Material based process model for linear noncircular coil winding processes with large wire gauge: Investigation of wire material influences on the winding process and compensation approaches

This paper comprises an overview of different simulation aspects for a material based process model approach and introduces considered model parameters. In order to consider all possible influences through the winding process, critical wire stress conditions, from wire feeding to stress intake while wire placement around the coil body edges, will be examined. The use of the developed model for different material determined aspects of the winding process will be discussed and possible counter-measures for avoidance or compensation of critical forces will be carried out. Synergies regarding new principles, like piezoelectric based wire brakes will be analyzed.