NURBS based trajectory generation for an industrial five axis needle winding robot

The needle winding technology is a promising alternative for the future production of electrical machines with distributed windings especially in the automotive environment. With its high flexibility and potential for full automation it is well suited to meet the demands of manufacturers for innovative production methods stemming from electrified mobility. Needle winding machines in their different kinematic versions are comparable to multi axes robots or NC machines. The trajectory of the needle is a major factor influencing the winding and therefore quality, efficiency and cost of the resulting electric machine. State of the art for the trajectory programming for needle winding machines is either point to point interpolation or the usage of cam disks. To improve the winding results and flexibility, a smooth trajectory planning algorithm was investigated. Beginning from an optimal winding pattern in the stator slots, the path and trajectory planning algorithm was presented.