What Makes Hairpin Motor Much Talked About?

Hairpin Motor

Electric vehicles are superb for their efficiency and hairpin mortar design, assembly and performance is behind them. Maximum output and simplified manufacturing are among the few top reasons why it’s a matter of discussion.

Germany is looked at as the hub of ace machinery and technology. And this time the hairpin technology for electric motors for cars is what we shall talk about. It’s expensive, efficient and much more!

So what is it?

Electric vehicles or E-mobility is the new thing. But before you venture into the experience it’s important to know its insights. 

While there are many factors that strategically add to the vehicle’s performance, the hairpin motor makes its own place. In this post, I shall shed light on what a hairpin motor does, and its advantages, and disadvantages for that matter. Scroll more to learn more.

What is hairpin technology?

Hairpin technology in vehicles is one of the innovative and much-talked-about things now. Basically, it’s a winding technology dedicated to stators in electric motors. 

In simpler words, this technology is based on winding for stators (the coil of wire housed inside the engine case), especially for E-motors and generators. Its superlative performance and the swiftness of E-motors are what make people notice it. 

So unlike the traditional winding technology, the hairpin technology features a stationary component with flat copper bars that are linked to the stator. The hairpin winding is pretty much well-received for its performance, but it also has its other side.

If you have been using traditional motors technology in your vehicle it’s about time to know why you should shift to hairpin motor technology, right now!

Why are hairpin motors important perks and downsides?

Unlike traditional (round wire) design, hairpin motors have flat wires. Hairpin motor for an e-vehicle is more like a game changer. 

For instance, its handy size is easy to be fitted in a modish automobile plus the performance is impressive. Hairpin winding technology has an optimal fill factor.  The improved heat dissipation and below 70% fill factor makes hairpin windings premium for EVs.

It means the copper lets out a robust magnetic field for which the stronger and better rotation of the rotor and torques becomes a practical thing. You get the ideal performance that has always been anticipated, till date! Few of its advantages are:

  • Best heating conduction
  • Minima temperature hike
  • Budget-friendly with less material
  • Save copper, improve efficiency
  • Small size without compromising on the size
  • Silent performance with no electromagnetic noise
  • Higher power density wit complete rate is amazing with 20% to 70% hike

 Downside of hairpin motor

  • It’s flat wide are lossy
  • Abstract design makes it somehow challenging to use
  • Not user-friendly for design, technology, equipment
  • The number of turns of the hairpin motor is relatively small
  • Demand specific requirements for copper wires, unlike traditional motor winding

Is hairpin design worth it?

For electric automobiles, a hairpin holds the best approach. So the hairpin motor and its design certainly make its worthwhileness justified.

Many renewed vehicles such as the BMW iX3 are based on hairpin wiring for efficiency. Also, Tesla also uses the hairpin motor for this very reason.

Tesla engines being robust and efficient let out the best performance! The hairpin motors are reliable to let out maximized power density and thermal performance. Moreover, its process of manufacturing is much simplified.

Coating use in hairpin motors

The hairpin motors especially use the protective coat of the insulating layer. It makes sure the electric current is not affray in random directions during the hairpin’s touch. Generally, a hairpin stator uses either Polyamide-imides (PAI), Polyether ether ketone (PEEK), or Polyamide-imides with polyimide foil (PAI+FEP) coating for protection.

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