- Refinement of needle winding technology
- Automation and control engineering
- Path and trajectory planning
- Modelling and system identification
- Learning systems and image recognition
Traction machines for all-electric and hybrid electric vehicles have to meet high requirements in terms of quality, power density and costs. In order to meet these demands, not only the design of the machine but also its production must be optimized.The industry standard for the production of rotating field stators is the insertion technology. It has disadvantages that are particularly evident in the field of electromobility. On one hand, the degree of copper filling and thus the power density are limited. As a consequence, the vehicle range is reduced. On the other hand, many manual activities are necessary in downstream manufacturing processes, which lead to high unit costs and greater deviations in quality. In contrast, the needle winding technology without end plates enables the wire to be precisely deposited in a compact form and thus maximum copper filling levels can be achieved. Furthermore, precise wire deposit allows the automation of downstream processes. Moreover, current market developments indicate that DC-excited synchronous motors are becoming increasingly prevalent in the drive train of electric vehicles. This expands the range of applications for needle winding technology with the production of optimized rotor windings. The aim of this research project is the enhancement and optimization of needle winding technology towards a digital product development process, which—similar to CAD/CAM—will enable an automated implementation of electromagnetically optimized winding patterns on flexible needle winding systems. The realization of this process requires the consideration of varied topics such as automated dynamic trajectory planning, wire tension modeling and control, the use of adaptive systems for process optimization and the development of automation concepts for downstream production steps.