Coil Winding Simulation Incorporating Copper Wire Contact to Predict Manufacturing Defects

To improve motor efficiency, aligned winding is crucial as it increases the slot fill factor through orderly wire placement. However, defects such as wire bulging and overlapping can arise from variations in winding speed, tension, and wire diameter, often requiring trial-and-error adjustments. While finite element methods have been used to analyze local deformation, they are computationally expensive for simulating the full winding process. We propose a mass-spring model for efficient wire simulation and extend it to three dimensions by considering wire-to-wire contact. To further reduce simulation time, we reduce the number of particles in low-impact regions and enable full 3D simulation. This method allows accurate prediction of bulging and overlapping, contributing to both winding quality and production efficiency in motor manufacturing.