Aluminum Hairpin Solution for Electrical Machines in E-Mobility Applications : Part I: Electromagnetic Aspects

Along with efficiency and performance, one of the main aspects of nowadays electric machines design is sustainability, especially when it comes to the transition period the automotive field is dealing with and the focus placed on electrification. This paper aims at lowering the environmental load of the electric machines, replacing copper hairpin stator windings with aluminum ones. This work compares the traditional copper hairpin design with aluminum hairpin solutions, resulted from a multi-objective genetic algorithm optimization. The optimization process has been performed with the aim of minimizing the losses as well as the utilization of rare-earth permanent magnets. Finally, the feasibility of such alternative design is evaluated from a thermal perspective, proposing potential layout of the cooling system for the selected design proposal. The paper first part is dedicated however to the electromagnetic aspects of the design with Aluminum hairpin as well as the optimization process employed. Finally, a comparison with respect to the copper solution in terms of efficiency, cost, weight and sustainability has been drawn.