Development of a high-production and economical production technology for form-forming coils of electrical drives

 

Motivation and Approach

Development of a high-production and economical production technology for form-forming coils of electrical drives. The performance of electric motors depends to a large extent on the quantity of the electrically conductive material used, usually copper wire. The space available in modern electric vehicles, however, is very limited and thus also the place for the electric motor. In order to make the best possible use of the offered volume, it is therefore necessary to optimize the currently established technology of the wound round-wire. Innovative processes enable the production of so-called forming coils by means of targeted deformation of the wire. In this case, much more material can be installed in the same installation space, which leads to a significant increase in efficiency and efficiency of electric motors. The project is carried out in cooperation with the companies Schaeffler and Breuckmann as well as the Institut für Bildsame Formgebung, in short: IBF, RWTH Aachen University and is funded by the German Federal Ministry of Education and Research.

Research Objectives

  • Development of an innovative tool technology, which makes it possible to produce coils manufactured in the form of a cost-effective coil.
  • Construction of technology demonstrators in the form of wheel hub drives using the new winding technology.
  • Increased mechanical power of the electric motor by 20 per cent, with the same installation space.

BMBF promotional number: 02P16A012.