In this paper the fundamental development of a new process chain for manufacturing of round wire windings will be presented. The development was carried out inside the project NeWwire which was a cooperation of several universities, the companies Volkswagen, Essex and Aumann. The project was publicly funded by the Federal Ministry of Education and Research (BMBF) in Germany. The basic approach of the new winding technology was motivated by the fact, that even with today's automated processes for the production of distributed round wire windings, a superior winding can still be created by a skilled worker. Based on the manual process and the need for automation, an alternative series of process steps was developed, tested with functional samples and implemented in machine prototypes for further development.

The optimization of the effective winding in the stator to increase the performance represents a special challenge. The aim is to accommodate as many copper conductors as possible in the narrow stator groove in a reproducible manner, with a high quality and short production times without damaging the enameled copper wire. Therefore, the compact winding process, based on the manual trickle winding process and complying with these requirements, is introduced in this paper. The basic ideas of this novel method are described in detail. The developed compact winding process enables layer winding with higher fill factors in the stator grooves of the windings and new production steps like compressing and cementing of wires for contributed windings. In addition, this method was successfully implemented into a test stand. Finally, further potential investigations are discussed and with reference to released publications.

Die Weiterentwicklung von Runddraht-Wickelverfahren zur Performancesteigerung elektrischer Antriebe stellt einen wichtigen Forschungsgegenstand am wbk Institut für Produktionstechnik des KIT dar. Im Rahmen bisheriger Arbeiten wurde in diesem Zusammenhang der neuartige Prozess des Kompaktwickelns entwickelt. Im vorliegende Beitrag werden dieser definiert, eine erste prototypische Umsetzung des Kompaktwickelns vorgestellt sowie mögliche industrielle Anwendungen und Zukunftsperspektiven skizziert.

The trend of globalization has led to a structural change in the sales and procurement markets of manufacturing companies in recent decades. In order not to be left behind by this change, companies have internationalized their production structures. Global production networks with diverse supply and service interdependencies are the result. However, the management of global production networks is highly complex. Key performance indicator (KPI) networks already exist at the corporate level and site level to support the management of complex systems. However, such KPI networks are not yet available to support the management of entire production networks. In this article, a KPI network for global production networks is presented, which links the key figures of the site level and the corporate level. By integrating both levels into a comprehensive KPI network, cause and effect relationship between the production-related KPIs and the strategic KPIs of a corporate strategy become transparent. To this end, this KPI network is integrated into a Performance Measurement and Management (PMM) methodology. This methodology consists of three phases: performance planning, performance improvement, and performance review. For testing the practical suitability, the PMM methodology is applied to the production network of an automotive supplier using a simulation model to estimate the effects of proposed improvement actions of the methodology.