Development and Implementation of a Compact Winding Process

The optimization of the effective winding in the stator to increase the performance represents a special challenge. The aim is to accommodate as many copper conductors as possible in the narrow stator groove in a reproducible manner, with a high quality and short production times without damaging the enameled copper wire.Therefore, the compact winding process, based on the manual trickle winding process and complying with these requirements, is introduced in this paper. The basic ideas of this novel method are described in detail. The developed compact winding process enables layer winding with higher fill factors in the stator grooves of the windings and new production steps like compressing and cementing of wires for contributed windings. In addition, this method was successfully implemented into a test stand. Finally, further potential investigations are discussed and with reference to released publications.