Comparison of Aluminium and Copper Conductors in Hairpin Winding Design for High Power Density Traction Motors

G. Petrelli; M. Cui; T. Zou; G. Sala; A. La Rocca; D. Barater; G. Franceschini; D. Gerada; M. Degano; C. Gerada

doi:10.1109/ICEM51905.2022.9910796

Comparison of Aluminium and Copper Conductors in Hairpin Winding Design for High Power Density Traction Motors

G. Petrelli
, M. Cui
, T. Zou
, G. Sala
, A. La Rocca
, D. Barater
, G. Franceschini
, D. Gerada
, M. Degano
, C. Gerada

Department of Electrical and Electronic Engineering

Research output: Chapter in Book/Conference proceeding › Conference contribution › peer-review

33 Citations (Scopus)

Abstract

Hairpin windings are becoming current/next generation solutions for traction motors of electric vehicles due to inherently reduced DC power losses and improved heat dissipation capability compared with random windings. Copper-based conductor has been widely accepted as default option for hairpin windings. Meanwhile, aluminum remains a popular conductor material based on its light-weight characteristic and flexibility in manufacturing. In this paper, both copper and aluminum conductors will be evaluated based on specific hairpin winding layout applied in design of a 150kW, 18000rpm traction motor. Influences of conductor sizes on machine performance and power losses will be investigated for these two winding materials by 2D FEA of parametrized machine topology. It is interesting to find that by bringing this "old-fashioned"comparison back to stage, aluminum conductor might be promising candidate for hairpin windings due to reduced AC losses, easier preforming and welding process and much reduced raw material costs.

Original language	English
Title of host publication	2022 International Conference on Electrical Machines, ICEM 2022
Publisher	Institute of Electrical and Electronics Engineers Inc.
Pages	1635-1641
Number of pages	7
ISBN (Electronic)	9781665414326
DOIs	https://doi.org/10.1109/ICEM51905.2022.9910796
Publication status	Published - 2022
Event	2022 International Conference on Electrical Machines, ICEM 2022 - Valencia, Spain Duration: 5 Sept 2022 → 8 Sept 2022

Publication series

Name	2022 International Conference on Electrical Machines, ICEM 2022

Conference

Conference	2022 International Conference on Electrical Machines, ICEM 2022
Country/Territory	Spain
City	Valencia
Period	5/09/22 → 8/09/22

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

SDG 7 Affordable and Clean Energy

Free Keywords

AC loss
aluminum windings
copper windings
Electric vehicle
hairpin winding
high speed machine
power density
traction motor

ASJC Scopus subject areas

Electrical and Electronic Engineering
Mechanical Engineering

Access to Document

10.1109/ICEM51905.2022.9910796

Cite this

Petrelli, G., Cui, M., Zou, T., Sala, G., La Rocca, A., Barater, D., Franceschini, G., Gerada, D., Degano, M., & Gerada, C. (2022). Comparison of Aluminium and Copper Conductors in Hairpin Winding Design for High Power Density Traction Motors. In 2022 International Conference on Electrical Machines, ICEM 2022 (pp. 1635-1641). (2022 International Conference on Electrical Machines, ICEM 2022). Institute of Electrical and Electronics Engineers Inc.. https://doi.org/10.1109/ICEM51905.2022.9910796

@inproceedings{755522b0196e4d8a88c3c92f14440cdd,

title = "Comparison of Aluminium and Copper Conductors in Hairpin Winding Design for High Power Density Traction Motors",

abstract = "Hairpin windings are becoming current/next generation solutions for traction motors of electric vehicles due to inherently reduced DC power losses and improved heat dissipation capability compared with random windings. Copper-based conductor has been widely accepted as default option for hairpin windings. Meanwhile, aluminum remains a popular conductor material based on its light-weight characteristic and flexibility in manufacturing. In this paper, both copper and aluminum conductors will be evaluated based on specific hairpin winding layout applied in design of a 150kW, 18000rpm traction motor. Influences of conductor sizes on machine performance and power losses will be investigated for these two winding materials by 2D FEA of parametrized machine topology. It is interesting to find that by bringing this {"}old-fashioned{"}comparison back to stage, aluminum conductor might be promising candidate for hairpin windings due to reduced AC losses, easier preforming and welding process and much reduced raw material costs.",

keywords = "AC loss, aluminum windings, copper windings, Electric vehicle, hairpin winding, high speed machine, power density, traction motor",

author = "G. Petrelli and M. Cui and T. Zou and G. Sala and \{La Rocca\}, A. and D. Barater and G. Franceschini and D. Gerada and M. Degano and C. Gerada",

note = "Publisher Copyright: {\textcopyright} 2022 IEEE.; 2022 International Conference on Electrical Machines, ICEM 2022 ; Conference date: 05-09-2022 Through 08-09-2022",

year = "2022",

doi = "10.1109/ICEM51905.2022.9910796",

language = "English",

series = "2022 International Conference on Electrical Machines, ICEM 2022",

publisher = "Institute of Electrical and Electronics Engineers Inc.",

pages = "1635--1641",

booktitle = "2022 International Conference on Electrical Machines, ICEM 2022",

address = "United States",

}

Petrelli, G, Cui, M, Zou, T, Sala, G, La Rocca, A, Barater, D, Franceschini, G, Gerada, D, Degano, M & Gerada, C 2022, Comparison of Aluminium and Copper Conductors in Hairpin Winding Design for High Power Density Traction Motors. in 2022 International Conference on Electrical Machines, ICEM 2022. 2022 International Conference on Electrical Machines, ICEM 2022, Institute of Electrical and Electronics Engineers Inc., pp. 1635-1641, 2022 International Conference on Electrical Machines, ICEM 2022, Valencia, Spain, 5/09/22. https://doi.org/10.1109/ICEM51905.2022.9910796

Comparison of Aluminium and Copper Conductors in Hairpin Winding Design for High Power Density Traction Motors. / Petrelli, G.; Cui, M.; Zou, T. et al.
2022 International Conference on Electrical Machines, ICEM 2022. Institute of Electrical and Electronics Engineers Inc., 2022. p. 1635-1641 (2022 International Conference on Electrical Machines, ICEM 2022).

Research output: Chapter in Book/Conference proceeding › Conference contribution › peer-review

TY - GEN

T1 - Comparison of Aluminium and Copper Conductors in Hairpin Winding Design for High Power Density Traction Motors

AU - Petrelli, G.

AU - Cui, M.

AU - Zou, T.

AU - Sala, G.

AU - La Rocca, A.

AU - Barater, D.

AU - Franceschini, G.

AU - Gerada, D.

AU - Degano, M.

AU - Gerada, C.

PY - 2022

Y1 - 2022

N2 - Hairpin windings are becoming current/next generation solutions for traction motors of electric vehicles due to inherently reduced DC power losses and improved heat dissipation capability compared with random windings. Copper-based conductor has been widely accepted as default option for hairpin windings. Meanwhile, aluminum remains a popular conductor material based on its light-weight characteristic and flexibility in manufacturing. In this paper, both copper and aluminum conductors will be evaluated based on specific hairpin winding layout applied in design of a 150kW, 18000rpm traction motor. Influences of conductor sizes on machine performance and power losses will be investigated for these two winding materials by 2D FEA of parametrized machine topology. It is interesting to find that by bringing this "old-fashioned"comparison back to stage, aluminum conductor might be promising candidate for hairpin windings due to reduced AC losses, easier preforming and welding process and much reduced raw material costs.

AB - Hairpin windings are becoming current/next generation solutions for traction motors of electric vehicles due to inherently reduced DC power losses and improved heat dissipation capability compared with random windings. Copper-based conductor has been widely accepted as default option for hairpin windings. Meanwhile, aluminum remains a popular conductor material based on its light-weight characteristic and flexibility in manufacturing. In this paper, both copper and aluminum conductors will be evaluated based on specific hairpin winding layout applied in design of a 150kW, 18000rpm traction motor. Influences of conductor sizes on machine performance and power losses will be investigated for these two winding materials by 2D FEA of parametrized machine topology. It is interesting to find that by bringing this "old-fashioned"comparison back to stage, aluminum conductor might be promising candidate for hairpin windings due to reduced AC losses, easier preforming and welding process and much reduced raw material costs.

KW - AC loss

KW - aluminum windings

KW - copper windings

KW - Electric vehicle

KW - hairpin winding

KW - high speed machine

KW - power density

KW - traction motor

UR - https://www.scopus.com/pages/publications/85141066091

U2 - 10.1109/ICEM51905.2022.9910796

DO - 10.1109/ICEM51905.2022.9910796

M3 - Conference contribution

AN - SCOPUS:85141066091

T3 - 2022 International Conference on Electrical Machines, ICEM 2022

SP - 1635

EP - 1641

BT - 2022 International Conference on Electrical Machines, ICEM 2022

PB - Institute of Electrical and Electronics Engineers Inc.

T2 - 2022 International Conference on Electrical Machines, ICEM 2022

Y2 - 5 September 2022 through 8 September 2022

ER -

Petrelli G, Cui M, Zou T, Sala G, La Rocca A, Barater D et al. Comparison of Aluminium and Copper Conductors in Hairpin Winding Design for High Power Density Traction Motors. In 2022 International Conference on Electrical Machines, ICEM 2022. Institute of Electrical and Electronics Engineers Inc. 2022. p. 1635-1641. (2022 International Conference on Electrical Machines, ICEM 2022). doi: 10.1109/ICEM51905.2022.9910796

Comparison of Aluminium and Copper Conductors in Hairpin Winding Design for High Power Density Traction Motors

Abstract

Publication series

Conference

UN SDGs

Free Keywords

ASJC Scopus subject areas

Access to Document

Other files and links

Fingerprint

Cite this