Alternative production process for electric machine windings

The development of production methods, research
on material engineering and analysis tools for energy conversion
processes establish a powerful design environment for any
unconventional electromagnetic or electromechanical device. The
design for manufacturability becomes the one of the main goals
of the design apart from cost and performance improvement. The
main focus of this paper lies on the development of production
methods, the design of the product, a wave-winding, and the
component assessment in an electrical machine. The production
of non-complex coil with maximized performance capability of
the molded core machine is the target for the design of the
winding and also the design for the winding machine. Four
different types of wave-windings are described and evaluated.
One of them, wind and bend with conventional wire, has main
focus in this work, and a prototype of the winding machine is
built to produce the single-layer whole-lap wave-winding. The
production method, manufacturing process and the processed
component features are analyzed in this paper.