Calculation of the Copper Filling Factor of Electric Traction Drives including Graphical Representation

In order to achieve a higher power density of electric traction drives, one significant optimisation variable is the copper filling factor. A self-developed MATLAB program makes it possible to graphically display the filling factors known from the literature in order to visualize optimisation potentials. It is possible to display quadratic, rectangular as well as trapezoidal slot geometrics with round wires or flat conductors. The different wire diameters and their isolation can be chosen from IEC 60317-0-1 or can be inserted manually. After entering the required parameters, the slot geometry is fitted with round or flat conductors according to the principle of the orthocyclic winding scheme. By varying the slot geometry and the wire parameters, the optimum filling factor for different applications can be determined graphically and mathematically, taking into account the assembly air.