Dynamic Behavior Analysis of Copper Wire for Motor Coil Manufacturing

Manufacturing defects such as bulging, or overlap can occur when winding copper wires by winding machines. In this paper, the method of dynamic behavior analysis of copper wire is proposed. First, the deformation of copper wire on physical constraints is formulated considering elastoplastic expansion, contraction, bending, and torsional deformation. Next, supplying of the copper wire is modeled to reduce computational load and unnecessary vibration of the copper wire in the simulation. Finally, the dynamic behavior of the copper wire is simulated when it is wound by the winding machine. The simulation results showed that the bulging problem is related to core rotation speed and the tension of copper wire supplied.