Innovative needle winding method using curved wire guide in order to significantly increase the copper fill factor

The increase of the copper fill factor is an essential production goal in stator winding technology in order to increase the degree of efficiency and the power density of electrical machines. Orthocyclic winding patterns allow the highest packing density. Currently for round-wire-windings there are only systems available on the market that facilitate random windings, which leads to a decrease of the fill factor. Therefore this paper introduces a concept allowing high fill factors for distributed windings by using the needle winding technology.