Design and Evaluation Methodology for Insulation Systems of Low Voltage Drives with Preformed Coils

The high copper fill factor of electrical machines with preformed coils allows for high torque and power densities. However, due to the manufacturing process, completely new challenges arise for the insulation system of machines with such preformed coils. Due to the complex geometry of the coil, conventional enameling processes, which are used in wire wound machines, are not suitable. Therefore, forming of enameled wire, as well as powder coating of already formed bare copper coils, are studied in this work as alternatives.