A Comprehensive Design Guideline of Hairpin Windings for High Power Density Electric Vehicle Traction Motors

Zou, Tianjie; Gerada, David; La Rocca, Antonino; Moslemin, Mohsen; Cairns, Alasdair; Cui, Mengmeng; Bardalai, Anuvav; Zhang, Fengyu; Gerada, Chris

Abstract

The rapidly increasing demand on power density levels of electric vehicle (EV) drive systems is pushing the boundaries of traction motor performance. 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. In this paper, a comprehensive design approach of hairpin winding layouts is firstly presented. The flexibility and limitation of end-winding patterns is thoroughly investigated in terms of basic pin connections, special jumpers, transposition, parallel branches, terminal positions, phase shift, winding pitches as well as slot-pole combinations. To address the challenge of much reduced practical layout options with increased slot number per pole per phase, two novel hairpin winding designs are proposed. A 160kW, 18000rpm PM traction motor featuring the new winding layout with 54-slot, 6-pole is developed using a multidomain design platformwhich puts special focus on the conductor size optimization. The advantages of the designed motor are clearly revealed by comparison with the more traditional 48-slot, 8-pole counterpart. Finally, a corresponding stator prototype with the proposed hairpin winding is built to validate its manufacturability.

Citation

Zou, T., Gerada, D., La Rocca, A., Moslemin, M., Cairns, A., Cui, M., Bardalai, A., Zhang, F., & Gerada, C. (2022). A Comprehensive Design Guideline of Hairpin Windings for High Power Density Electric Vehicle Traction Motors. IEEE Transactions on Transportation Electrification, 8(3), 3578-3593. https://doi.org/10.1109/TTE.2022.3149786

• Journal Article Type: Article
• Acceptance Date: Jan 24, 2022
• Online Publication Date: Feb 7, 2022
• Publication Date: 2022-02
• Deposit Date: Feb 13, 2022
• Publicly Available Date: Feb 24, 2022
• Journal: IEEE Transactions on Transportation Electrification
• Electronic ISSN: 2332-7782
• Publisher: Institute of Electrical and Electronics Engineers
• Peer Reviewed: Peer Reviewed
• Volume: 8
• Issue: 3
• Pages: 3578-3593
• DOI: https://doi.org/10.1109/TTE.2022.3149786
• Keywords: Electrical and Electronic Engineering; Energy Engineering and Power Technology; Transportation; Automotive Engineering
• Public URL: https://nottingham-repository.worktribe.com/output/7465906
• Publisher URL: https://ieeexplore.ieee.org/document/9706460
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