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Copper wire in typical hairpin geometry
Hairpin technology is a winding technology for stators in electric motors and generators and is also used for traction applications in electric vehicles. In contrast to conventional winding technologies, the hairpin technology is based on solid, flat copper bars which are inserted into the stator stack. These copper bars, also known as hairpins, consist of enameled copper wire bent into a U-shape, similar to the geometry of hairpins.[1]
In addition to hairpins with U-shape, there are two other variants of bar windings, the so-called I-pin technology and the concept of continuous hairpin windings.
I-Pins are straight copper wire elements that are inserted into the stator slots. Unlike Hairpins, these Pins are not bent prior to insertion into stack. However, contacting is necessary on both sides of the stator. In the concept of continuous hairpin windings, so-called winding mats are produced and afterwards inserted into the stack from the inner diameter.
Hairpin stators are most commonly used for synchronous machines.[2]
^Porsche. "The powertrain: Pure Performance". Retrieved 2022-07-27.
^Karlsruhe Institute of Technology (KIT). "Wissen kompakt: Produktion elektrischer Traktionsmotoren" (PDF) (in German). Retrieved 2022-04-21.
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