Direct winding of inside slotted stators: Needle winding applications for concentrated and distributed windings

摘要

Today there is an increasing demand for electronically commutated brushless DC motors (in short EC-motors). These motors with permanent magnet rotors are characterized by their compact design. At the same time they offer high performance, due to the intelligent and concentrated needle winding technology. In ideal cases the amount of copper wire can be reduced by 50%, and the amount of steel up to 30%. An additional benefit is the reduction of energy consumption. The reduced gap between the winding and lamination results in improved heat dissipation. This also leads to a 20% increase in duty cycle of the drive in overload operation. Just as important as the choice of the right winding process is the component design. i.e. the optimization of the customer products during the design phase, in a joint effort. The requirements on the components of electric motors are ever increasing. A modification in lamination thickness by 0.2 mm can increase the fill factory by one percent. The best winding machine cannot produce good windings, if the bobbin is not designed properly.