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The difference between a hairpin motor and a traditional flat copper wire motor

Release time:2021/09/03

The difference between a hairpin motor and a traditional flat copper wire motor


The hairpin motor is the shape of the stator winding like a hairpin. In the manufacturing process of the hairpin stator, the windings are first made into the shape of the hairpin and then inserted into the stator slot, and then the ends of the hairpin are welded on the other end according to the design.

hairpin motor.jpg

Hairpin motors are also a kind of flat copper wire motors. Traditional flat copper wire motors are used in many industries, such as: high-power asynchronous motors, mining motors, DC motors, wind generators, power generators, high-power traction motors, large High-power winch motors, locomotive motors, etc. In recent years, hairpin motors have been favored by more and more motor manufacturers. What is the difference between hairpin motors and traditional flat copper wire motors?


hairpin motor manufacturing.jpg


1. Different designs:

The number of turns of the hairpin motor is less than that of the traditional flat copper wire motor. At present, one slot has 8 turns at most;

The hairpin motor is threaded in technology, so the notch does not need to be fully opened, and the half-opened slot is beneficial to reduce the cogging torque;


2. The structure is different:

The winding structure of the hairpin motor is composed of several hairpins during the manufacturing process. The traditional flat copper wire motor is a formed winding;


3. The hairpin motor is basically made of wave winding due to the process and structure, and the traditional flat copper wire motor can be used for stacked winding;

hairpin motor stator making.jpg

4. Different processes:

The hairpin motor is threaded, and then the ends of each turn are welded, and the number of ends of each slot is equal to twice the number of turns;

The drive rectangular copper wire motor directly puts the formed winding into the slot, each slot has only two heads;.


5. Different applications:

hairpin motors are currently mainly used in new energy vehicles, with permanent magnet motors as the main design.

The motor is the key to the drive system of a new energy vehicle, and its performance is directly related to the dynamic performance of the new energy vehicle. New energy vehicle motors pursue high power, small size, high torque, and high speed (high power density, high torque density). After years of development of new energy vehicle motors, and with the maturity of motor technology and equipment, motor windings have gradually developed from the previous round copper wire design to the flat copper wire winding design. The hairpin motor satisfies the pursuit of high power density and high torque density of electric motors for new energy vehicles, conforms to the development trend of the industry, and has more and more room for development.

Traditional flat copper wire motors are used in many industries, such as: high-power asynchronous motors, mining motors, DC motors, wind generators, power generators, high-power traction motors, high-power winch motors, locomotive motors, and so on.

hairpin motor stator manufacturing.jpg

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