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TITOLARE DI BORSA DI STUDIO presso: Dipartimento di Ingegneria "Enzo Ferrari"

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2020 - An analytical approach for the design of innovative hairpin winding layouts [Abstract in Atti di Convegno]
Arzillo, A.; Nuzzo, S.; Braglia, P.; Franceschini, G.; Barater, D.; Gerada, D.; Gerada, C.

This work deals with an analytical approach aimed at accurately predicting Joule losses in innovative hairpin winding layouts. While hairpin windings are seeing an everincreasing use in automotive and aerospace applications due to their inherently high slot fill factor, they also present drawbacks such as the non-uniform current distribution potentially occurring across their cross section. This phenomenon is emphasized at high frequencies, leading to a significant increase of the effective conductor resistance and, consequently, of copper losses. Hence, particular attention has to be given to the design of electrical machines employing hairpin conductors, aiming to reduce the high-frequency losses as much as possible. In this paper, an analytical model based on previous investigations is updated and modified in order to increase the degrees of freedom in the design and analysis of hairpin windings. With the developed analytical model, the copper losses associated to innovative hairpin configurations can be accurately predicted. The findings also confirm that such alternative layouts can effectively reduce the Joule losses when compared to traditional hairpin technologies.

2020 - Challenges and Future opportunities of Hairpin Technologies [Relazione in Atti di Convegno]
Arzillo, A.; Braglia, P.; Nuzzo, S.; Barater, D.; Franceschini, G.; Gerada, D.; Gerada, C.

Hairpin windings are seeing an ever-increasing application and development in electrical machines designed for high power and torque densities. In fact, due to their inherently high fill factor, they are very attractive in applications, such as transportation, where these characteristics are considered main design objectives. On the other hand, high operating frequencies also contribute to improve power density of electrical machines. However, at high fundamental frequencies, hairpin windings are characterised by increased Joule losses due to skin and proximity effects. Hence, while these technologies are introducing new opportunities, a number of challenges still need to be addressed. These include manufacturing aspects, contacting processes, thermal management, etc. This paper presents an overview of the current state-of-the-art of hairpin technologies and propose possible future opportunities. The authors' perspective is then finally provided, showing how innovative winding patterns can potentially overcome the above mentioned challenges.