Production-oriented design of electric traction drives with hairpin winding

J Fleischer, L Hausmann, F Wirth - Procedia CIRP, 2021 - Elsevier
In recent years, the manufacturing of stators by hairpin technology has proven its ability to
fulfill the requirements on quality, productivity and robustness of traction drive applications in …

Methodology for the mechanical characterization of rectangular winding wire in the context of electric mobility

F Wirth, S Vitzthum, J Gerner, A Koprivc… - 2023 13th …, 2023 - ieeexplore.ieee.org
The increasing market share of electrified powertrains results in a high demand for efficient
and powerful electric traction motors. Against this background, bar winding technologies …

Metamodeling of numerical simulations for optimization of hairpin bending processes

F Wirth, L Hausmann, A Eppler… - 2021 11th International …, 2021 - ieeexplore.ieee.org
As a result of the progressive electrification of mobility solutions, manufacturing technologies
for distributed stator windings need to be improved in order to meet the automotive demand …

Opportunities of model-based production-oriented design of stators with hairpin winding

L Hausmann, F Wirth, J Fleischer - 2020 10th International …, 2020 - ieeexplore.ieee.org
The hairpin technology is a promising and widely used production method that meets the
growing demand for high productivity and quality in the manufacturing of electric drives …

Defect types and mechanisms of hairpin coils in manufacturing of electric traction motors

F Wirth, F Fraider, J Gerner… - … 2023; 9. Fachtagung …, 2023 - ieeexplore.ieee.org
As a consequence of the increasing relevance of electrified drive trains for mobility solutions,
manufacturing technologies for electric traction motors need to be continuously improved in …

[HTML][HTML] Multilayer laminated Cu coil/CaO–Li2O–B2O3–SiO2 glass-ceramic preparation via a novel insulation packaging strategy for flat wire motor applications

H Zhu, Y Song, G Pan, N Chen, X Song, L Xia… - Nano Materials …, 2024 - Elsevier
A new insulation packaging strategy for the stator windings of flat wire motors based on
LTCC technology was studied for the first time. The study aimed to replace traditional plastic …

Flexible Twisting Process of Stators with Hairpin Winding

L Hausmann, F Wirth, J Fleischer - 2022 12th International …, 2022 - ieeexplore.ieee.org
In recent years, the hairpin technology has become the most relevant process chain for
manufacturing of stator windings applied in electric traction motors. However, there are still …

Evolution of molten pool, in-process defects and dependent quality of laser-contacted hairpins using Lissajous cycles

T Zhu, S Ji, C Zhang, W Ma - Optics & Laser Technology, 2025 - Elsevier
Laser contacting process for copper hairpin windings determines the performance of motors,
considered as a significant and challenging part in manufacturing electric automobiles. The …

Structural analysis of the forming process for hairpin windings for electric motor applications: torsional-flexural instability issues

SG Barbieri, V Mangeruga, M Giacopini… - 2022 International …, 2022 - ieeexplore.ieee.org
Electric motor manufacturing technology is evolving due to automotive transport
development. Besides, environmental issues and the need of CO 2 emission reduction have …

A novel interpolator designed for laser scanning welding of hairpin windings in electric vehicle motors

T Zhu, C Zhang, Y Yin - The International Journal of Advanced …, 2024 - Springer
Electric vehicles are recently prosperous due to decarbonization and electrification in
transportation. However, manufacturing their motor windings with stable high quality is …