Optimization of Direct Winding Processes Based on a Holistic Control Approach

摘要

The winding process in electric motor manufacturing consists of individual subsystems such as the movement of the wire guide, the wire tension control system, and the movement of the coil. Although the overall process is already highly automated these days, for control the single subsystems are only considered isolated due to the complexity of the overall process. The individual subprocesses are controlled on the basis of target values which only have an indirect effect on the product quality and the relevant properties. As a result, there is no consideration of the entire, coupled winding process yet. However, a holistic view of the complete winding process offers the advantage that all influences can be incorporated to optimize relevant parameters such as the copper fill factor or other parameters. This paper presents a first step towards a generalized control concept for direct winding technologies and, in particular, presents a methodological description of the optimization of the relevant process variables. This holistic view is further extended to an optimization-based framework in order to consider relevant process parameters and control variables in the form of cost functions and to optimize the coil production regarding relevant characteristics.