator tooth geometry as well as the magnetic properties in comparison to conventional techniques.","PeriodicalId":423456,"journal":{"name":"2014 4th International Electric Drives Production Conference (EDPC)","volume":"68 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2014-12-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"121556104","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}
J. Bonig, B. Bickel, M. Spahr, C. Fischer, J. Franke
{"title":"Explicit dynamics process simulation of linear coil winding for electric drives production","authors":"J. Bonig, B. Bickel, M. Spahr, C. Fischer, J. Franke","doi":"10.1109/EDPC.2014.6984403","DOIUrl":"https://doi.org/10.1109/EDPC.2014.6984403","url":null,"abstract":"Slowly but steadily, more and more electric vehicles push onto the consumer market. For a cost efficient production of electrical engines, in first-class quality and in sufficient quantity, it is indispensable to understand the process of coil winding. Thereby the prediction of the wire behavior is one of the key challenges. Therefore, a detailed model is built to investigate wire behavior during the linear winding process. The finite element based simulation tool LS-DYNA serves as explicit dynamics tool. To represent the high dynamic process of winding within this simulation, some first adaptions have to be made. This means, that dynamic influences such as rotational speed or acceleration of the coil body are definable. Within process simulation, the given boundary conditions are applied to the model. The material properties of the wire under scrutiny are validated by a tensile test and by the values out of datasheets in previous research. In order to achieve the best convergence, different contact algorithms are selected for each individual contact behavior. Furthermore, specific adjustments to the mesh are necessary to gain significant results. State of the art in coil winding is an experimental procedure, which delivers adequate process parameters and, thus, expertise in winding technology. Nevertheless, there are a lot of different, interacting parameters, which have to be optimized in terms of boundary conditions. The simulation model of winding process, in which varying parameters can be optimized pertaining to the optimal winding result, calls for extensive research in this field. The generated model enables the user not only to influence the process parameters but also to modify the geometry of a winding body. To make the simulation scientifically sound, it is validated by previous experiments and simulations","PeriodicalId":423456,"journal":{"name":"2014 4th International Electric Drives Production Conference (EDPC)","volume":"26 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2014-12-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"129875415","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}
{"title":"A material model for lamination stacks based on rough contacts","authors":"V. Luchscheider, K. Willner, M. Maidorn","doi":"10.1109/EDPC.2014.6984431","DOIUrl":"https://doi.org/10.1109/EDPC.2014.6984431","url":null,"abstract":"This contribution presents, how to identify a material model of a lamination stack. The contact behavior between the single sheets is nonlinear and influences the behavior of the whole stack. The Simulation of the contact behavior is performed with contact models for normal and tangential direction. Due to the fact that calculating all sheets with contact is computational very expensive, a FE2-method is presented. With this method the calculation of the stack's behavior is based on a representative volume element. Further it is possible to identify a material model for the whole stack, which has got a linear and a nonlinear part. The linear part is caused by the material of the sheet, whereas the nonlinear part is a result of the contact behavior.","PeriodicalId":423456,"journal":{"name":"2014 4th International Electric Drives Production Conference (EDPC)","volume":"37 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2014-12-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"129912199","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}
A. Kampker, Andreas Maue, C. Deutskens, Ruben Forstmann
{"title":"Standardization and innovation: Dissolving the contradiction with modular production architectures","authors":"A. Kampker, Andreas Maue, C. Deutskens, Ruben Forstmann","doi":"10.1109/EDPC.2014.6984429","DOIUrl":"https://doi.org/10.1109/EDPC.2014.6984429","url":null,"abstract":"Industry is faced with increasing product variety, technical complexity and shortened product life cycles today. In spite of these increasing challenges consumers are not willing to pay for risen efforts. Industry relies on effective and efficient management and coordination of the departments involved across company and supply chain during all phases of product and process development. Modular Production Architectures (MPA) are a useful management-tool for the upcoming difficulties during product and process development. Especially, MPA can contribute to dissolve the contradiction between standardization and innovation. In this paper current standardization approaches are presented, i.e. general modular product architectures and process construction kits. MPA are then derived from the existing models as a standardization approach for the product-process-link. The methodology is described using a three step approach. Firstly, the product type range and the production steps have to be determined. Subsequently, the best-practice is to be identified by comparing different alternatives or benchmarking across competitors. In the last step the product design boundary parameters have to be implemented in the whole process chain. The paper is terminated by a validation of the presented approach in automotive industry.","PeriodicalId":423456,"journal":{"name":"2014 4th International Electric Drives Production Conference (EDPC)","volume":"9 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2014-12-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"125460173","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}
D. Coupek, A. Verl, A. Lechler, J. Aichele, S. Junker
{"title":"Defect reduction in the production of electric drives by downstream compensation and space-resolved inspection","authors":"D. Coupek, A. Verl, A. Lechler, J. Aichele, S. Junker","doi":"10.1109/EDPC.2014.6984428","DOIUrl":"https://doi.org/10.1109/EDPC.2014.6984428","url":null,"abstract":"Improving the material efficiency in the production of electric drives is necessary as the electric automotive sector is growing very fast. Here, a method for early defect identification and downstream compensation, which allows defect reduction and consequently waste reduction, is presented. This reduces the waste motor parts (rotor stacks) and decreases the amount of rare earths to be recycled. A new inspection device was developed that allows a space-resolved in-line inspection of single rotor stacks as well as assembled rotors, in the same inspection station. This inspection device was realized as a demonstrator system, which is explained in detail in this paper. The inspection results are used as input for the downstream compensation methods, selective and sequential rotor assembly. Both methods combine stacks that are out of tolerances in such a way that the final rotor is within the specified limitations. Thus, low quality parts form a high quality assembly without having to scrap stacks and magnets.","PeriodicalId":423456,"journal":{"name":"2014 4th International Electric Drives Production Conference (EDPC)","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2014-12-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"130569725","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}
{"title":"Investigation of the segment order in step-skewed synchronous machines on noise and vibration","authors":"J. Blum, J. Merwerth, H. Herzog","doi":"10.1109/EDPC.2014.6984413","DOIUrl":"https://doi.org/10.1109/EDPC.2014.6984413","url":null,"abstract":"This paper deals with the noise radiated by step-skewed permanent magnet excited synchronous machines and the particular influence of the segment order on the vibro-acoustic behavior. It is well known that the shape of the electromagnetic forces acting along the circumference of the stator core is decisive for the generation of noise and vibration. The influence of the axial behavior of these forces is, however, to a great extend unexplored. A first insight is gained in this paper by means of a structural dynamic response analysis of a stator for different skewing sequences. Each sequence excites a particular combination of structural modes differing in their axial behavior. Structural modes of a low axial order have shown to be significantly more relevant concerning the acoustic behavior of a machine. Therefore, an analytic method is developed that allows a comparison of different skewing arrangements regarding the excitation axial modes without the necessity of structural FE simulations. A comparison of three particular skewing arrangements (linear, v-shaped, and zigzag predicts a significant influence on the vibro-acoustic behavior. To validate the results, three prototype traction machines have been built. The measurement results follow the predicted influence with differences in the sound pressure level of more than 10dB.","PeriodicalId":423456,"journal":{"name":"2014 4th International Electric Drives Production Conference (EDPC)","volume":"12 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2014-12-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"133799775","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}
F. Blanc, J. Fleischer, S. Sautter, Tobias Delzs, Jurgen Hagedorn
{"title":"Fault analysis of linear winding processes for noncircular orthocyclic coils: Investigation of winding scheme dependencies within the winding process development","authors":"F. Blanc, J. Fleischer, S. Sautter, Tobias Delzs, Jurgen Hagedorn","doi":"10.1109/EDPC.2014.6984402","DOIUrl":"https://doi.org/10.1109/EDPC.2014.6984402","url":null,"abstract":"This paper comprises an overview of different aspects for the development of an orthocyclic winding scheme design. Based on an analysis of the process dependencies, winding faults will be characterized and counter measures will be introduced. It is the overall goal to investigate the use of different process parameters for fault correction and to investigate the parameter dependencies regarding winding speed on the winding scheme. For a detailed process investigation, the application of a multi-body-dynamic simulation will be introduced.","PeriodicalId":423456,"journal":{"name":"2014 4th International Electric Drives Production Conference (EDPC)","volume":"58 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2014-12-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"133081321","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}
G. Lempidis, Yichuan Zhang, M. Jung, R. Marklein, S. Sotiriou, Yanqi Ma
{"title":"Wired and wireless charging of electric vehicles: A system approach","authors":"G. Lempidis, Yichuan Zhang, M. Jung, R. Marklein, S. Sotiriou, Yanqi Ma","doi":"10.1109/EDPC.2014.6984421","DOIUrl":"https://doi.org/10.1109/EDPC.2014.6984421","url":null,"abstract":"In this paper the complete topology of a multifunctional charging system for electric vehicle (EV) is discussed. A resonant inductive energy transfer system is analyzed, simulated and experimentally validated. Finally, a control strategy for the bidirectional LLC resonant converter is proposed in order to increase efficiency in partial load operation.","PeriodicalId":423456,"journal":{"name":"2014 4th International Electric Drives Production Conference (EDPC)","volume":"9 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2014-12-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"129497769","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}
J. Richnow, P. Stenzel, A. Renner, D. Gerling, Christian Endisch
{"title":"Influence of different impregnation methods and resins on thermal behavior and lifetime of electrical stators","authors":"J. Richnow, P. Stenzel, A. Renner, D. Gerling, Christian Endisch","doi":"10.1109/EDPC.2014.6984406","DOIUrl":"https://doi.org/10.1109/EDPC.2014.6984406","url":null,"abstract":"The relationship between impregnation process and winding temperature has not been analyzed in detail yet. Therefore, one purpose of this paper is to investigate the correlation between impregnation process, resin absorption, applied resin, and thermal behavior. Apart from thermal behavior, it has to be ensured that the lifetime of the manufactured electrical machines still meets industrial specifications. The lifetime is primarily affected by the quality of the insulation system. So the second purpose of this paper is to investigate the influence of the named aspects on the lifetime of an electrical machine.","PeriodicalId":423456,"journal":{"name":"2014 4th International Electric Drives Production Conference (EDPC)","volume":"29 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2014-12-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"130522511","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}
{"title":"Comparison of end of line tests for serial production of electric motors in hybrid truck applications","authors":"A. Butov, A. Verl","doi":"10.1109/EDPC.2014.6984405","DOIUrl":"https://doi.org/10.1109/EDPC.2014.6984405","url":null,"abstract":"This paper focuses on the steps to compare methods to detects faults at the end of line (EOL) testing section after the assembly of permanent magnet synchronous motors (PMSM) for automotive, especially truck applications. In detail two philosophies were discovered in case of using end of line test benches to check all functionalities of an electric motor after all assembly steps. The comparison is a practical approach and involves three parts to investigate on the passive end of line test bench as a sufficient method to detect all critical faults and the performance of PMSMs.","PeriodicalId":423456,"journal":{"name":"2014 4th International Electric Drives Production Conference (EDPC)","volume":"16 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2014-12-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"124127788","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}