Optimization of Permanent Magnet Synchronous Motors with Wave-Wound Flat Wire Windings

Although the slot filling rate of the flat wire winding is improved, the larger cross-sectional area of the winding at high speeds and frequencies leads to increased eddy current losses, which can restrict the high performance. This study combines the hairpin winding design with Permanent Magnet Synchronous Motors (PMSMs) and analyzes the impact of hairpin winding optimization on motor power density. To determine the optimization variables, the theoretical derivation of alternating current (AC) loss in hairpin winding is explored. Six parallel branch configurations for wave-wound winding are proposed, and the correctness of the AC loss calculation method is verified through Finite Element Analysis (FEA) simulations. After AC loss, eddy current loss ratios, and torque and other multiple perspectives analysis, a suitable hairpin winding design is selected. After optimization, the power density and efficiency of the motor are improved.