Geometry modeling method of a stator forming coil for permanent magnet traction motors in rail transit for manufacturing

Facing the comprehensive promotion of CR450, permanent magnet traction motors need to be applied in batches. In response to the swift trial production requirements of various stator forming coil models in manufacturing and considering the correlation between design and manufacturing parameters, we research the geometric model of stator forming coils for manufacturing. In this study, the geometry modeling technique of the stator forming coil is elucidated. The essential structures are precisely modeled via the analytical geometry method. A correlation model illustrating the relationship between the design parameters and the manufacturing parameters of these structures is established to consider the calculation error. We propose a 3D scanning structural feature modeling approach that extracts coil features and employs fitting methods to invert key structural model elements on point cloud datasets for experimental validation. Leveraging the point cloud model, the critical structural size computation method is deployed to calculate structural parameters. The results demonstrate that the comparative errors in the span width and height of the nose end between forward and reverse modeling are 0.45% and 2.6%, respectively. This addresses the issue of design parameters being challenging to accurately guide manufacturing and can offer effective support for the design and manufacturing assembly of stator forming coils with various model specifications.