Stator design for flexible manufacturing in hairpin technology

Hairpin technology represents a disruptive innovation within the product architecture of electric drives for automotive applications. Due to the modified design of such stator topologies, a variety of requirements and restrictions arise within the industrial production process. Different drive topologies, fields of application or customer requirements generate a very diverse product spectrum and often require product-specific production solutions. This paper examines the trade-off between product and process requirements within hairpin technology. A method will be developed that aims towards identifying appropriate product design features to enable future development of variant-flexible hairpin stator designs that meet both product and production requirements.