Simulation of distributed windings using the insert technique

Sammanfattning: During the insert process when the windings of an electric motor are pushed into the stator slots, some detrimental phenomena can occur that affect the efficiency and life of the motor. To detect these phenomena and optimize the process, a simulation would be useful. An investigation of the possibility to perform a simulation, using an appropriate numerical method for the insert process of distributed windings in a permanent magnet synchronous motor, was performed. During the project, a literature study was carried out to investigate existing methods and key-parameters for the simulation of the process. Explicit finite element method has been shown to be a suitable numerical method for simulating another winding process. An explicit finite element analysis was performed with a simplified model of the stator, the wires, the transmission tool and the needles by using the software Abaqus/CAE. In order to reduce the computational time, beam elements were used to model the wires and the other parts as rigid bodies. The model accounted for example contact and provided numerical results. The result was a suitable model. However, it needs to be developed further.