Segmented Hairpin Topology for Reduced Losses at High-Frequency Operations

Nowadays, one of the key challenges in transport electrification is reduction components’ size and weight. The electrical machine plays a relevant role this regard. Designing machines with higher rotational speeds excitation frequencies most effective solutions to increase power densities, but comes at cost increased losses cores windings. This challenge even more pronounced preformed windings, such as hairpins, which enable slot fill factors shorten manufacturing cycle times. In work, an improved hairpin winding concept proposed, aiming minimize high-frequency while maintaining benefits deriving from implementation windings onto machines. Analytical finite element models are first used assess proposed concept, namely segmented hairpin, proving compared conventional layouts. Experimental tests also performed on number motorettes comprising both configurations. Finally, these experimental results against those collected equipped random demonstrating competitiveness layout operations.