New energy moving vehicle. Light hybrid, heavy-duty hybrid-electric vehicle, commerical car use hair-pin windings.
Hair pin is a form of flat wire rectangular shape conductor with U shape and twisting angle, the edge enamel always was removed.
Electric motor with flat wire was widely used in big power asynchronous motor, mine motor, wind driven generator, fire power generator, high-power tractor, winch motor above 8000pounds, locomotive motor, aero space motor.
Comparing to traditional motor conductors, hair-pin motor have below four features.
1. Design of hair-pin motor’s notch (slot groove ) are not fully and completely opened,
It is half opened which can reduce cogging torque,
Most of hair-pin motor is with less turns than other motors,
For light hybrid, they can be 2 turns, and heavy-duty hybrid-electric vehicle,
they can be up to 8turns, which motor manufacturers
always call 2 layers, 4 layers, 6 layers, 8 layers.
2. Structures are different, hair-pin motor always comprised of several types size of hairpins and
Traditional Flat copper wire motor usually is formed winding.
According to structure and manufacturing process, hairpin motor are basically wave windings,
And the conventional flat copper wire motor are lap windings.
3. The manufacturing process of hair pin motor is different, hairpin embedded into slot and weld
Two conductor terminals, so the no. Of head terminals is equal to twice the number of turns.
The traditional flat copper wire motor put the formed winding into the slot,
and each slot have only two heads terminal.
4. The motor application is different.
The hairpin motor is mainly used in new energy vehicle, and the design is based on
permanent magnet motors.