Dynamic behavior analysis of copper wire for predicting defects in the winding process of a motor coil
In recent years, efforts to promote energy conservation have become more active, and there is an increasing demand for high-efficiency motor coils. The efficiency of permanent magnet motors is closely related to manufacturing engineering. By winding copper wire at high density, not only coil resista...
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| Main Authors: | , , , , , , |
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| Format: | Article |
| Language: | Japanese |
| Published: |
The Japan Society of Mechanical Engineers
2025-02-01
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| Series: | Nihon Kikai Gakkai ronbunshu |
| Subjects: | |
| Online Access: | https://www.jstage.jst.go.jp/article/transjsme/91/944/91_24-00200/_pdf/-char/en |
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| Summary: | In recent years, efforts to promote energy conservation have become more active, and there is an increasing demand for high-efficiency motor coils. The efficiency of permanent magnet motors is closely related to manufacturing engineering. By winding copper wire at high density, not only coil resistance but also energy losses due to coil heating can be reduced. However, manufacturing defects reducing coil density can occur in the winding process. When they occur, rewinding of copper wires must be performed aligning several parameters based on the experience of operators. Therefore, this paper proposes a simulation method for the dynamic deformation of copper wire in the winding process to predict defects in the motor coil manufacturing process. First, the copper wire is assumed to be an elastic-plastic body and modeled discretely as a set of mass points connected by springs. The deformation of the copper wire is considered to be expansion, contraction, bending, and twisting. In particular, an object coordinate system for each mass point is introduced to express the twisting deformation. Next, to maintain the consistency of the copper wire, constraints between the spatial coordinates of each mass point and the direction of the object coordinate system are formulated. Under these constraints, the equations of motion are solved to predict the dynamic behavior of the copper wire. In this paper, the simulation domain of the winding process is limited to speed up the calculation. Since the copper wire is supplied from outside the simulation domain, constraints on the supply point are also formulated. Finally, a simulation of winding the copper wire around a rectangular core was performed. The simulation results showed that the defect of loose winding, called "bulging" is related to the rotation speed of the core and the tension of the supplied copper wire. |
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| ISSN: | 2187-9761 |