NeWwire1 - Design of an Induction Machine with an automatable pitched double-layer lap winding

This paper discusses design aspects for a fully automated, pitched double-layer lap wound winding in electric traction machines suitable for mass production. At first the electrical machine is designed for a given specification by using general analytical equations. The comparison of a pitched double-layer lap wound windings against the conventional single-layer winding shows the benefits. Sequentially, commercial software tools calculate the torque- and performance-speed curves. The necessary manual process steps for the production of a desired stator are explained and the challenge for a fully automated production process becomes apparent. The fully automated production process of pitched double-layer lap wound windings with their positive electromagnetic characteristics, requires restrictions in the design of the electrical machine. For the verification of the innovative manufacturing process, a demonstrator was manufactured in the NeWwire research project during the project period.