Scripting-Based 3D Geometry Modelling of Hairpin Windings in EV Traction Motors: Design for Manufacturing

This paper presents a pure scripting-based and time-efficient 3D geometric modelling tool of hairpin windings for electrical vehicle traction motors. Developed with a 'design for manufacturing' motivation, it enables optimizing winding design with both electrical and mechanical aspects of hairpin conductors considered. Without dependence on commercial CAD software, the tool can rapidly generate high-fidelity 3D models of windings with both welding and insertion end, based solely on winding layouts and geometric parameters of the stator. The modelling process is fully parameterized, enabling high flexibility for design iteration and manufacturing adaptation. Through a case study on a 48-slot, 8-pole, 6-layer hairpin winding stator, typical challenges regarding physical interference and manufacturing feasibility arising from pin arrangements are highlighted. To address these issues, tailored geometry tuning strategies are developed. Combined with these strategies, the tool integrates a partitioned checking and auto-tuning algorithm that can rapidly detect and resolve geometric interferences, ultimately producing collision-free and manufacturable 3D hairpin winding models.