AC Copper Loss Analysis of Hairpin Windings for Permanent Magnet Synchronous Motors Considering Eddy Current Effects

With the increasing demand for high efficiency and power density of motors in the context of electrified transportation, hairpin windings have become a popular trend for designers. This study offers a design method which is aimed to reduce the AC copper losses generated when using hairpin windings in permanent magnet synchronous motors, and specifically deal with the effects of skin effect and proximity effect on conductor AC copper losses. On this basis, the influence of conductor dimensions, different parallel branch numbers, and slot dimensions on AC copper losses is systematically investigated. The research findings indicate that a properly designed hairpin winding topology can effectively reduce the AC copper losses of permanent magnet synchronous motors, thereby improving motor efficiency and power density.