Document Type : Research Paper
Abstract
The orthocyclic winding technique is an ideal choice for concentrated motor stator coil production due to its higher fill-factor advantage. The orthocyclic winding procedure, however, is faced with the challenge of guaranteeing accurate placement of the wire on the bobbin coil in addition to other associated structural design requirements, leading to a situation termed the linear winding design optimization problem (LW-DOP). This research investigates the application of the Crow Search Algorithm (CSA), a modern metaheuristic, to optimize the orthocyclic winding strategy used in electric motor manufacturing and rewinding in a bid to solve the LWDOP. The study specifically focuses on the Equal-Number-of-Turns-Per-Layer Orthocyclic Winding (ENOTPL-OW) scheme, aiming to minimize winding diameter and width tolerances to enhance motor rewinding performance and product durability. Key design parameters, including winding diameter, width, and wire diameter, are formulated into an objective function for optimization. Through extensive MATLAB-based simulations, the influence of CSA parameters, specifically the flock size and maximum iteration count, on the convergence and solution quality of the CSA is analyzed. The results demonstrate that the CSA effectively identifies optimal parameter settings, achieving a minimal net tolerance error of 10⁻⁶ at a maximum iteration count of 50 and a flock size of 25. In addition, when compared to a state-of-the-art swarm intelligence technique called particle swarm optimization, the CSA exhibited a clear superior fitness response. The findings indicate that this metaheuristic driven approach offers a robust, efficient and potentially better method for determining precise rewinding policies, addressing a significant gap in the application of optimization techniques for pre-winding parameter optimization in orthocyclic topologies. In conclusion, the proposed methodology presents a promising tool for improving the design and reliability of concentrated winding-based motor stators
