Hairpin Windings Manufacturing, Design, and AC Losses Analysis Approaches for Electric Vehicle Motors

2021 11th International Electric Drives Production Conference (EDPC 2021) 2021
Payam Shams Ghahfarokhi, Andrejs Podgornovs, Antonio J. Marques Cardoso, Ants Kallaste, Anouar Belahcen, Toomas Vaimann

This paper investigates the hairpin winding configuration as a solution to increase the power density of electric vehicle motors by enhancing the slot filling factor. Moreover, the paper presents various manufacturing techniques of this winding and describes it in detail. Further, it provides a novel additive manufacturing method as an alternative option for conventional production methods to mitigate AC losses using flat rectangular conductors in hairpin winding rods. Following the proper connection of conductors in parallel paths is considered, and the essential rules for this purpose are described. Finally, the analytical and numerical approaches for calculating AC copper losses and the AC loss factor are presented in detail.

Keywords
AC copper losses, hairpin winding, manufacturing techniques, traction motors
DOI
10.1109/EDPC53547.2021.9684208
Hyperlink
https://ieeexplore.ieee.org/document/9684208

Shams Ghahfarokhi, P., Podgornovs, A., Marques Cardoso, A., Kallaste, A., Belahcen, A., Vaimann, T. Hairpin Windings Manufacturing, Design, and AC Losses Analysis Approaches for Electric Vehicle Motors. In: 2021 11th International Electric Drives Production Conference (EDPC 2021), Germany, Erlangen, 7-9 December, 2021. Piscataway: IEEE, 2021, pp.28-34. ISBN 978-1-6654-1810-2. e-ISBN 978-1-6654-1809-6. Available from: doi:10.1109/EDPC53547.2021.9684208

Publication language
English (en)