Authors: Stefano Nuzzo, Davide Barater, Chris Gerada and Piermaria Vai
The technological advancements in the field of both electrical machines and power electronics are extremely promising and seem permitting to achieve the demanding power density and efficiency levels required nowadays by the transportation sector. However, the reliability of components and of their production process is currently a challenge. This is especially true for electrical machines, whose windings and the associated manufacturing process are still far from obtaining the high levels of automation, programmability and repeatibility required by the transportation market to meet the on-going green revolution objectives. This article looks into hairpin windings and proves that they can be a key enabler in this direction, highlighting how high power density, efficiency, reliability and automation can be all pursued at the same time. However, several challenges currently characterizing hairpin technologies still need to be eliminated or at least mitigated. This work thus outlines a number of future actions aiming to address such challenges, which will eventually enable the complete penetration of hairpin windings in transportation thus meeting the green revolution requirements.