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Título
A comparison between continuous and hairpin windings for electric traction drivesAutor-a
Grupo de investigación
Accionamientos aplicados a la tracción y a la generación de energía eléctricaOtras instituciones
GKN AutomotiveVersión
Postprint
Derechos
© 2023 IEEEAcceso
Acceso abiertoVersión del editor
https://doi.org/10.1109/EDPC60603.2023.10372165Publicado en
13th International Electric Drives Production Conference (EDPC). Pp. 1-8. Regensburg (Germany), 29-30 November, 2023 Editor
IEEEPalabras clave
Windings
electric vehicle
interior permanent magnet synchronous motor
design for manufacturing ... [+]
electric vehicle
interior permanent magnet synchronous motor
design for manufacturing ... [+]
Windings
electric vehicle
interior permanent magnet synchronous motor
design for manufacturing
ODS 7 Energía asequible y no contaminante
ODS 9 Industria, innovación e infraestructura [-]
electric vehicle
interior permanent magnet synchronous motor
design for manufacturing
ODS 7 Energía asequible y no contaminante
ODS 9 Industria, innovación e infraestructura [-]
Resumen
Present change in mobility to vehicle electrification involves highly exigent requirements on product performance and production technologies. In the manufacturing of electric machines, the stator win ... [+]
Present change in mobility to vehicle electrification involves highly exigent requirements on product performance and production technologies. In the manufacturing of electric machines, the stator winding is the most challenging and cost demanding process. Within this context, the existing winding technologies need to be optimised to improve their product and process robustness. Axially inserted hairpins are widely used since they present an attractive design for high power and high torque density traction applications. However, the welding of the hairpins is a complex step that leads to high costs of rejects and frequent appearance of faults. Consequently, the radially inserted continuous winding provides a whole new potential for electric powertrains where the manufacturing process can be significantly simplified. This paper introduces a comparison of two flat wire assembly technologies for mass-produced stators: continuous and hairpin windings. Production stages of each winding technology are reviewed. Moreover, main design constraints and challenges of continuous winding motors are exposed. A Finite Element Method (FEM) based performance comparison of two Interior Permanent Magnet Synchronous Machines (IPMSM) with hairpin and continuous winding is presented. The torque, power, torque ripple, losses, Worldwide Harmonised Light Vehicles Test Procedure (WLTP) efficiency and demagnetisation characteristics are analysed. Finally, new design considerations to overcome the limitations and the performance reduction of continuous winding motors are proposed. [-]
Financiador
Comisión EuropeaPrograma
HORIZON 2.5Número
101096306URI de la ayuda
https://doi.org/10.3030/101096306Proyecto
Novel concept of a Low Cost, High Power Density and Highly Efficient Recyclable motor for next generation mass produced electric vehicles (HEFT)Colecciones
- Congresos - Ingeniería [341]