Hairpin Windings for Electric Vehicle Motors: Modeling and Investigation of AC Loss-Mitigating Approaches

The hairpin winding configuration has been attracting attention as a solution to increase the power density of electric vehicle motors by enhancing the slot-filling factor. However, this winding configuration brings high AC losses during high-speed operation and we require new approaches to tackle this challenge. This paper considers reducing AC losses by proposing two main methods: correct transposition of conductors in parallel paths, and enhancing the number of conductor layers in a slot. First, the proper connection of conductors in parallel paths is considered, and the essential rules for this purpose are described. Next, the paper uses a numerical approach to deal with the effect of incorrect conductor transposition in winding paths on generating additional AC losses due to circulating currents. Finally, the impact of the number of conductor layers in the mitigation of AC losses is also discussed in detail. According to the results, by increasing the number of layers, ohmic losses in the layer near the slot opening dramatically decrease. For instance, ohmic losses in the layer near the slot opening of the eight-layer setup were 82% less than the two-layer layout.