Numerische, analytische und empirische Modellierung des Heißcrimpprozesses

Description

In order to fulfill the challenging plan of the German government of developing the country to a global key supplier of the electric mobility sector, high capacity production technologies have to be established. For this purpose, the present research work focuses on the holistic development of the joining process, which is one core step within the manufacturing chain of electric drives production. Therefore, all potentially used technologies for joining of insulated copper wires will be assessed. It is shown, that by now no holistic method for process modelling is introduced, which is capable of considering all potentially relevant goal criteria of the joining process. To close this research gap, three different process modelling approaches are investigated using the example of the thermo-crimping process. Here, first the complexity of an analytical calculation is shown, which represents the three-dimensional and unsteady heat-generation and -distribution processes of this joining technology. Secondly, another process modelling approach, consisting of a numerical FEM-analysis, is investigated. The derived simulation model is capable of illustrating the mechanical deformation processes as well as heat dissipation and -distribution procedures. Afterwards, a third process modelling method shows high applicability. Corresponding investigations illustrate, that a statistically developed regression-analysis is an excellent method to mathematically describe the joining technologies in the field of electric drives manufacturing including all important process and quality target values.