Hairpin winding electric machine and methods

A system for a stator assembly of an electric motor, comprising:

• a plurality of slots radially positioned around an inner cylindrical surface;
• and
• a winding scheme for the stator assembly applicable in all integrated slot distributed winding scenarios, the winding scheme including:
• selecting a plurality of hairpin wires to be arranged through the slots to form a plurality of parallel paths such that each parallel path in the plurality of parallel paths spans all the slots per pole per phase of the electric motor;
• arranging the plurality of hairpin wires such that each of the parallel paths in the plurality of parallel paths encompasses all hairpin layers;
• and
• maintaining an equal number of conductors for each of the parallel paths in the plurality of parallel paths regardless of slot position.

A hairpin winding design for an electric motor, comprising:

• a plurality of parallel paths per phase, where each parallel path occupies one slot per pole in the stator of the motor,
• a layer-group winding configuration consisting of two layers, wherein multi-layer windings are grouped into two-layer groups, and jumper wires are used to electrically connect different layer groups,
• the number of parallel paths per phase is 2×q for a 3-phase motor, where q is the number of slots per pole,
• the hairpin winding configuration is scalable, allowing for easy adaptation to 6-phase motor systems by adjusting the number of parallel paths per phase.

A method for manufacturing hairpin windings for an electric motor, comprising:

• inserting conductors into the slots of a stator of the motor,
• twisting and welding the conductors at various points to form a secure connection,
• using jumper wires with a slot pitch of (yn+1−q) to connect different layer groups of conductors, where each jumper wire connects the end of one layer group to the start of the next layer group,
• welding connection rings to the windings to ensure proper electrical phase alignment for each group of parallel paths.

A universally applicable method for assembling hairpin windings for electric motors of any desired number of parallel pairs, comprising:

• using conductors with equal leg lengths for the majority of the winding, and conductors with unequal leg lengths where the longer leg is used for jumper connections between layer groups,
• inserting these conductors into the stator of the motor and twisting them to form a secure electrical connection,
• connecting layer groups using jumper wires that have the same slot pitch of (yn+1−q) for all configurations, regardless of the number of parallel paths or layer groups,
• ensuring that the winding configuration maintains electrical alignment and maximizes the slot fill factor for the specific motor design.