Simulation of the assembly process of the insert technique for distributed windings

As the efficiency of electric power trains in hybrid electric vehicles should be increased and at the same time the manufacturing costs reduced, different motor designs and production concepts need to be considered. Because of the nearly sinusoidal magnetic field inside, the stator design with distributed windings, which is typically produced with the insert technique, is technically preferred. The insert technique offers a high productivity because the complete winding assembling process can be done in one step. This results in the fact, that nearly 80% of all electric motors worldwide have distributed windings. In order to enhance the possibilities for distributed windings with the insert technique, the current fill factor needs to be improved. Due to the fact that the actual wire placement cannot be measured und thus not optimized, a simulative approach with a multi-body simulation is used to understand the process interactions between the wires, the stator groove and the tool. This approach will be presented in this paper.