Oil Spray Cooling with Hairpin Windings in High-Performance Electric Vehicle Motors

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

*Corresponding author for this work

Research output: Chapter in Book/Report/Conference proceedingConference contributionScientificpeer-review

5 Citations (Scopus)
117 Downloads (Pure)


This paper presents a survey about implementing hairpin winding with an oil spray cooling system on the new generation of electrical vehicle (EV) motors as an option to produce high power density, high efficiency, cost-effectiveness, lightweight, reliable EV motors. It provides the advantages and drawbacks of this rectangular winding compared to random winding and considers the hairpin winding production aspects. According to the high AC losses of this configuration, the paper considers two conventional approaches for calculating these losses with their advantages and drawback. Then it proposes the novel hybrid FEA method for calculating the AC copper losses to overcome the weaknesses of analytical and numerical methods. Finally, it provides a holistic view related to the oil spray cooling of the electrical machine and points the future work associated with this cooling method

Original languageEnglish
Title of host publicationProceedings of 2021 28th International Workshop on Electric Drives
Subtitle of host publicationImproving Reliability of Electric Drives, IWED 2021
Number of pages5
ISBN (Electronic)9780738144436
Publication statusPublished - 22 Mar 2021
MoE publication typeA4 Article in a conference publication
EventInternational Workshop on Electric Drives - Virtual, Online
Duration: 27 Jan 202129 Jan 2021
Conference number: 28


WorkshopInternational Workshop on Electric Drives
CityVirtual, Online


  • electric vehicle
  • electrical motors
  • hairpin winding
  • spray cooling
  • thermal management


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