Hairpin winding design. Section 2 presents the preliminary design of the machine, including dimensions and specifications. In this winding technology, solid, usually, rectangular conductors are continuously inserted into a lamination stack. Design rules for Jul 31, 2023 · 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. The hairpin which are associated in serial (thanks to back connections) are called parallel path or elementary coil. This work aims to investigate the design rules and the additional losses in an AC hairpin winding. However, the uncertainty and necessity of rapid product development despite fuzzy target systems still cause that processes, machines and equipment – as well as the electric design Therefore, the selection of the suitable winding technology and a proper design are mandatory to fulfill the challenging requirements defined by transportation electrification. This paper considers reducing AC losses by proposing two main methods: correct May 31, 2025 · Compared to random winding, hairpin winding inherently features the "design for manufacturing" characteristic to achieve a much higher slot fill factor and consistent end turn patterns for . May 22, 2024 · Optimizing hairpin winding for performance involves a holistic approach that encompasses design, materials, manufacturing processes, and quality control measures. Hairpin windings are becoming a popular option for EV motors due to their reduced DC losses and improved heat dissipation capability when compared to traditional random windings. Hyundai and Kia, for example, integrate this technology into their Electric Global Modular Jan 1, 2021 · In recent years, the manufacturing of stators by hairpin technology has proven its ability to fulfill the requirements on quality, productivity and robustness of traction drive applications in automotive industry. May 23, 2023 · Hairpin winding, with its compact design and improved performance characteristics, is particularly advantageous in high-performance electric vehicles and applications with space limitations. Apr 30, 2024 · Hairpin winding, I-pin winding and X-pin winding are all types of flat wire winding with high power density and efficiency. Such a winding type is more and more used in traction motor of electric and hybrid-electric vehicles. What Is a Hairpin Electric Motor? Feb 23, 2023 · Hairpin winding is a growing technology that is quickly making its place in the automotive industry to design motors that are more efficient. This paper considers reducing AC losses by proposing two main methods: correct May 19, 2025 · HairPin Winding Technology Hair-pin winding is a technology that replaces traditional fine round wire with flat copper hair-pin enamel wires in the stator windings of drive motors. The new technology for winding an assembled stator from the outside deliv-ers – under otherwise identical condi-tions – practi May 17, 2021 · Based on these design rules, a traction motor with hairpin winding technology is modelled in a finite element analysis (FEA) software. Compared to the state-of-the-art in this paper, deep investigations are carried out to obtain the Oct 9, 2022 · Hairpin windings have less flexibility with respect to com- mon windings, especially because wave patterns must be used and it is more difficult to properly design the per-phase parallel Products Manufactured with Hairpin Winding Machine Technology Hairpin winding machines are used to form, align, and insert hairpin coils into a stator design with precision and efficiency. This paper analyses and compares the effects of different hairpin winding layers on electromagnetic and thermal performance in order to improve the torque, power density and efficiency of traction motors. However, no test is available while considering a hairpin winding topology. Compared to stranded windings, hairpins consist of rectangular conductors. New patterns for more Hairpin windings are becoming a popular option for EV motors due to their reduced dc losses and improved heat dissipation capability when compared to traditional random windings. The use of a hairpin winding enables better modelling of HF effects due to the fact that the positions of the conductors within the winding and within the end winding area of the machine are de-fined, which simplifies the calculation of the HF pa-rameters. Abstract: 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. This paper considers reducing AC losses by proposing two main methods Mar 17, 2023 · In the design of a hairpin winding, it is possible to influence the transient potential differences by employing a method called “shifting” within the winding scheme and thus to reduce the maximum potential differences that occur. springer. By leveraging advanced design software, engineers can optimize the layout and configuration of hairpin windings to maximize efficiency and minimize losses. a corresponding high-frequency model of the electri-cal machine. In this paper, a comprehensive design approach of hairpin winding layouts is firstly presented. This paper investigates the circulating currents issue in com-monly adopted hairpin winding patterns, analysing working points with different saturation levels and speeds. These copper bars, also known as hairpins, consist Apr 10, 2025 · Their advanced winding design boosts power, reduces energy loss, and enables more compact, reliable motors—making them ideal for the next generation of electric machines. Sep 5, 2022 · The hair-pin winding has become prominent in drive-train motors for electric and hybrid vehicles, with many creative examples in manufacturing. Apr 14, 2023 · Hairpin Winding – A Powerful Solution to Electric Machine Design Hairpin winding is a relatively new technology that the automotive sector is increasingly interested in due to the growing affordability and effectiveness of manufacturing processes. The paper deals with the comparison of stator winding technologies to be used for high speed electrical machines for propulsion applications. However, this winding configuration brings high AC losses during high-speed operation and we require new approaches to tackle this challenge. Finally, the hairpin winding confers greater solidity to the heads of the machines and thus facilitates the design in presence of robustness constraints typical of electric traction applications [9]. The number of turns in series per phase is defined by the number of conductors per layer, the number of layers and the number of parallel paths. The actual trend is to require higher operating frequency. In the high-performance Turbo S model, these motors deliver up to 560 kW (751 hp). This technology is essential in manufacturing electric motors and components found in electric vehicle applications. In Sect. In fact, the motor power and speed are continuously increasing even though keeping a high number of poles to reduce the end winding Mar 1, 2023 · Continuous hairpin technology (CHP), also known as wave winding or S-wind, is increasingly under investigation of the industrial sector. In this article, a comprehensive design approach of hairpin winding layouts is first presented. In contrast to conventional winding technologies, the hairpin technology is based on solid, flat copper bars which are inserted into the stator stack. Mar 28, 2025 · Featuring a hairpin winding design, the Taycan’s high-efficiency PMSMs convert over 90% of electrical energy into propulsion. 2. In addition, endless winding delivers yet another step forward in reducing the winding head length when compared to I-pin winding or hairpin winding. Hairpin motors can keep up with larger batteries, use less space, weigh less (and hence reduce the weight of the vehicle). Hairpin winding has the highest reliability, but the manufacturing The hairpin winding technology is increasing its impact in the industrial and automotive sectors, thanks to the well-known advantages in terms of motor performance and manufacturing process. Since wave patterns must be adopted, there are significant differences compared to the traditional winding design, in particular concerning the parallel paths conductors disposition. Other automotive manufacturers have also adopted hairpin windings to boost motor performance. The design and the export of projects from FluxMotor ® to Flux ® 2D can be done. Nov 4, 2022 · 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. ” Copper wire in typical hairpin geometry Hairpin technology is a winding technology for stators in electric motors and generators and is also used for traction applications in electric vehicles. Since the shape of the stator coils resembles a hairpin, this type is commonly known as a “hairpin motor” or a “flat wire motor. See full list on link. 3, the electromagnetic and thermal performance for winding topologies with various In the software winding datasheet, the parameters written in blue correspond to user input parameters and the parameters written in black correspond to data resulting from computations. On this basis, a targeted design of winding plans with hairpins can be achieved. The exact conductor position is only sub-ject to the respective production erformance features principally listed at the beginning apply. However, the design of the asymmetric winding is very critical to obtaining the best benefit regarding the efficiency and the thermal performance of the motor. Through our advanced hairpin winding solutions, manufacturers have increased production Sep 8, 2022 · Hairpin Winding Technology for Electric Traction Motors: Design, Prototyping, and Connection Rules Abstract: Compared to traditional windings, hairpin windings feature higher fill factors and increased robustness to mechanical stresses. Although ‘push-through’ hair-pin coils have long been used in other industries, especially in heavy machines, it is probably fair to say that relatively few changes took place before the more recent impact of the automotive industry [2]. com Dec 23, 2024 · The asymmetric design of hairpin windings is known as a method for reducing AC losses in electric motors, especially at high frequencies. 9e jeq dirrva 9d4f ejy2 2tcs vqyqy jv6 et fuz