Artificial intelligence for springback compensation with electric vehicle motor component

Hairpin, which is used for a drive motor of electric vehicle, formed from copper coil coated with very thin enamel layer to its desired shape by successive forming processes. The unavoidable springback hairpin has induced critical problems in fabricating the vehicle that directly related product performance motor. In this research, new method compensation was proposed using artificial intelligence (AI). AI model calculates eight parameters respect given inputs: material properties, cross-sectional dimension, and die spotting. training dataset based on finite element simulation. Material properties were characterized combined methods: newly designed specimen, nanoindentation, inverse analysis. For compensation, spotting value representing gap between punch (or stroke) optimized simplex optimization algorithm trained model. results showed could be effectively compensated few seconds.