- The document describes the hairpin winding manufacturing process for electric motors used in electric vehicles. It involves cutting wire to length, forming hairpins, winding assembly including inserting the windings into the stator slots, and quality checks. Key steps discussed in more detail include wire cutting, hairpin forming using different technologies, and the winding design process which aims to optimize performance and costs.

1. 16 Dec 2020 1
This project has received funding from the European Union’s Horizon 2020 research
and innovation programme under grant agreement No 770143
1
This project has received funding from the European Union’s Horizon 2020 research
and innovation programme under grant agreement No 770143
16 Dec 2020
Rare earth free e-drives
featuring low
manufacturing cost
European Copper Institute
Aurubis
Breuckmann e-Mobility
Tecnomatic
Webinar #3: Induction motors for e-mobility
- advanced manufacturing features

2. 16 Dec 2020 2
This project has received funding from the European Union’s Horizon 2020 research
and innovation programme under grant agreement No 770143
ReFreeDrive Project Overview
13 partners, 6 European countries
OEM
Validation
Project
coordination
Power
electronics
Vehicle
integration &
testing
Copper
Steel
Motor Design &
Manufacturing

3. 16 Dec 2020 3
This project has received funding from the European Union’s Horizon 2020 research
and innovation programme under grant agreement No 770143
ReFreeDrive Project Overview
Why rare earth elements free solutions?
Environment & LCA
CostSupply risk
Market uncertainties

4. 16 Dec 2020 4
This project has received funding from the European Union’s Horizon 2020 research
and innovation programme under grant agreement No 770143
ReFreeDrive Project Overview
• The main aim of this project is to develop rare earth‐free traction
technologies
Project Objectives
INDUSTRIAL
FEASIBILITY
MASS
PRODUCTION
LOWER
COSTS
• Material selection
• Manufacturing processes
• Design optimisation
• Scalability

5. 16 Dec 2020 5
This project has received funding from the European Union’s Horizon 2020 research
and innovation programme under grant agreement No 770143
ReFreeDrive Project Overview
ProjectTechnologies: we will design & manufacture
8 different e-motors for electrical powertrains
Induction machines
with copper rotor
Fabricated
Die Cast
Synchronous
reluctance machines
PMassisted
Without PM
75kW and 200kW
8
motors

6. 16 Dec 2020 6
This project has received funding from the European Union’s Horizon 2020 research
and innovation programme under grant agreement No 770143
ReFreeDrive Project Overview
Target figures
30% INCREASE
SPECIFIC TORQUE
50% MOTOR
LOSSES REDUCTION
15% COST
REDUCTION
50% INCREASE
OF POWER DENSITY IN
POWER ELECTRONICS

7. 16 Dec 2020 7
This project has received funding from the European Union’s Horizon 2020 research
and innovation programme under grant agreement No 770143
ReFreeDrive Project Overview
Please visit:
www.refreedrive.eu
and
ElectricDrivetrainInnovationCluster
in LinkedIn

8. European Commission
Grant Agreement No770143
Fabricated copper rotor
Denise Willems – Aurubis Belgium

9. Alloys – Cu vs CuAg
200
250
300
350
400
450
500
550
600
20 50 100 150 175 200 250 300 325 350 400 500 550
UTS(N/mm²)
Temperature (°C)
Annealing Curves
Cu
CuAg0,002
CuAg0,005
CuAg0,01
CuAg0,05
CuAg0,1
CuAg0,4
CuAg0,7
CuAg1

10. Portfolio
Aurubis Specialities provides a wide range of copper segments from simple to
complex designs
Standard Dimensional Range

11. Recycling Casting Casting Plastic Deformation
Production Process – Cu Parts
Cu+ACP
Electrolysis
Ag
200E/T 400E/T
Cold Reduction Cut to Length De-burring
400E/T 200E/T 200E/T
Casting
200E/T
Rolling
400E/T
Punching
400E/T
0,098kg/Piece 0,69E/Piece
(0,54/0,15)
0,553kg/Piece 3,65E/Piece
(3,05/0,6)

12. Production Process – Squirrel Cage Assembly
Lamination Stack
XXX E/Assy
Rotor x50
34,44E/Assy
End Ring x2
7,31E/Assy
Bearings x2
XXX E/Assy
Assembly +
Soldering
18,5 E/Assy
Shaft
XXX E/Assy
Balancing
1,5 E/Assy
IM Inner Rotor Cost 61,75 Euros (excluding steel parts)

13. AC-Motors
6
Aurubis Bars & Profiles provides constant product quality and cut to lengths
Thank you for your attention

14. High Performance Cast Rotors with Zero Porosity
David Schmitz
Technical Director
breuckmann eMobility

15. 2
Agenda
1. Introduction
2. Basics of Casting Technology
3. Zero Porosity Rotor (ZPR®) Casting Technology
4. Advantages of ZPR®

16. 3
Breuckmann Group
Business Areas
Casting Technology
Core Competencies
1. Tool Design
2. Tool Manufacture
3. Die Casting > 1000°C
4. CNC Post-Processing
Hungary Kft.
TECH Center
Poland
Key Facts
5 Locations in Europe
Annual Turnover > 25 mio. €
> 200 Employees
> 120 Years Business Activity
Headquarters
Operations

17. 4
Rotor Examples
AluminiumCopper

18. 5
Milestones in Rotor Casting
OEM – USA 2016 TIER1 – USA 2018OEM – DE 2015
R 0,52 mm R 0,38 mmR 0,61 mm
Open and closed slots

19. 6
Mnufacturing of High
Performance Rotors
Packaging
• Stacking and fixing of laminations onto a
mandrel
Preaheating
• Preheating the lamiation stack
Casting
• Rotor casting
Removing
mandrel
• Removal of mandrel from cast rotor
Lamination delivery
Rotor
Casting
• Melting temperature
• Tool temperature
• Melt treatment
• Gating system
• Piston velocity
• Venting
Post
processing
• Machining, shaft insertion, balancing
Ready for assembly in the motor

20. 7
Basics of Casting Technology
2nd Phase 3rd Phase
Reflection of a jam wave
𝒗 𝒌 < 𝒗 𝒌𝒓𝒊𝒕
Over shock wave
𝒗 𝒌 > 𝒗 𝒌𝒓𝒊𝒕
Perfect 1st phase
𝒗 𝒌 = 𝒗 𝒌𝒓𝒊𝒕
Die
1st Phase

21. 8
Current Status of the Industry
Standard high pressure casting
with turbulent filling
Enclosed air

22. 9
Laminar Squeeze Casting (LSC)
Breuckmann´s Laminar Filling
Venting

23. 10
Zero Porosity Rotor -
CT Analysis
Side A
0% Porosity
Side B
0% Porosity

24. 11
Zero Porosity Rotor -
Advantages
Superior mechanical characteristics
+ 12,5 % max. rpm
Maximum Process Stability
Higher Electrical Conductivity

25. Rotation Moves Us All Thank you very much

27. 2
SUMMARY
- Hairpin Winding Manufacturing process
- Hairpin Winding design criteria
+39 0861 839030
www.tecnomatic.it
m.vetuschi@tecnomatic.it
Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied,
described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified,
distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A.

28. 3
OVERVIEW OF PROCESS STEPS
Wire Cut
to length
Hairpin
Forming
Winding
Assembly
Winding
Insertion
Insertion
into stack
Slot liner
Forming
Free-ends
Twisting
Winding
Welding
Quality
Checks
CROWN
ASSEMBLY
FINAL ASSEMBLYINSERTION INTO THE STACK
HAIRPIN
FORMING
SLOT LINER
INSERTION
Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved
Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied,
described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified,
distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A.

29. 4
WINDING DESIGN TRADE-OFF CRITERIA
CODESIGN
The codisegn approach was adopted during the design of the Induction Motor for the Re Free
Drive project held by the project partner Motor Design Limited, maximizing motor performance
by designing the stator lamination and the winding as a whole:
Winding Specs Review
Definition of Winding schemes
and Winding-Ends dimensions
Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved
Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied,
described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified,
distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A.

30. 5
WINDING DESIGN TRADE-OFF CRITERIA
Winding Specs Review
Calculation of Winding Losses
&
Verification of Insulation Specs
Definition of Winding schemes
and Winding-Ends dimensions
Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved
Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied,
described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified,
distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A.
CODESIGN
The codisegn approach was adopted during the design of the Induction Motor for the Re Free
Drive project held by the project partner Motor Design Limited, maximizing motor performance
by designing the stator lamination and the winding as a whole:

31. 6
WINDING DESIGN TRADE-OFF CRITERIA
3D modelling
Winding Specs Review
Calculation of Winding Losses
&
Verification of Insulation Specs
Definition of Winding schemes
and Winding-Ends dimensions
Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved
Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied,
described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified,
distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A.
N.2 N.4 N. 8 flat wires per slot
CODESIGN
The codisegn approach was adopted during the design of the Induction Motor for the Re Free
Drive project held by the project partner Motor Design Limited, maximizing motor performance
by designing the stator lamination and the winding as a whole:

32. 7
WINDING DESIGN TRADE-OFF CRITERIA
CODESIGN
Maximizing motor performance by designing the stator lamination and
the winding as a whole:
N.2
Process Design
Performance/Cost Front
N.43D modelling
Winding Specs Review
Calculation of Winding Losses
&
Verification of Insulation Specs
Definition of Winding schemes
and Winding-Ends dimensions
Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved
N. 8 flat wires per slot
Max speed = 18 krpmBase Speed = 8 krpm
Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied,
described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified,
distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A.
Large
improvement
from 2 to 4
layers
Lower
improvements
@ 6/8 layers @
speed<base

33. 8
KEY PROCESS STEPS
WIRE CUT TO LENGTH
Wire Cut
to length
Hairpin
Forming
Winding
Assembly
Winding
Insertion
Insertion
into stack
Slot liner
Forming
Free-
ends
Twisting
Winding
Welding
Quality
Checks
Includes
1. Enamel stripping
2. Free-ends preparation
for welding
3. Wire cut
For different wire lengths, automatically varying.
Standard
Mid-path
Phase terminals
Slot exit
Potentially, corrections can be performed on the fly.
Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved
Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied,
described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified,
distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A.

34. 9
KEY PROCESS STEPS
Wire Cut
to length
Hairpin
Forming
Winding
Assembly
Winding
Insertion
Insertion
into stack
Slot liner
Forming
Free-
ends
Twisting
Winding
Welding
Quality
Checks
HAIRPIN FORMING Different forming technologies can be applied, according to the product specifications and cycle time.
PLANAR BENDING (2D)
CIRCUMF. BENDING (3D)
SEPARATED OR INTEGRATED BENDING OPERATIONS
Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved
Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied,
described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified,
distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A.

35. 10
KEY PROCESS STEPS
Wire Cut
to length
Hairpin
Forming
Winding
Assembly
Winding
Insertion
Insertion
into stack
Slot liner
Forming
Free-
ends
Twisting
Winding
Welding
Quality
Checks
WINDING ASSEMBLY
CROWN ASSEMBLY CROWN COMPLETION WINDING ASSEMBLY
Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved
Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied,
described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified,
distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A.

36. 11
KEY PROCESS STEPS
Wire Cut
to length
Hairpin
Forming
Winding
Assembly
Winding
Insertion
Insertion
into stack
Slot liner
Forming
Free-
ends
Twisting
Winding
Welding
Quality
Checks
FREE-END TWISTING Pocket matrices bend the hairpin legs, moving their
ends of a predetermined distance in
• Circumferential direction
• Radial direction
matching the Insulation Resin application Process
and the Product Requirements.
CW
CCW
TWISTING POCKETS
RADIAL WIDENING
CLEARANCE
BETWEEN
WELDED PAIRS
Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved
Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied,
described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified,
distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A.

37. 12
KEY PROCESS STEPS
Wire Cut
to length
Hairpin
Forming
Winding
Assembly
Winding
Insertion
Insertion
into stack
Slot liner
Forming
Free-
ends
Twisting
Winding
Welding
Quality
Checks
WINDING WELDING
Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved
Tecnomatic uses Trumpf Sources for Laser Welding
Welding templates are used to accurately displace
the pairs to be welded and to protect the insulation
coating.
Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied,
described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified,
distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A.

38. 13
KEY PROCESS STEPS
Wire Cut
to length
Hairpin
Forming
Winding
Assembly
Winding
Insertion
Insertion
into stack
Slot liner
Forming
Free-
ends
Twisting
Winding
Welding
Quality
Checks
QUALITY CHECKS
Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied,
described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified,
distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A.
Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved

39. 14
Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved
The winding scheme is reviewed, to reduce the process complexity and preserve motor efficiency and robustness.
Winding and motor should be designed as a whole with manufacturability constraints (CODESIGN)
Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied,
described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified,
distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A.
PRODUCT-PROCESS TRADE-OFF CRITERIA

40. 15
PRODUCT-PROCESS TRADE-OFF CRITERIA
layer 1
layer 2
layer 3
layer 4
mid-core CUT VIEW
of SLOT EMBEDDED
PHASE CONDUCTORS
MULTIPLE PHASE SEPARATORS in SLOT SINGLE PHASE SEPARATOR in SLOT
Process
Features
Simplification of twisting process Simplification of slot-liner and winding
insertion into the stator core
Product
Features
Shorter winding-end Larger copper to slot filling factor
Slot
insulation
Slot
insulation
Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved
The winding scheme is reviewed, to reduce the process complexity and preserve motor efficiency and robustness.
Winding and motor should be designed as a whole with manufacturability constraints (CODESIGN)
Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied,
described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified,
distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A.

41. 16
Insertion side
Twisted side
Hairpin 3 Hairpin 1 Hairpin 2Hairpin 4
Hairpin 3 Hairpin 1 Hairpin 2I-pin1I-pin2
INVERTER CONNECTIONS at TWISTED SIDE
ROLLED OUT
STATOR VIEW
INVERTER CONNECTIONS at INSERTION SIDE
Hairpin 4 substituted by two I-pins
Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved
Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied,
described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified,
distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A.
PRODUCT-PROCESS TRADE-OFF CRITERIA

42. 17
WINDING DESIGN TRADE-OFF CRITERIA
Insertion side
Twisted side
ROLLED OUT
STATOR VIEW
Possibly shorter winding-endsProduct
Features
Bus-bar is required
Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved
Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied,
described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified,
distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A.
Hairpin 3 Hairpin 1 Hairpin 2Hairpin 4
Hairpin 3 Hairpin 1 Hairpin 2I-pin1I-pin2
INVERTER CONNECTIONS at TWISTED SIDE
INVERTER CONNECTIONS at INSERTION SIDE

43. 18
Insertion side
Twisted side
ROLLED OUT
STATOR VIEW
Process
Features
Minimum number of shape variants Simplification of twisting process
Simplification of assembly process Simplification of welded-pairs
encapsulation process at twisting side.
Possibly shorter winding-endsProduct
Features
Bus-bar is required
Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved
Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied,
described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified,
distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A.
Hairpin 3 Hairpin 1 Hairpin 2Hairpin 4
Hairpin 3 Hairpin 1 Hairpin 2I-pin1I-pin2
INVERTER CONNECTIONS at TWISTED SIDE
INVERTER CONNECTIONS at INSERTION SIDE
PRODUCT-PROCESS TRADE-OFF CRITERIA

44. 19
Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved
Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied,
described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified,
distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A.
Balance of paths:
Berardi, Grazia, and Nicola Bianchi. "Design guideline of an AC hairpin winding." 2018 XIII International Conference
on Electrical Machines (ICEM). IEEE, 2018.
Bianchi, Nicola, and Grazia Berardi. "Analytical Approach to Design Hairpin Windings in High Performance Electric Vehicle
Motors." 2018 IEEE Energy Conversion Congress and Exposition (ECCE). IEEE, 2018.
PRODUCT-PROCESS TRADE-OFF CRITERIA
PRODUCT WINDING FEATURES PROCESS FEATURES
Efficiency (ac resistance)
Heat dissipation
Torque density
Suitability for mass production
Number of layers
Number of parallel paths
Slot filling factor
Geometry and clearances of the Winding-
ends
N. of segment length variants
N. of hairpin shape variants
Interleaved or independent crowns
N. of welds
N. of jumpers
Slot liner geometry

45. 20
CONCLUSIONS
- Outline of the process steps for the IM winding of the
ReFreeDrive project
- Design criteria for winding specs of ReFreeDrive project with
Performance to Cost target
Copyright © 2020 Tecnomatic S.p.A. All Rights Reserved
Tecnomatic S.p.A.’s proprietary technology is subject to patents and/or patent applications, and other intellectual property rights. This document and its contents, as well as all intellectual property that is or may be embodied,
described, disclosed, displayed, or referenced herein, is strictly CONFIDENTIAL, and is the sole property of Tecnomatic S.p.A., who hereby and expressly reserves all right, title, and interest in and to it. No part of this document may be reproduced, modified,
distributed, transmitted, displayed, reduced to practice, or incorporated into any other document or medium whatsoever, by any means now known or hereafter created, without the express prior written consent of Tecnomatic. S.p.A.

46. THANK YOU FOR THE ATTENTION
+39 0861 839030
www.tecnomatic.it
m.vetuschi@tecnomatic.it