Hairpin Motor Production Technologies

Alexander Kuehl, Research Director Electormechanical Engineering, Friedrich-Alexander-University Erlangen-Nuremberg (FAU)

The electrification of the drive train of passenger cars is currently undergoing an evolution from windings previously drawn in, which are known from industrially used electrical machines, to windings specially tailored to the requirements of mobile electric traction. A main trend is the use of pluggable shape windings, so-called hairpins. In order to fully exploit the economic advantages of this winding, elaborated production concepts and strategies are required. Due to the novelty and the currently ongoing innovation of these type of windings, the differentiated manufacturing possibilities per process step have not yet been fully defined. In view of the economic efficiency, high process speeds with increasing process reliability play a major role. The aim of this presentation is to show a process chain of hairpin technology that is as universally valid as possible, to name the different alternatives for each process step and to explain their characteristics.

Alexander Kuehl did his doctoral thesis in the field of winding technology for electric motors at the Friedrich-Alexander-University Erlangen-Nuremberg (FAU) Since 2014 he is heading the Research Center for Electric Drives Production at the institute FAPS of the FAU.

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