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Abstract
Interior permanent magnet (IPM) machines with hairpin windings have attracted significant attention in EV applications owing to their low DC resistance and excellent thermal capabilities. In this paper, we present a comprehensive investigation of AC winding losses in IPM machines for traction applications, including analytical modeling, the influence of design parameters, and finite element (FE) verification. The proposed analytical model can predict the trends in AC winding losses for any number of bar conductors and slot/pole combinations. The results of the parametric study, obtained via the analytical model, are presented to examine the effects of key design parameters, such as conductor width and height, phase arrangement, and slot-per-pole-per-phase (SPP). To incorporate more practical issues into the analysis of IPM machines with hairpin windings, extensive FE simulations were conducted. The results indicated that the AC winding losses decrease with an increasing number of conductor layers and phases inside the slot.
Highlights
In the past decade, there have been significant technical advances in the electric vehicle (EV) market to satisfy global environmental regulations
Among the different types of traction machines, interior permanent magnet synchronous machines (IPMSMs) are the most popular in the market owing to their excellent torque density and efficiency and their wide constant power speed ratio (CPSR) [2]
An interior permanent magnet (IPM) machine exhibits the highest efficiency when compared to any other type of machine, efforts are underway to further increase the efficiency of IPM machines by advancing machine topologies, materials, and manufacturing techniques
Summary
There have been significant technical advances in the electric vehicle (EV) market to satisfy global environmental regulations. Hairpin windings have been adopted by many EV manufacturers to reduce fuel consumption over standard driving cycles, as well as production lead time. This is because hairpin windings typically exhibit a higher copper fill factor, shorter end windings, lower DC resistance, higher torque density, excellent thermal performance, and a highly automated manufacturing process [3–6]. Hairpin winding allows precise placement of each conductor within a slot and a consistent arrangement of the end windings. Given these features, hairpin windings are highly effective in oil cooling systems.
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