Analytical Approach to Design Hairpin Windings

in High Performance Electric Vehicle Motors

Nicola Bianchi, Grazia Berardi
Department of Industrial Engineering, University of Padova, Padova, Italy

I. Abstract TABLE I
Data sheet of electrical machine for EVs.
This work deals with the analysis and design of a
hairpin winding. Such a winding type is more and more model 2p Vdc Imax Pmax T max nbase nmax
used in traction motor of electric and hybrid electric — (V) (A) (kW) (Nm) (rpm) (rpm)
vehicle. It allows a higher slot fill factor in comparison Prius 8 650 250 60 207 2800 13500
with the traditional round wire windings. This yields a high Lexus 600 8 650 400 165 300 5000 10230
Accord M 8 700 350 124 300 4000 12000
reduction of the Joule losses, when the motor is required to BMW i3 12 360 475 125 250 4000 11400
develop high torque, e.g., during accelerations. However,
due to the high cross-area section of such rectangular-
Torque Higher Torques
shape conductors, the current is non-uniformly distributed
(Higher Currents)
in the conductors, and this causes a reduction of the
benefit of the higher copper area. In addition, due to 200-300 Nm Higher Speeds
(Higher Frequencies)
the high frequency at the higher speeds, parallel paths
are often required. Particular care has to be posed when
such parallels are designed, with proper transposition of
12 - 16 krpm
the wires, to avoid a non uniform distribution of the
current in the parallel paths. The motor parameters are Mechanical speed
computed analytically and then validated by means of a
Fig. 1. Typical torque versus speed characteristic.
Finite Element analysis. Satisfactory results are achieved.
The additional losses are computed according to the
conductor geometry and the whole winding connections
in Table I, the maximum torque is around some hundreds of
(parallel paths, transposition, and so on) with a satisfactory
N m’s, the typical output power is even slightly higher than
precision.
100 kW, and the speeds up to fifteen thousands or rounds per
II. List of symbols minutes.
kfill – slot fill factor The actual trend is to require higher and higher peak torque
kw – fundamental winding factor and operating frequency. The typical torque versus speed char-
f Hz frequency acteristic is shown in Fig. 1. Increasing the torque corresponds
m – no. of phases to an operating current density increase. To contain the motor
Nt – no. of series connected turns temperature rise, it is possible to increase the conductors cross-
npp – no. of parallel paths area section, so that the adoption of hairpin conductors is
nw – no. of conductors within the slot advantageous.
ncs – no. of serial conductors per slot On the other side, the increase of the speed yields an
p – no. of pole pairs increase of the maximum operating frequency, when the motor
Q – no. of slots for an EV is operating in flux-weakening region. The number
q – no. of slots per pole and per phase of poles is kept quite high to reduce the end winding length
yc – coil throw (in no. of wires) and to limit the flux due to the stator current reaction. For
yq – slot throw (in no. of slots) instance when a 8-pole machine runs at 15 000 rpm, the oper-
αs deg slot angle (360/Q) ative frequency reaches a thousand Hz. The higher operative
Φ Wb flux per pole frequencies cause higher iron losses and additional losses in
stator winding conductors, especially if solid conductors with
III. Introduction a high cross-area section are adopted.
The present-day research in Electric Vehicle (EV) is more In addition, in EVs the DC bus voltage is more and more
and more focused on increasing electrical machines power increased during the last years (see Table I), reaching some
density. This means to reduce machine size, to increase torque hundreds Volt’s. Then, operations at high currents and high
and speed, that is, to increase its power density. As reported frequency require to design the windings with parallel paths.

978-1-4799-7312-5/18/$31.00 ©2018 IEEE 4398

Such parallel paths yield reduced cross-area section of the slots and trapezoidal teeth, as in Fig. 4. In this way, a high
conductors (limiting the additional losses) and allow to satisfy slot fill factor is achieved, together with the consequent lower
the voltage limit. However, a particular care has to be taken DC Joule losses amount.
in designing such parallels, adopting proper transpositions of
the wires to avoid a non uniform distribution of the currents
in the parallel paths. The number of series-connected turns Nt
is computed from VDC and maximum frequency f as:
VDC
V̂ph ≈ √ = 2πkw Nt f Φ (1)
3
In EV application, hairpin windings are often adopted. They
are characterized by rectangular cross-area section conductors
which are shaped in advance, as an hairpin, as shown in
Fig. 2(a). Their name comes from their hairpin shape. Then
they are inserted into the stator slots, as in Fig. 2(b), their final
Fig. 4. Stator with rectangular slots. Eight conductors in the slot. Three
parts are bent again (c) and welded to the following conductor hairpin coils are also drawn (front connection).
so as to form a lap winding, (d).
Fig. 3 shows a photo of an hairpin conductor.

PRE-FORMED INSERTION
CONDUCTOR

active
parts

Fig. 5. Photo of a stator with complete hairpin winding. Courtesy of

(a) (b)
Tecnomatic Group, (www.tecnomatic.it).

front connections
Adopting such a rectangular shaped conductor within a rect-
angular shape slot yield a very high fill factor, kfill . Fig. 6 shows
a graphical comparison of traditional trapezoidal slot with
round conductors and the rectangular slot with rectangular
conductors. This improve the performance at high torque and
WELDING low speed: a higher current is allowed, and the heat transfer
BENDING back from the slot to the iron teeth is easier. On the contrary,
connections
a solid conductor with a high cross area section yields a
(c) (d)
worse distribution of the current during the high frequency
Fig. 2. Basic concept of hairpin winding. operations. As an example, Fig. 7 shows the current density
distribution in four rectangular conductors within the slot. The
distribution of the current density in the fourth one is also
drawn.

Fig. 6. Comparison of slot shapes with corresponding round-shape and

rectangular-shape conductors.

Fig. 3. Structure of rectangular hairpin conductor. Therefore, to reduce the additional losses, when possible,
it is convenient to increase the number of conductors within
In hairpin windings, the cross area section is rectangular, the slot and to decrease their cross area section. To do that it
therefore the stator lamination is designed with rectangular is opportune to increase the number of parallel paths. This is

4399
 r third layer
1
second laye
layer four

Current Density (A/mm 2 )

0.8

rst layer
0.6 1 2
0.4

0.2 3
0
0 1 2 3
Rectangular Wire Length (mm) 4
(a)
Fig. 7. Current density distribution in four rectangular conductors within the
slot (computation at frequency f = 1000 Hz.

slot per pole: 1 2

possible when the machine is characterized by a low value of e2
DC bus voltage or by a high operating frequency. Then, the q = 2
number of series connected turns Nt and serial conductors per
e1
slot ncs results quite low, so the number of parallel paths can be
selected in a wider range. It should be noted that the maximum
(b)
number of conductors within the slot nw equals eight.
Fig. 8. Rules to satisfy the voltage and current distribution constraints
IV. General rules
The hairpin windings have to be designed according to
R1 the wires that belong to the winding path have to be
particular conditions. They derive from lap winding connection
lodged in all the layers of the slot. This is because, the
rules.
impedance of the conductors in various layers is different.
General rules deal with the proper positioning of the series
conductors (of each phase) in the stator slots. This means the B. Second rule: Slots per pole arrangement
definition of the path according to the proper layers and slots Similarly, when the number of slots per pole and per phase
per pole. Such conditions allow to determine if parallel paths is higher than unity, say q > 1, the electro-motive force (EMF)
are possible, so as to limit the losses due to a non uniform induced in the conductors of the adjacent slots is different.
current distribution. The angular displacement corresponds to an electrical angle
αes = 360 · p/Q. It follows that conductors of the same phase
A. First rule: layer arrangement lodged in adjacent slots has to be series connected.
When the machine is fed by AC current the resistance In this case, the condition that has to be satisfied, as shown
and the inductance of the conductors in each slot layers in Fig. 8(b), is:
are different. As known, the resistance increases with the R2 the wires that belong to the same winding path have to
frequency, while the inductance decreases. These changes are be lodged in all the slots per pole per phase, no matter
higher for conductors close to the air gap due to the leakage on which layer. This is because, the electromotive forces
flux. induced in one slot is different from the other one when
As a consequence, the impedance of the various conductors q > 1.
is different. Therefore, while the series connection is always
feasible, it is not possible to parallel connect conductors that V. Assumptions
are on the different layers. In order to find a general rule to design such a kind
When parallel connection is necessary, particular care has of winding for each combination of 2p, nw , and q, some
to be paid on the connections of the conductors. The parallel assumptions are made. They are reported hereafter.
connection has to be done after a transposition of the con- (i) An integral number of slots per pole per phase q is
ductors so as to achieve the same impedance of the parallel considered. This allows a regular distribution of the
paths. On the contrary, the current is not uniformly distributed conductor of the various phases.
among the conductors, with a rapid increase of the additional (ii) Only full-pitch windings are considered. No chorded
losses. windings.
It is imperative to design a transposition of the conductor (iii) The number of conductors within the slot, nw , is even.
passing from slot to slot. In other words, the same wire has to This is natural when lap windings are considered.
be lodged in different layers during its path. As will be shown, (iv) The conductors belonging to the same winding path have
such a transposition is fundamental to reduce the additional to be placed in the slot so as to fill all the layers and all
losses in these windings, to avoid the current density might the slots per pole of that phase. See rules R1 and R2 in
reach exorbitant values. Section IV. This allows to improve the current distribution
An example of a wrong connection is reported in Section X. as already remarked above.
Therefore, the condition that has to be satisfied, as shown (v) The front connections are always equal in order to guar-
in Fig. 8(b), is: antee hairpins with the same pitch, and to make easier the

4400
 slot number In both cases the connections do not involve a change in
start
layer the slot angle αes = 2πp/Qs , where Qs is the number of stator
front back number slots.
1 2 connection 7 8 connection 13 14
5 A B
49
The  D and  E connections are used when the position
1 25 29 1
wire 2 26 30 of the following coil is lodged in a different slot per pole.
6 50 2
number 3 7 27 31 51 3
In particular, 
D connection to connect a coil in a backing
4 8 ... 28 32 ... 52 4 slot, while 
E connection to connect a coil in a leading slot.
Thus, the wire occupies a different slot with compared to the
Fig. 9. Connection: number definition. Example of two slots per pole per previous pole, that is, it moves of an angle αes , backwards or
phase, q=2, coil throw yq =6, number of conductors per slot nw =4. forwards, respectively.
The possible cases are reported in Fig. 10.
insertion in the stator slots of the wires (please refer to yq,f front
Fig. 2(b) considering all hairpins to be inserted together A connections
at the same time). The front connection is characterized
by the coil throw
Q
yq,f ≈ . (2)
2p

rst second
layer layer
(vi) The back connections are kept as much as possible with B D
yq,b shorter connection to
equal length. The use of long and short connections is back change the slot per pole
limited as much as possible. connections
start

A. Connections
As stated above, different types of connections are involved.
Hereafter, the wires are numbered progressively. The notation
at first considers the wire in the different layers, then it goes
on the following slot. Let’s refer to Fig. 9. In the winding
second third
drawings, solid and dashed lines are used to highlight the odd E layer C layer
and the even layer respectively. yq,b yq,b
longer back connection to back connection to
The front connection is characterized by the same pitch, change the slot per pole change layer position
i.e., the same in all the possible patterns. Its coil throw is
defined as Fig. 10. Schematic sketch of winding connections.
yq,f = yq nw + 1. (3)

and represented by the line labeled as  A . VI. Winding construction

The back connection is characterized by a different pitch, According to the rules described in Section IV and the
according to the proper connection between the turns. For the assumptions reported in Section V, the winding procedure is
back connections there are several cases. They are character- carried out as follows.
ized by a coil throw equals to: (i) In the first revolution around the stator, the turn sides are
⎧ lodged in the first two layers, that is, the winding is moving
⎪
⎪
⎪ 
B yc,b = yq nw − 1
⎪
⎪
⎪
between the first and second layer. In addition, the turn sides
⎪
⎪
⎨C yc,b = yq nw + 1 are lodged in the same slot per pole position (e.g., in the slot
⎪
⎪
⎪
(4)
⎪
⎪ 
D yc,b = (yq − 1)nw − 1 per pole on the right hand side).
⎪
⎪
⎪
⎩E yc,b = (yq + 1)nw + 1 After a complete revolution along the stator, the number of
turns inset within the slots is p.
The  B connection is used when the coil is connected to a (ii) After a complete revolution, the back connection yc,b
coil in the position: the coil side is connected to the following is modified, so as to change the position of slot per pole,
and previous coil side that are lodged in the same electrical i.e., connection D or  E as defined in Fig. 10. Then, a new
position, e.g., the coil side on the first layer of the slot on the revolution along the stator is carried out.
left hand side. Referring to Fig. 9, wire 1 and wire 49 are in This procedure is repeated a number of times equal to the
the same electric position. The back connection  B connects number of slots per pole and per phase q.
the wire 26 to 49. (iii) After the complete q revolutions along the stator, the back
The  C connection is used when the coil, whose sides are connection is modified, to change the layer level, that is, the
lodged in two layers, is connected to a coil whose sides are connection  C as defined in Fig. 10 is applied. Therefore, the
lodged in the successive layers. In fact, the coil throw leads winding connections move from the first and second layers to
to a number of wire corresponding to a higher layer. the third and fourth layers.

4401

(iv) The winding procedure (ii) is repeated in such layers, up
to fill all the slot per pole of that phase, i.e., q times. Then,
the layers are changed, as described in (iii).
(iv) The connections end when the last two layers in the slots
are filled. Following such a procedure, all layers and slots per
pole per phase are filled in the same ways.
A. Examples
Fig. 11 shows an example referring to a 4-pole machine
with two slots per pole per phase (i.e., 2p = 4 , q = 2). There
are nw = 2 conductors per slot.
The phase winding is split in two parts, which are distin-
guished by black and red color. The circles identify the starting
and ending points. The “start” and “end” notation depends
on their position with respect to the poles. Each of them is
lodged in the first and second layer alternatively, so that they
are characterized by the same impedance. Consequently, they
could be series or parallel connected, indifferently.
It is worth noticing that both slots per pole are filled in the
same way, and all layers are filled equally. This is in accord
with the rules R1 and R2 of Section IV.
yq,f
A A A A
D B B D
yq,b
start start
end end
Fig. 11. Example 1: sketch of winding connections with 2p = 4 poles, q = 2
slots per pole and per phase, nw = 2 conductors per slot.
A second example is shown in Fig. 12, referring to a 4-pole
machine with two slots per pole per phase (i.e., 2p = 4, q = 2)
and nw = 4 conductors per slot.
Only a part of the phase winding is shown. It is worth
following the connections from “start” to “end”. At first
there are four coil sides lodged in the first and second layer,
alternatively, remaining within the slots per pole on the right
hand side. Then, by means of the back connection  C , the
followings coils are lodged in the third and fourth layer, and
also in the slots per pole on the left hand side. At the end, all
the four layers and both slots per pole are filled in the same
way, according to the rules R1 and R2 above.
B. The elementary winding
It is possible to define an elementary winding, which is
characterized by the minimum number of series-connected
conductors. Let’s remark that it is “minimum” with respect
the manufacturing process described above. According to this
elementary winding, it is possible to determine a procedure
that allow an easy computation of the hairpin winding.
The manufacturing process of such an elementary winding
is described hereafter.
4402
yq,f
A A
B
C E
yq,b
start end
Fig. 12. Example 2: sketch of winding connections with 2p = 4 poles, q = 2
slots per pole and per phase, nw = 4 conductors per slot.
(1.) During the first revolution, the turn sides are lodged in
first two layers.
(2.) After a complete revolution the back connection is chosen
to change layers, that is, from the first and second layers to
the third and fourth layers. In this second revolution the turn
sides are lodged in the third and fourth layers.
(3.) Similarly, after each revolution, the layers are changed. In
this way, the rule R1 is satisfied.
It is also noticing that in each complete revolution along
the stator p turns are placed within the slots. The number
of changes of layer position corresponds to the number of
conductors per slots, that is, the number of layers nw . Then it
results that the number of revolutions has to be nw /2.
(4.) At the same time, the rule R2 has to be satisfied. Then,
during the revolutions described above, in addition to the
change of layers, the position of the slot per pole has be
changed. For instance, from the slot per pole on the right to
the adjacent one. The change of slot position is repeated so as
to fill equally all the q slots per pole of that phase (i.e., q − 1
times).
(5.) According to such a change of layers and slots per pole
and per phase, the minimum number of series connected turns
can be computed as:
n 
w
Nsct = LCM p, q (5)
2
where LCM means least common multiple. Table II, reports
some combinations of q, 2p, and nw .
(6.) Once Nsct is computed, the maximum number of parallel
paths is equal to:
2pnw q
npp = (6)
2Nsct
An example of such an elementary winding is shown in
Fig. 13.
As said above, p turns are placed within the slots per
revolution. After each revolution the layer position is changed.
For given nw layers, a number of revolutions nw /2 are carried,
so that, at the end, p · nw /2 are connected. On the other hand,
the q slots per pole per phase have to be equally filled.
However, the number of turns p·nw /2 is not often a multiple
of q. In this case, it is necessary to increase the number of
revolutions around the stator, always respecting the uniform
distribution among the layers.
 A

Hy
Jz
B D

start end 1 k nw

Fig. 13. Example of elementary winding: sketch of winding connections with

2p=4 poles, q=2 slots per pole and per phase, nw =4 conductors per slot. Fig. 14. Reference frame to analytically compute the current density distri-
bution within the rectangular slot.

Some examples are given in Table II. In the first three

rows, the number of turns p · nw /2 results to be multiple of q. Assuming Hx = 0, as reported in Fig. 14, the current density
Therefore, the insertion of p · nw /2 turns is enough to satisfy distribution within each k-th wire is given by
both rules R1 and R2. On the contrary, for the combinations 
q = 2, 2p = 6, nw = 2 and q = 2, 2p = 6, nw = 6, the I k cosh(ax) − (k − 1) cosh[a(x − h p )]
Jz,k (x) = a (8)
number of turns p · nw /2 (they are reported in bold font) is not wp sinh(ah p )
multiple of q. Thus, p · nw /2 turns are not enough to fill the be where a is defined as a = (1 + j)/δ and δ is the skin depth,

lodged uniformly in the layers and slot position. The number that is, δ = 1/ π f σμ.
of revolutions has to be increased, and the number of turns The analytical current density distribution along the x-axis
for a proper transposition increases (it becomes twice in this is shown in solid green line in Fig. 15. It refers to a correct
case). The number of turns results in Nsct (reported in bold transposition of the wires in the slot, as remarked by the
font as well). It follows that the maximum number of parallel rules above. It corresponds to have a series connection of all
paths decreases. conductors.
To validate the results, the current density distribution from
TABLE II FEA is reported by black dots. Even with a proper connection
Example of connected turns
of the wires, it is worth noticing that the current density rises
q 2p nw p
nw
Nsct
up to 50 A/mm2 , in correspondence of the slot opening. A
2 non uniform current density distribution in each conductor is
2 4 2 2 2 also evident: it is concentrated on one side of the conductor
2 4 4 4 4
2 4 6 6 6 cross section, due to the proximity effect when more than one
2 6 2 3 6 conductor is in the slot. At the frequency of about f = 1 kHz
2 6 4 6 6 the ratio between the AC and DC losses is around kAC =
2 6 6 9 18
5.5. Such a ratio kAC is related to the operative frequency, the
impact of the frequency is focused.
VII. Stator winding additional losses
VIII. Analytical losses computation
According to the rules defined above, all layers and slots per
pole are equally filled by the elementary windings, so that a To estimate the losses in the conductors, it is possible to
proper transposition of the conductors is achieved. Therefore, use the standard relationships. A proper wire transposition is
the additional losses, not negligible at high frequencies, can be considered.
predicted considering a single slot only. The nominal current The reduced height is computed from the slot and wire
is imposed within each conductor of the slot and the Joule dimension, and the penetration depth δ p
losses are computed. 
wp hp
ξ= n ·
A. Current density distribution using rectangular wires ws δ p
In this section a slot filled with rectangular elementary wires Such a value is used to determine the two functions:
is considered. The slot is modeled with eight elementary wires,
each one characterized by a width wp = 3.75 mm and a height
hp = 2.75 mm. sinh(2ξ) + sin(2ξ)
ϕ(ξ) = ξ (9)
The additional losses are analytically computed and verified cosh(2ξ) − cos(2ξ)
by Finite Element Analysis (FEA). To solve the problem sinh(ξ) − sin(ξ)
ψ(ξ) = 2ξ (10)
analytically, the Maxwell’s equations are used: cosh(ξ) + cos(ξ)
⎧
⎪
⎪ ∂H x ∂Hy Then, the increase of the resistance for conductors placed
⎪
⎪
⎪ − + = Jz
⎨ ∂y ∂x in the the k-th layer is computed as
⎪
⎪
⎪ 1 ∂Jz 1 ∂Jz ∂B (7)
⎪
⎪
⎩ ux − uy =
σ ∂y σ ∂x ∂t kk = ϕ + (k2 − k) · ψ

4403
 107 Operating frequency f = 1133.33 Hz
5
20

Current density (A/m 2 )

Analitical
FEM nc = 2
4
nc = 4
3
15 nc = 6
2 nc = 8

P (pu)
1
10
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
Position in the slot (pu)
f = 1000 Hz
5
f = 600 Hz
f = 300 Hz

0
0 1 2 3 4 5
(pu)

Fig. 16. Additional losses varying the number of conductors within the slot.

Fig. 15. Current density along the slot with a correct transposition of the
wires. The current is the same in each conductor. Computation at frequency Λm
1 kHz. Nt = = 30 (11)
Bg1,pk Di Lstk
kw
p
It approaches unity for the conductor at the bottom of the slot, 3Nt
ncs = 2 =4 (12)
and assumes higher value for the conductor at the slot opening, Qs
where the magnetic field strength is higher. The resistance It is possible to place in each slot 4 or 8 conductors nw . In
factor for the winding is obtained as the average value of the the first case nw conductors are series connected to guarantee
factors kk computed for all the nw layers. the voltage constrain, in the other case two parallel paths are
required.
A. Additional losses varying the frequency When nw = 4, the minimum number of series connected
turns to ensure a correct parallel connection (that takes into
The additional losses due to the skin and the proximity effect
account the general rules R1 and R2 of Section IV) results:
are computed varying the frequency in the range from 0 to n p 
1200 Hz. In addition, nw = 2, nw = 4, nw = 6, and nw = 8 Nsct = LCM
w
,q = 8 (13)
conductors per slot are considered even if the slot is filled by 2
the same copper amount. The results are shown in Fig. 16. While if nw = 8, the minimum number of series connected
As expected, the solution with nw = 8 conductors per slot is turns results:
the more convenient up to f = 1200 Hz. In this case, in fact, n p 
w
Nsct = LCM , q = 16 (14)
the current results to be more uniformly distributed, due to the 2
lower height of the conductors. This solution leads to lower additional losses as above
But comparing the nw = 2 and nw = 4 it worth noticing shown in Fig. 16.
that for frequencies higher than 600 Hz nw = 2 leads to less
additional losses. This means that the choice nw is related to X. Example of additional losses due to a wrong parallel
the nominal operative frequency of the machine. connection
An example is given hereafter to weigh the impact of a
IX. Example of series connected turns determination wrong connection of the parallel path.
Lets consider the slot with four conductors.
Let us refer to Lexus motor characteristics reported in A first path is considered to be formed by conductors lodged
Tab. 1. The main geometrical data are: stator inner diameter in the first and second layer. A second path is considered to
Di = 130 mm, stack length Lstk = 135 mm and number be formed by conductors lodged in the third and fourth layer.
of stator slots Qs = 48. At the base speed of 4000 rpm, They are then connected in parallel.
the simulated first harmonic of air-gap flux density results The impedance of the various conductors is computed at
in Bg1,pk = 1.3 T and the linkage flux, according to Vdc , is f = 1 kHz.
Λm = 0.095 V s. The corresponding number of serial turns per In order to consider the transposition of Fig. 17 (b) the
phase Nt and serial conductors per slot ncs are reported in (11) parameters Ri and Li of each layer have to be determine. A
and (12): time harmonic simulation is carried out feeding all the wires in

4404
 ...
first
path
second ...
path
(a)

iup Rup Lup

itot
Rdown Ldown

idown (b)

Fig. 17. Lumped parameter model of the stator winding.

Fig. 18. Current density distribution at 1000 Hz with right (a) and wrong (b)
parallel connection.
order to take into account the mutual coupling. The equivalent
resistance of each wire is calculated using the resultant AC
Joule losses : 
1 |J|2
R= 2 dv (15)
I VCu σ
and the inductance is computed as:
  [2] M. Popescu, J. Goss, D. A. Staton, D. Hawkins, A. Boglietti, Y. C.
Re V J¯z · Ãz dv
L= Cu
(16)
I2
where VCu is the volume of the wire, J¯z is the complex vector
of the z-axis component of the current density and Ãz is the
magnetic vector potential complex conjugate.
Once determined both resistance and inductance of each
wire it is possible to solve the circuit of Fig. 17 (b) where Rup
is the average value of the first and second layers resistance
and Rdown the average value of the third and fourth layers
resistance. Similarly for Lup and Ldown .
With these parameter it is possible to solve the circuit
performing a loop up to convergence in order to simulate the
wrong parallel connection.
The results at f = 1000 Hz are reported in Fig. 18(b). In this
configuration the current is concentrated in the third and fourth
layer. The losses with a wrong connection result to be about
1.5 times higher than the losses with the proper connection.
In addition, not only the losses result increased, but also there
is a thermal problem in the wires near the airgap. A correct
transposition is therefore mandatory.
XI. Conclusion
The procedure to correctly design a stator winding using
hairpin wires is reported. Different connection patterns are
shown. The series connection of all elementary winding is
always feasible since the wires are transposed and stator
winding additional losses are contained. In order to have
parallel paths is necessary to take into account both the voltage
and the current constraints. Furthermore it is necessary to
ensure that the front and back connections are as uniform as
possible. The proposed connection schemes fulfil these two
constraints. A FEA analysis has been used to rapidly compute
the additional losses varying the number of conductors within
the slots and to find out the most appropriate value according
to the machine nominal frequency.
4405
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