Implementation of the needle winding technique for diamond coils

摘要

For the flexible production of increased efficient electric traction drives, a new winding method in terms of the indirect needle winding has been developed. It is the aim to show the full potential of the new winding technique by the manufacturing of an improved motor winding, which consists of diamond coils with twisted litz wire. Adapted devices, in particular a winding template and a needle winding tool, are investigated in several concepts and the evaluated favorites are implemented. A complete winding cell is equipped with all necessary components to demonstrate the feasibility of the modified process technology.