Developing a Novel Electromotor Concept
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The scope of this master thesis is the product development of the production technology at Alva Industries AS during the spring of 2017. The master thesis is a continuation of the previous project thesis and is done at The Department of Mechanical and Industrial Engineering at the Norwegian University of Science and Technology. The work is part of the research and prototype laboratory TrollLABS, run by Professor Martin Steinert. The startup company Alva has invented a novel production process for producing stators for electrical motors. Using a specially designed weaving loom, a three-phase pattern of conductive copper is woven and later cast in an epoxy resin. Compared to conventional production, this can provide tailored stator dimensions and a more light-weight design. The scope of this thesis is to evaluate the first prototype of the production process and further develop concepts for multiple shuttle controlling. For the development work, a wayfaring model and a rapid prototyping approach were used. As a contribution to the studies of the fuzzy front end of product development at TrollLABS, this methodology in context of Alva's work is discussed. The resulting concept of garage sorting and reel handling is as far as the author is concerned an innovative solution within the field of weaving. The garage sorting needs further detailing before implementation. A detailed documentation of both the work that has been done and the methodology used during the time of the project is presented in this thesis. A positive employment certificate was received for the contribution of the project and master thesis. Alva Industries AS has been granted funding from The Norwegian Research Council through the STUD-ent programme and will start the process of patenting the production technology. The collaboration with TrollLABS continues with another project thesis the coming fall. A proposition for further work is provided to help with Alva's continuing development.