Optimized development of electro-mechanical devices

A method for producing a winding assembly for an electro-mechanical device, wherein the winding assembly comprises a circuit board with winding conductor tracks configured to conduct the operating currents operating the electro-mechanical device, the method comprising:

• optimizing, in a computerized optimization tool, the design of the winding assembly;
• manufacturing the circuit board with the winding conductor tracks according to the optimized design of the winding assembly;
• and
• forming the winding assembly of the electro-mechanical device with the manufactured circuit board,
• wherein the design of the winding assembly is optimized in the computerized optimization tool based on at least one of
• an optimization function depending on at least one of Joule losses, unbalanced current losses, eddy current losses in the conductor tracks, eddy current losses outside of the conductor tracks, hysteresis losses, aerodynamical losses and mechanical losses, and
• a device model which considers at least one of Joule losses, unbalanced current losses, eddy current losses in the conductor tracks, eddy current losses outside of the conductor tracks, hysteresis losses, aerodynamical losses and mechanical losses,
• wherein the computerized optimization tool is configured to optimize the design of the winding assembly based on at least one of:
• (i) a directional or dimensional parameter of a cross-section of the conductor tracks;
• (ii) the number of conductor tracks connected in parallel or in series;
• (iii) thickness of one or more of the conductor tracks;
• (iv) a dimension of the winding assembly;
• (v) the superpositions of the circuit board;
• (vi) a directional or dimensional parameter of a cross-section of an optional substrate of the circuit board;
• (vii) the connection of the coil assemblies;
• (viii) the number of coil assemblies;
• (ix) materials of the circuit board or the substrate;
• and
• (x) the number of winding terminals and the position of the winding terminals.

A method for producing a winding assembly for an electro-mechanical device, wherein the winding assembly comprises a circuit board with winding conductor tracks configured to conduct the operating currents operating the electro-mechanical device, the method comprising:

• optimizing, in a computerized optimization tool, the design of the winding assembly;
• manufacturing the circuit board with the winding conductor tracks according to the optimized design of the winding assembly;
• and
• forming the winding assembly of the electro-mechanical device with the manufactured circuit board,
• wherein the design of the winding assembly is optimized in the computerized optimization tool based on at least one of
• an optimization function depending on at least one of Joule losses, unbalanced current losses, eddy current losses in the conductor tracks, eddy current losses outside of the conductor tracks, hysteresis losses, aerodynamical losses and mechanical losses, and
• a device model which considers at least one of Joule losses, unbalanced current losses, eddy current losses in the conductor tracks, eddy current losses outside of the conductor tracks, hysteresis losses, aerodynamical losses and mechanical losses,
• wherein the method comprises the further step of converting, in a computerized conversion tool, the optimized design of the winding assembly into a design of the circuit board including positions and dimensions of:
• (i) the conductor tracks;
• and/or
• (ii) the connectors connecting different layers of conductor tracks on the circuit board and/or
• (iii) an substrate wherein the circuit board with conductor tracks for the optimized design of the winding assembly is manufactured based on the converted design of the circuit board.

A method for producing a winding assembly for an electro-mechanical device, wherein the winding assembly comprises w a circuit board with winding conductor tracks configured to conduct the operating currents operating the electro-mechanical device, the method comprising:

• optimizing, in a computerized optimization tool, the design of the winding assembly;
• manufacturing the circuit board with the winding conductor tracks according to the optimized design of the winding assembly;
• and
• forming the winding assembly of the electro-mechanical device with the manufactured circuit board,
• wherein the design of the winding assembly is optimized in the computerized optimization tool based on at least one of
• an optimization function depending on at least one of Joule losses, unbalanced current losses, eddy current losses in the conductor tracks, eddy current losses outside of the conductor tracks, hysteresis losses, aerodynamical losses and mechanical losses, and
• a device model which considers at least one of Joule losses, unbalanced current losses, eddy current losses in the conductor tracks, eddy current losses outside of the conductor tracks, hysteresis losses, aerodynamical losses and mechanical losses,
• wherein the computerized optimization tool is configured to optimize the winding assembly based on an optimization of at least one material used for the winding assembly.

A method for producing a winding assembly for an electro-mechanical device, wherein the winding assembly comprises a circuit board with winding conductor tracks configured to conduct the operating currents operating the electro-mechanical device, the method comprising:

• optimizing, in a computerized optimization tool, the design of the winding assembly;
• manufacturing the circuit board with the winding conductor tracks according to the optimized design of the winding assembly;
• and
• forming the winding assembly of the electro-mechanical device with the manufactured circuit board,
• wherein the design of the winding assembly is optimized in the computerized optimization tool based on at least one of
• an optimization function depending on at least one of Joule losses, unbalanced current losses, eddy current losses in the conductor tracks, eddy current losses outside of the conductor tracks, hysteresis losses, aerodynamical losses and mechanical losses, and
• a device model which considers at least one of Joule losses, unbalanced current losses, eddy current losses in the conductor tracks, eddy current losses outside of the conductor tracks, hysteresis losses, aerodynamical losses and mechanical losses,
• wherein the computerized optimization tool is configured to optimize the electro-mechanical device based on a combined optimization of the winding assembly and the design of the remaining electro-mechanical device.

A non-transitory computer readable medium having stored thereon executable instructions for developing an optimized electro-mechanical device with a winding assembly formed by a circuit board with conductor tracks, the executable instructions configured, when executed on a computing device, to optimize the design of the winding assembly for the electro-mechanical device, wherein

• the design of the winding assembly is optimized based on an optimization function depending on at least one of the Joule losses, unbalanced current losses, eddy current losses in the conductor tracks, eddy current losses outside of the winding conductor tracks, hysteresis losses, aerodynamical losses and mechanical losses,
• wherein a device model of the electro-mechanical device models the mechanical behavior and/or the electromagnetical behavior of the electro-mechanical device, wherein the model of the electro-mechanical device is defined by a set of model parameters in an allowed model parameter space, wherein at least one operation parameter of the electro-mechanical device is received, wherein the design of the winding assembly is optimized in the computerized optimization tool by repeating different optimization cycles with different value sets for the set of model parameters, wherein each optimization cycle performs the following steps with a value set for the set of model parameters of the respective optimization cycle:
• determining the mechanical behavior and/or the electromagnetical behavior of the electro-mechanical device based on the device model for the at least one operation parameter and for the value set of the actual optimization cycle;
• calculating a result of the optimization function based on the determined mechanical behavior and/or the electromechanical behavior;
• and
• comparing the result of the optimization function with at least one result of the optimization function of at least one previous optimization cycle, if there is any previous optimization cycle.