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Development of the coil forming process and develop a programmable forming tool

Work Package Leader: Mr. Pier Vai

Objectives

To take forward the design of the coil forming processes and tools considering the outcome of WP1. Coils with different dimensions, geometries, wire sizes and types will be considered and samples built for assessing practical feasibility

Description

Task1 – Development of the programmable forming tool

After the investigation conducted in WP1, the architecture and principal components needed to realize the coil forming tool will be investigated. The automated coil forming structure and functions will be modelled and simulated at behavioural/functional level. 

Flexibility and Robustness of the design to parameter tolerance and variation will be also preliminarily investigated. Coils with different dimensions, geometries, wire sizes and types will be considered and samples built for assessing practical feasibility.

After preliminary design review, corrections will be discussed and implemented, if needed.  Then, the suitable components for AUTO-MEA will be identified, a first version of the system electrical and mechanical layout will be designed together with the dedicated firmware. As the test setup construction implies several custom-made parts, contacts with the manufacturers will be made to ensure the feasibility of the required customisations. A detailed description of the system will be reported in the Detailed design report at the end of the WP.

Coppering will conduct the activities for this task. UniMore will perform test (task 2) on coil samples and assist Coppering in the individuation and possible weak points in the coil manufacturing process.

Task 2 – Test coil for practical feasibility

During this WP coil samples with different dimensions, geometries, wire sizes and types will be built for assessing practical feasibility. UniMore will conduct experimental test on the coils in order to assess:

  • Slot fill factor 
  • DC and AC resistance
  • thermal conductivity
  • Ability to withstand dv/dt
  • dimensional tolerances
  • repeatability of sample manufacturing
  • winding degradation with temperature