Improving the Inductive Crimping Technology in the Production of Electric Motors

The development of the electric motor goes back to a discovery by the Danish scientist Hans Christian Oersted, which was made 200 years ago [1]. He discovered that electric current has a magnetic effect and thus laid the foundation for further electromagnetic research work in the following years. Today, research on the processes of the electric motor production is more up to date than ever. Demands for increasing power densities are accompanied by higher efficiencies as well as lower losses, especially in the field of electrified automobiles and aviation. An important process step to meet these requirements is the contacting of the motor terminals, with the aim of reducing the electrical resistance of the winding. Therefore, in this paper the further development of the inductive crimping process is presented. Within the first chapters, the state of the art of the stripping and contacting process in the electric machine production as well as the challenges of the contacting process will be described. This is followed by a discussion of the inductive heating as well as the feasibility study of the inductive crimping process. Afterwards, the improvement of the process will be presented and the resulted connection will be qualified mechanically and electrically.