Multi-set rectangular copper hairpin windings for electric machines

A stator for an electric machine, the stator comprising

• a. a stator core having a plurality of slots formed therein, including a plurality of even numbered slots and a plurality of odd numbered slots;
• b. a plurality of hairpin conductors positioned in the slots of the stator core, each of the hairpin conductors comprising a bent end turn and two legs, and each slot of the stator including four hairpin legs;
• c. a first set of hairpin windings formed from the plurality of hairpin conductors, the first set of hairpin windings including a first layer of hairpin legs and a second layer of hairpin legs in the slots of the stator core, the first layer of hairpin legs carrying a different phase current than the second layer of hairpin legs in the even numbered slots;
• and
• d. a second set of hairpin windings formed from the plurality of hairpin conductors and side-by-side with the first set of hairpin windings, the second set of hairpin windings including a third layer of hairpin legs and a fourth layer of hairpin legs in the slots of the stator core, the third layer of hairpin legs carrying a different phase current than the fourth layer of hairpin legs in the even numbered slots.

A stator for an electric machine, the stator comprising

• a. a stator core having a plurality of slots formed therein, including a plurality of even numbered slots and a plurality of odd numbered slots;
• b. a plurality of hairpin conductors positioned in the slots of the stator core, each of the hairpin conductors comprising a bent end turn and two legs, and each slot of the stator including four hairpin legs;
• c. a first set of hairpin windings formed from the plurality of hairpin conductors, the first set of hairpin windings including a first layer of hairpin legs and a second layer of hairpin legs in the slots of the stator core, the first layer of hairpin legs carrying the same phase current as the second layer of hairpin legs in each of the plurality of slots;
• and
• d. a second set of hairpin windings formed from the plurality of hairpin conductors and side-by-side with the first set of hairpin windings, the second set of hairpin winnings including a third layer of hairpin legs and a fourth layer of hairpin legs in the slots of the stator core, the third layer of hairpin legs carrying the same phase current as the fourth layer of hairpin legs in each of the plurality of slots, and the second layer of hairpin legs carrying a different phase current than the third layer of hairpin legs in each of the even numbered slots.