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M.Sc. Felix Wirth

Research Associate
department: Machines, Equipment and Process Automation
office hours: to be agreed
room: 012, Geb. 50.36
phone: +49 1523 9502630
Felix WirthMcu7∂kit edu

76131 Karlsruhe
Kaiserstraße 12

M.Sc. Felix Wirth

Area of Research:

  • Electric machine manufacturing
  • Hairpin Technology


General Tasks:




Test benches:


Curriculum Vitae:

seit 11/2017 Research Associate at the Institute for Production Science (wbk) at the Karlsruhe Institute of Technology (KIT)
04/2017 - 08/2017 Stay abroad at the amtc of Tongji University, Shanghai
10/2012 - 10/2017 Studies of Mechanical Engineering at Karlsruhe Institute for Technology (KIT)



[ 1 ] Hofmann, J.; Sell-Le Blanc, F.; Krause, M.; Wirth, F. & Fleischer, J. (2016), "Simulation of the Assembly Process of the Insert Technique for Distributed Windings". Proceedings of 6th International Electric Drives Production Conference (E|DPC), eds. IEEE, pp. 144-148.
As the efficiency of electric power trains in hybrid electric vehicles should be increased and at the same time the manufacturing costs reduced, different motor designs and production concepts need to be considered. Because of the nearly sinusoidal magnetic field inside, the stator design with distributed windings, which is typically produced with the insert technique, is technically preferred. The insert technique offers a high productivity because the complete winding assembling process can be done in one step. This results in the fact, that nearly 80% of all electric motors worldwide have distributed windings. In order to enhance the possibilities for distributed windings with the insert technique, the current fill factor needs to be improved. Due to the fact that the actual wire placement cannot be measured und thus not optimized, a simulative approach with a multi-body simulation is used to understand the process interactions between the wires, the stator groove and the tool. This approach will be presented in this paper.

[ 2 ] Wirth, F.; Kirgör, T.; Hofmann, J. & Fleischer, J. (2018), "FE-Based Simulation of Hairpin Shaping Processes for Traction Drives". 2018 8th International Electric Drives Production Conference (EDPC), eds. IEEE, pp. 1-5.
Based on the present change in mobility, there are novel requirements on production technologies of electric drives regarding process reliability, ability for automation, productivity as well as mechanical and electric filling factors. Providing significant advantages compared to conventional winding technologies, the hairpin technology combined with the usage of flat copper wire is a promising opportunity to fulfill the upcoming standards. Hence, the AnStaHa project aims the qualification of the hairpin technology for application in mass production. In spite of numerous advantages, the application of the hairpin technology also shows weaknesses. In particular, the shaping of hairpins is considerably more complex than corresponding process sequences of other winding technologies. The main reasons for this are the rectangular cross section and resulting directional properties of flat copper wires, significant springback effects as well as process-related damage of the wire insulation. Therefore, basic knowledge about the deformation behavior of the wire is required for process dimensioning within the context of system design. This paper handles the numerical simulation of hairpin shaping using the commercial finite element software suite Abaqus FEA. The FE-based approach is validated by experiments for different geometries and includes the complete forming process of hairpins, which is considered to be implemented in two following steps - U-bending and 3-D-shaping. Because the numerical analysis takes wire springback into account, the results can be used for a digital evaluation of hairpin shaping processes during the period of system design.