Resource-efficient, innovative coil production for increased filling factor

Due to new requirements regarding the efficiency of electrical machines it is necessary to increase the slot filling factor of such machines. Forming technology offers an excellent opportunity to achieve this aim. The paper therefore presents a method for flexibly adapting the cross-sectional shape of the coil to the geometry of the slot. First, the potentials and limits of forming technologies are presented. Furthermore, the forming tool required for the cross-sectional adaptation is described. Advantages and limits of the method are analyzed and evaluated. In particular, factors such as elongation and burr formation play a decisive role here. Finally, an outlook is given and possible research approaches are discussed.