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Characterization of rectangular copper wire forming properties and derivation of control concepts for the kinematic bending of hairpin coils

Wirth, F. 1; Nguyen, C.; Hofmann, J. 1; Fleischer, J. 1
1 Institut für Produktionstechnik (WBK), Karlsruher Institut für Technologie (KIT)


As a result of the continuously growing demand for electric vehicles, innovative production technologies must be developed to fulfill the high automotive requirements for productivity and quality in the manufacturing of electric drives. By providing advantages regarding the degree of automation, the productivity as well as the attainable filling factors in comparison to established round wire winding technologies, the hairpin technology shows a high potential for meeting the requested specifications but also technological weaknesses, especially concerning the process reliability. The referring production process of stators is normally based on the spatial forming of open, hairpin-shaped coils of enameled flat copper wire as well as subsequent joining and contacting processes. Consequently, the hairpin coils represent the elementary components of the process chain and can be either shaped by robust tool-bound or flexible kinematic bending processes that enable the shaping of different contours at moderate tool costs. In this paper, the essential mechanical forming and product properties of flat copper wires with different dimensions and insulation coatings are characterized by means of uniaxial tensile tests as well as metallographic analyses of the material structure, at first. ... mehr

Verlagsausgabe §
DOI: 10.5445/IR/1000120487
Veröffentlicht am 24.06.2020
DOI: 10.1016/j.promfg.2020.04.209
Zitationen: 19
Zitationen: 17
Cover der Publikation
Zugehörige Institution(en) am KIT Institut für Produktionstechnik (WBK)
Publikationstyp Zeitschriftenaufsatz
Publikationsjahr 2020
Sprache Englisch
Identifikator ISSN: 2351-9789
KITopen-ID: 1000120487
Erschienen in Procedia manufacturing
Verlag Elsevier
Band 47
Seiten 678-685
Projektinformation AnStaHa (WM_BW, FIIAR 089)
Bemerkung zur Veröffentlichung 23rd International Conference on Material Forming, ESAFORM 2020; Cottbus, Germany; 4 -8 May 2020
Nachgewiesen in Scopus
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