A Comprehensive Design Guideline of Hairpin Windings for High Power Density Electric Vehicle Traction Motors

The rapidly increasing demand on power density levels of electric vehicle (EV) drive systems is pushing the boundaries traction motor performance. Hairpin windings are becoming a popular option for EV motors due to their reduced dc losses and improved heat dissipation capability when compared traditional random windings. In this article, comprehensive design approach hairpin winding layouts first presented. flexibility limitation end-winding patterns thoroughly investigated in terms basic pin connections, special jumpers, transposition, parallel branches, terminal positions, phase shift, pitches, as well slot–pole combinations. To address challenge much practical layout options with increased slot number per pole phase, two novel designs proposed. A 160-kW, 18 000-r/min permanent magnet (PM) featuring new 54-slot, 6-pole developed using multidomain platform, which puts focus conductor size optimization. advantages designed clearly revealed by comparison more 48-slot, 8-pole counterpart. Finally, corresponding stator prototype proposed built validate its manufacturability.