Hairpin vs. Traditional Winding: Key Technical Differences in Modern Stator Manufacturing

https://www.gwinsys.com/hairpin-vs-traditional-winding.html

As electric motor technology advances—especially in the era of high-efficiency EV powertrains—manufacturers are increasingly shifting from conventional round-wire windings to hairpin winding technology. A modern hairpin stator production line enables highly automated, repeatable, and high-precision manufacturing, making hairpin stators a preferred solution for next-generation traction motors. Understanding the technical differences between hairpin winding and traditional winding methods helps illustrate why this new approach is rapidly becoming an industry standard.

1. Conductor Shape: Rectangular vs. Round Wire

Hairpin Winding

• Uses rectangular (flat) copper wire, which provides superior slot fill and lower electrical resistance.

• Larger cross-section improves current-carrying capability and reduces heat generation.

• Consistent geometry allows automated forming, insertion, and welding.

Traditional Winding

• Uses round copper wire wound continuously into the stator slots.

• Slot fill factor is limited by the circular geometry.

• Electrical efficiency is lower due to increased copper losses.

Technical Impact: Hairpin conductors significantly reduce copper loss, improving motor efficiency and thermal performance.

2. Manufacturing Process and Automation Level

Hairpin Winding

• Highly compatible with automation.

• Production steps—cutting, bending, insertion, twisting, laser welding, and insulation—are performed by a fully automated hairpin stator production line.

• Ensures tight tolerances and consistent quality.

Traditional Winding

• Relies more on manual or semi-automated coil winding processes.

• Quality can vary with operator skill.

• More difficult to guarantee precise conductor placement.

Technical Impact: Hairpin technology enables mass production with better repeatability, fewer defects, and higher efficiency.

3. Slot Fill Factor and Power Density

Hairpin Winding

• Rectangular wire packs more efficiently, achieving up to 70–80% slot fill.

• Better electromagnetic performance increases torque density and motor output.

Traditional Winding

• Slot fill typically ranges 40–55% depending on wire diameter and winding method.

• Lower fill results in reduced performance potential.

Technical Impact: Higher slot fill equals higher torque density, making hairpin stators ideal for EV traction motors.

4. End-Turn Geometry and Thermal Behavior

Hairpin Winding

• Short, uniform end turns reduce copper usage and minimize I²R losses.

• Excellent thermal conduction between conductors and stator core.

Traditional Winding

• Long, irregular end turns reduce efficiency.

• More hotspots due to uneven conductor distribution.

Technical Impact: Hairpin stators support higher continuous power and improved thermal stability.

5. Electrical Performance and NVH Characteristics

Hairpin Winding

• Lower resistance and more uniform electromagnetic fields.

• Reduced motor noise and vibration due to consistent geometry.

Traditional Winding

• Higher AC losses, less predictable electromagnetic distribution.

• NVH performance depends strongly on winding quality.

Technical Impact: Hairpin windings often deliver smoother, quieter motor operation—critical for EVs.

6. Flexibility and Application Scope

Hairpin Winding

• Best suited for high-power, high-efficiency motors:

• EV traction motors

• Hybrid motors

• High-performance industrial drives

Traditional Winding

• More flexible for motors requiring:

• Lower cost

• Smaller scale

• Irregular slot geometries

Technical Impact: Hairpin technology excels in applications where efficiency, density, and durability matter most.

Hairpin winding technology represents a major leap forward in electric motor manufacturing. With superior slot fill, lower losses, improved thermal characteristics, and high automation potential, hairpin stators deliver performance levels unmatched by traditional round-wire windings. A fully automated hairpin stator production line enables manufacturers to reduce labor costs, increase production throughput, and achieve consistent high-precision results—making it the ideal solution for next-generation electric motor production.

https://www.gwinsys.com/Hairpin-Stator-Assembly-Line.html

https://www.gwinsys.com/hairpin-vs-traditional-winding.html
Jieyun Intelligent Equipment (Suzhou) Co., Ltd.

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