Design Analysis of an Interior Permanent Magnet Synchronous Motor with Hybrid Hair-Pin and Litz Wire Windings

To meet the demands for weight reduction and cost efficiency, the design of interior permanent magnet synchronous motors (IPMSMs) for electric vehicles is inevitably evolving toward high-speed operation, compactness, and improved efficiency. This paper proposes and analyzes a novel hybrid winding design that combines hair-pin coils and litz wire coils. The objective of this hybrid approach is to leverage the high-fill-factor advantage of hair-pin windings while mitigating the increased high-frequency copper losses caused by skin effect—an area where litz wire excels. Finite element analysis (FEA) is used to evaluate and compare the performance of the proposed hybrid stator design against conventional winding configurations, including round wire windings and pure rectangular windings. Key factors such as fill factor and skin effect are thoroughly considered in the analysis. Additionally, a system-level evaluation is conducted based on assumed electric vehicle parameters, providing a comprehensive assessment of efficiency and energy losses under real-world operating conditions.