Investigation of the Temperature Effects on Copper Losses in Hairpin Windings

Today, an extensive electrification is occurring in all industrial sectors, with a special interest seen in the automotive and aerospace industries. The electric motor, surely, is one of the main actors in this context, and an ever-increasing effort is spent with the aim of improving its efficiency and torque density. Hairpin windings are one of the recent technologies which are implemented onto the stator of the electric motor. Compared to conventional random windings, it inherently features lower DC resistance, higher fill factor, better thermal performance, improved reliability, and an automated manufacturing process. However, its bottleneck is the high ohmic losses at high-frequency operations due to skin and proximity effects (AC losses), resulting in a negative impact on the temperature map of the machine. Nevertheless, while it is well-known that DC losses increase linearly with the operating temperatures, the AC losses trend needs further insight. This paper demonstrates that operating the machine at higher temperatures could be beneficial for overall efficiency, especially at high-frequency operations. This suggests that a paradigm shift is required for the design of electric motors equipped with hair-pin windings, which should therefore focus on a temperature-oriented approach. In addition, the effect of the rotor topology on AC losses, which is often overlooked, is also considered in this paper. The combination of these effects is used to carry out observations and, eventually, to provide design recommendations. Finite element electromagnetic and thermal evaluations are performed to prove the findings of this research.