Comprehensive Drive-Cycle-Based Analysis of Hairpin vs Stranded Windings for EV

Winding analysis is crucial for enhancing electric vehicle (EV) performance as it directly impacts motor efficiency, thermal management, and torque production. By examining different winding technologies, this study aims to identify optimal designs that improve overall motor performance and reliability. In this paper, a comprehensive analysis of hairpin and stranded windings for highway and urban drive cycles is conducted for two interior permanent magnet synchronous motors rated at 150 kW for EV. By integrating two distinct drive cycles, the research aims to provide a detailed assessment of efficiency, losses, and torque characteristics for each winding type. Additionally, the machines are evaluated at critical operational points, considering peak currents, and torque under the specified drive cycles. This drive cycle-based analysis provides a holistic view of the performance, reliability, and efficiency of hairpin and stranded windings, facilitating better design decisions.