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

Payam Shams Ghahfarokhi; Andrejs Podgornovs; Antonio J. Marques Cardoso; Ants Kallaste; Anouar Belahcen; Toomas Vaimann

doi:10.1109/EDPC53547.2021.9684208

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

Payam Shams Ghahfarokhi, Andrejs Podgornovs, Antonio J. Marques Cardoso, Ants Kallaste, Anouar Belahcen, Toomas Vaimann

Research output: Chapter in Book/Report/Conference proceeding › Conference article in proceedings › Scientific › peer-review

14 Citations (Scopus)

Abstract

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.

Original language	English
Title of host publication	2021 11th International Electric Drives Production Conference, EDPC 2021 - Proceedings
Publisher	IEEE
Number of pages	7
ISBN (Electronic)	978-1-6654-1808-9
DOIs	https://doi.org/10.1109/EDPC53547.2021.9684208
Publication status	Published - 2021
MoE publication type	A4 Conference publication
Event	International Electric Drives Production Conference - Virtual, Erlangen, Germany Duration: 7 Dec 2021 → 9 Dec 2021

Conference

Conference	International Electric Drives Production Conference
Abbreviated title	EDPC
Country/Territory	Germany
City	Erlangen
Period	07/12/2021 → 09/12/2021

Keywords

AC copper losses
hairpin winding
manufacturing techniques
traction motors

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10.1109/EDPC53547.2021.9684208

Cite this

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

abstract = "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",

author = "Ghahfarokhi, {Payam Shams} and Andrejs Podgornovs and {Marques Cardoso}, {Antonio J.} and Ants Kallaste and Anouar Belahcen and Toomas Vaimann",

note = "Publisher Copyright: {\textcopyright} 2021 IEEE.; International Electric Drives Production Conference, EDPC ; Conference date: 07-12-2021 Through 09-12-2021",

year = "2021",

doi = "10.1109/EDPC53547.2021.9684208",

language = "English",

booktitle = "2021 11th International Electric Drives Production Conference, EDPC 2021 - Proceedings",

publisher = "IEEE",

address = "United States",

}

Ghahfarokhi, PS, Podgornovs, A, Marques Cardoso, AJ, Kallaste, A, Belahcen, A & Vaimann, T 2021, Hairpin Windings Manufacturing, Design, and AC Losses Analysis Approaches for Electric Vehicle Motors. in 2021 11th International Electric Drives Production Conference, EDPC 2021 - Proceedings. IEEE, International Electric Drives Production Conference, Erlangen, Germany, 07/12/2021. https://doi.org/10.1109/EDPC53547.2021.9684208

Hairpin Windings Manufacturing, Design, and AC Losses Analysis Approaches for Electric Vehicle Motors. / Ghahfarokhi, Payam Shams; Podgornovs, Andrejs; Marques Cardoso, Antonio J. et al.
2021 11th International Electric Drives Production Conference, EDPC 2021 - Proceedings. IEEE, 2021.

Research output: Chapter in Book/Report/Conference proceeding › Conference article in proceedings › Scientific › peer-review

TY - GEN

T1 - Hairpin Windings Manufacturing, Design, and AC Losses Analysis Approaches for Electric Vehicle Motors

AU - Ghahfarokhi, Payam Shams

AU - Podgornovs, Andrejs

AU - Marques Cardoso, Antonio J.

AU - Kallaste, Ants

AU - Belahcen, Anouar

AU - Vaimann, Toomas

PY - 2021

Y1 - 2021

N2 - 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.

AB - 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.

KW - AC copper losses

KW - hairpin winding

KW - manufacturing techniques

KW - traction motors

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U2 - 10.1109/EDPC53547.2021.9684208

DO - 10.1109/EDPC53547.2021.9684208

M3 - Conference article in proceedings

AN - SCOPUS:85125784488

BT - 2021 11th International Electric Drives Production Conference, EDPC 2021 - Proceedings

PB - IEEE

T2 - International Electric Drives Production Conference

Y2 - 7 December 2021 through 9 December 2021

ER -

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

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Keywords

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