Hairpin Winding Technology for Electric Traction Motors: Design, Prototyping, and Connection Rules

In high speed electrical machines, one of the main challenges that can be faced is the high frequency losses in the machine windings due to both skin and proximity effects. This paper studies the effect of using different types of magnet wires on the AC losses in the winding of high speed electric machines. Using finite element modelling (FEM), the conductors are subdivided into multiple strands to calculate the losses in each conductor and in each layer. Aiming at loss minimization, different arrangements are introduced and compared at a wide range of frequencies. Further, four coil designs are prototyped using different magnet wires or arrangements. Moreover, the design and performance are compared with highlighting the pros and cons of each case. Eventually, recommendations are provided based on the obtained results for a better selection of magnet wire.

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“…Using the expression of 𝐽 (𝑦) in the equation of the Joule losses, the ratio the AC and the DC resistance 𝜑(ζ) is obtained [34].…”

Section: Analytical Formulation Of Conductors At High Frequencymentioning

confidence: 99%

Selection of Magnet Wire Topologies With Reduced AC Losses for the Windings of Electric Drivetrains

et al. 2022

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Circularity potential of electric motors in e-mobility: methods, technologies, challenges

Di Gerlando,

Gobbi,

Magnanini

et al. 2024

Jnl Remanufactur

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The imperative shift toward sustainable development mandates a revolutionary transformation in the transportation sector. While the transition from internal combustion engines to electric motors represents a pivotal step, its ecological impact may fall short of expectations. This undertaking is motivated by the recognition that a truly impactful transition necessitates intricate strategies, addressing resource consumption during manufacturing and minimizing post-use waste. This literature review is dedicated to enhancing the framework of circular strategies within the realm of electric motors, with a specific focus on remanufacturing. The objective is to cultivate a conscientious approach to product development, primarily centered on the four key pillars of circularity: reuse, remanufacture, upgrade, and recycle. The primary goal is to furnish a comprehensive overview of the myriad possibilities associated with reusing products, either in parts or as a whole. Upon introducing the circular approach, this review underscores pivotal enabling technologies essential for a successful transition. These include inspection, disassembly, rewinding, and demagnetization. The ensuing discussion delves into the technological challenges faced and presents cutting-edge solutions poised to redefine the landscape. The concluding section extends the perspective to the future, introducing innovative studies and solutions still in their developmental stages. This review is tailored for decision-makers, policymakers, and researchers, providing them with a valuable overview and facilitating discussions to propel our society toward a sustainable and responsible future in electric motor technology.

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Common-Mode Impedance of an Electric Motor and the Impact of Material and Geometry Uncertainties

Stenmark,

Rylander,

Botha

et al. 2024

2024 International Symposium on Electromagnetic Compatibility – EMC Europe

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Hairpin Winding Technology for Electric Traction Motors: Design, Prototyping, and Connection Rules

Cited by 13 publications

References 13 publications

Selection of Magnet Wire Topologies With Reduced AC Losses for the Windings of Electric Drivetrains

Selection of Magnet Wire Topologies With Reduced AC Losses for the Windings of Electric Drivetrains

Circularity potential of electric motors in e-mobility: methods, technologies, challenges

Common-Mode Impedance of an Electric Motor and the Impact of Material and Geometry Uncertainties

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