Handbook of Coil Winding (eBook)

Dipl.-Ing. Jürgen Hagedorn has about 30 years of professional experience in coil winding technology. Since 2002, he has been working on the process development at Aumann GmbH. Dr.-Ing. Florian Sell-Le Blanc has been the head of pre-development at Aumann GmbH since 2016. From 2011 to 2015 he was an academic assistant in the Department of Machines, Systems and Process Automation at the Karlsruhe Institute of Technology (KIT). Prof. Dr.-Ing. Jürgen Fleischer has been the head of the Institute of Production Science since 2003 at KIT. Previously he worked in different management positions in research and development, planning and production at Daimler-Benz, ABB Daimler-Benz Transportation and as a President Regional and Commuter Trains at Bombardier Transportation. From 2008 until he was the Chairman of the Executive Board of the international Machine Tool Group MAG Industrial Automation Systems during a sabbatical from his academic position.

Preface 5
Table of contents 7
1Introduction 10
1.1 Introduction to coil winding technology 10
1.1.1 Definition of coil winding technology 11
1.1.2 Delimitation of winding technology from other manufacturing processes 12
1.1.3 Typical process chain for the production of winding goods 14
1.2 Introduction to coil technology 17
1.2.1 Definition of coils 18
1.2.2 Physical principles 20
1.2.3 Coil types 35
1.2.4 Introduction to bobbins 40
1.2.5 Introduction to bobbin materials 52
1.2.6 Coil design influences on manufacturing properties 60
1.3 Introduction to electric motors 67
1.3.1 Definition of electric motors 68
1.3.2 Functional principles of electric motors 70
1.3.3 Applications of electric motors 78
1.3.4 General requirements for windings 84
1.3.5 Concentrated windings for electric motors 85
1.3.6 Distributed windings for electric motors 86
References 91
2Enamelled copper wire 92
2.1 Conductor properties 92
2.1.1 Copper as an electrical conductor 93
2.1.2 Other conductor materials 99
2.1.3 Geometries of the conductor cross section and conductor variants 102
2.2 Process chain for conductor manufacturing using the example of enamelled copper wire 108
2.2.1 Process chain overview 108
2.2.2 Drawing processes 111
2.2.3 Rolling process 114
2.2.4 Continuous annealing process 115
2.2.5 Cleaning processes 118
2.3 Conductor insulation 120
2.3.1 Definition of insulation properties and testing procedures 121
2.3.2 Introduction to insulation materials 124
2.3.3 Enamelling processes for insulation application 126
2.4 Use of lubricants 132
2.4.1 Definition of lubricant properties 132
2.4.2 Introduction to lubricant materials 134
2.4.3 Processes for lubricant application 134
References 136
3Winding technology 137
3.1 Basics of winding technology 138
3.1.1 Physical basics 138
3.1.2 Introduction to winding schemes 143
3.2 Central functions of winding technology 158
3.2.1 Wire tension control 158
3.2.2 Balancing free wire lengths 163
3.3 Winding processes 166
3.3.1 Introduction to winding processes 166
3.3.2 Machine elements of winding technology 169
3.3.3 Control technology for winding tasks 173
3.3.4 Linear winding technology 176
3.3.5 Flyer winding technology 189
3.3.6 Needle winding technology 197
3.3.7 Toroidal winding technology 207
3.3.8 Insertion technology 209
3.3.9 Trickle winding or Fed-in winding 215
3.3.10 Selection methodology for winding processes 219
3.3.11 Analysis of winding faults 222
3.4 Peripheral processes 227
3.4.1 Preparing assembly processes 227
3.4.2 Contacting processes 229
3.4.3 Bonding processes 231
3.4.4 Coil testing 234
3.4.5 Subsequent assembly processes 236
3.4.6 Secondary insulation 237
References 241
4Automation 242
4.1 Introduction 242
4.1.1 Definition of automation 243
4.1.2 Criteria for the degree of automation 246
4.1.3 Parameters for process automation 248
4.1.4 Different phases of automation 254
4.1.5 Amortisation scenarios 256
4.2 Automation Concepts 263
4.2.1 Industrial assembly concepts 263
4.2.2 Conveying systems and layouts for manufacturing lines 267
4.2.3 Types of interlinkage for manufacturing lines 273
4.2.4 Degrees of automation for winding machines 275
4.2.5 Part properties relevant to automation 276
4.3 Automation techniques 279
4.3.1 Common automation solutions 279
4.3.2 Integration of manual workplaces 283
4.4 Operation of automation 285
4.4.1 Quality control 285
4.4.2 Error susceptibility – process capability 287
4.4.3 Error diagnosis 291
4.4.4 Maintenance 293
4.4.5 Requirements for operating 295
References 297
Index 298