Asymmetric Hairpin Winding Design for Losses Reduction with Thermal Analysis for an Electric Vehicle Case Study

The asymmetric design of hairpin windings is known as a method for reducing AC losses in electric motors, especially at high frequencies. 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. Compared to the state-of-the-art in this paper, deep investigations are carried out to obtain the optimum design of the asymmetric hairpin windings while still employing a conventional manufacturing method. An analytical model is developed to speed up the investigation process, and the results of the analytical model are validated with a finite element method (FEM) model. The conclusions from the analytical investigation are considered in the design of an electric vehicle (EV) motor. The performance of the motor is studied for two different driving profiles to validate the rules of the asymmetric windings design and check the degree of dependency of the design of asymmetric windings on the application. It is proved that using asymmetric design reduces motor losses and improves thermal performance.