Research on Quantification Methods for Nonlinear Forming Length of Ultra-Thin Flat Wires in Flat Wire Motors

Because of the imprecision of length quantification in the manufacturing of flat wire windings for flat wire motors, empirical allowances have long been a common practice in production, which in turn leads to considerable material waste and elevated production costs. This paper presents an integrated solution that fuses material experiments, reverse engineering, simulation iteration and parametric design, realizing accurate prediction and quantitative calculation of winding forming length. First, high-precision elastic-plastic constitutive relationships of flat wires are acquired through room-temperature uniaxial tensile tests. On this basis, reverse engineering is applied to derive the initial geometric characteristics and process motion paths of flat wire windings from the 3D model of finished products. Next, an innovative closed-loop iterative compensation algorithm is constructed, with the forming height of the innermost flat wire layer serving as an absolute reference; finite element simulation is then utilized to dynamically optimize the forming length of each flat wire layer. Finally, a parametric design system with a visual interactive interface is developed, which enables an intelligent workflow where precise cutting lengths and equipment motion curves are automatically generated upon input of key design parameters. Production validation results show that this method drastically reduces the length allowances of flat wires, markedly lowers the production scrap rate, and shortens the process debugging cycle of new motor models by more than 80%.