Automatisierter Entwurf von Haarnadelwicklungen anhand von tabellarischen Belegungsplänen

Hairpin windings are being used increasingly in electric traction motors to reach high torque and power requirements within a limited installation space. Hairpin windings in particular are attractive for automotive applications since they have high slot fill factor, short end windings and enable a highly automated manufacturing process. However, their high current displacement effects may be a drawback. These can be reduced by realizing parallel branches while keeping the same number of effective turns per phase. Thereby the conductor height is decreased which results in a smaller current displacement effect. Realizing windings with parallel branches involves the risk of developing circulating branch currents. These can be eliminated by an appropriate connection of the conductors. This article presents an automated design tool for hairpin windings, which generates all possible winding configurations as winding diagrams for different combinations of number of poles and slots. The suppresion of circulating currents and the identification of advantages and disadvantages of each winding present a challenge due to the high amount of connecting options. Therefore, quality factors are developed and implemented into the software, which allow a clear evaluation.