Alternative production process for electric machine windings

The development of production methods, research on material engineering and analysis tools for energy conversion processes establish a powerful design environment for any unconventional electromagnetic or electromechanical device. The design for manufacturability becomes the one of the main goals of the design apart from cost and performance improvement. The main focus of this paper lies on the development of production methods, the design of the product, a wave-winding, and the component assessment in an electrical machine. The production of non-complex coil with maximized performance capability of the molded core machine is the target for the design of the winding and also the design for the winding machine. Four different types of wave-windings are described and evaluated. One of them, wind and bend with conventional wire, has main focus in this work, and a prototype of the winding machine is built to produce the single-layer whole-lap wave-winding. The production method, manufacturing process and the processed component features are analyzed in this paper.