rranged cooling channel features a geometrically simple design and is significantly easier to manufacture compared to conventional radially arranged cooling jackets in electric machines.   The winding production eliminates the need for basket making, bending, and separating, which are necessary in hairpin manufacturing. The complex process of assembling the complete winding in the stator lamination stack is also omitted. Prototyping and testing ...

Market & Tech Reports  Updated at: 2025/07/17

The electric powertrain does not use in-wheel motors, but rather has a motor, inverter, and reducer for each of the four wheels, which are combined and installed in the front e-Axle and rear e-Axle.   The four drive motors are 8-pole IPMSM (Interior Permanent Magnet Synchronous Machine) motor with hairpin-type (SC winding) flat-wire wave windings, with a maximum output of 220kW and a maximum torque of 320Nm.   In addition, MarkLines Co., Ltd. h...

Market & Tech Reports  Updated at: 2025/06/16

BorgWarner iM-575 SiC-D integrated drive module   Beyond its 9 AKM and LFP battery systems, BorgWarner's exhibit at ACT Expo 2025 highlighted the iM-575 SiC-D integrated drive module developed with its Cascadia Motion subsidiary. The iM-575 combines BorgWarner's HVH320-216 high-voltage hairpin motor with Cascadia Motion's CM350 inverter which features a Viper silicon carbide power module. The drive module provides a peak torque of 1,...

Market & Tech Reports  Updated at: 2025/06/06

an finished motors.   Core stamping and lamination can be performed with electromagnetic steel sheets of 0.2mm to 6.5mm, and the lineup also includes CFRP rotors that are reinforced by covering the rotor surface with CFRP, which uses carbon fiber. Core and CFRP rotorCFRP rotor display panel Hairpin-wound stator Hairpin-wound stator display panel   Motor drive unit Motor drive unit display panel   Fukuta Electric has abundant...

Market & Tech Reports  Updated at: 2025/02/27

alent to 0.738 lb/ft.) It uses a permanent magnet (PM) synchronous motor (with locking differential) at the front and two induction motors (with torque vectoring control) at the rear. The stators for the Cyberbeast's front and rear motors have been changed from the conventional wire-wound type to a hairpin type, a first for Tesla.   Previous Tesla vehicles have used inverters with electronic boards shaped like the borders of the United States, b...

Market & Tech Reports  Updated at: 2024/11/13

d area in question, detecting the effects of the generated heat and thermal diffusion using an infrared array sensor, and inspecting for internal defects such as voids and cracks in addition to surface defects. The laser welding monitor LWM (Laser Welding Monitor), which may be useful when welding hairpin-type motor windings (SC windings) with a laser, monitors, evaluates, and records each laser weld, ensuring 100% traceability during production...

Market & Tech Reports  Updated at: 2024/10/29

., Ltd.   Korens EM: Stator assembly for EV drive motor, rotor assembly for EV drive motor Stator assembly display panel Rotor assembly display panel   Korens EM Co., Ltd. had a panel showing its stator and rotor assemblies for EV drive motors.   Most of the stator assemblies use a hairpin stator (SC winding) with a maximum output of 33kW to 205kW, and the company has mass production experience of over 50,000 units.   Rotors are...

Market & Tech Reports  Updated at: 2024/10/10

mplex shaped core gives rise to portions which are difficult to wind, such cores are often divided into pieces. Conversely, there is a structure in which a series of windings are made by inserting a large number of rectangular cross-section (improved space efficiency by winding with no gaps), short hairpin-shaped coil wires into the stator, welding the protruding sides in pairs then covering; such configuration started to be widely used in Toyota...

Market & Tech Reports  Updated at: 2024/09/05

r). Display panel for drive unit VREMT nameplate on front inverter   The rear unit's motor is an interior permanent magnet synchronous motor (IPMSM) with a maximum output of 310kW, peak torque of 440Nm, and maximum rotational speed of 18,000 rpm.   The stator uses flat wire SC windings (hairpin type), and the rotor is skewed in six steps to prevent vibration. Rear motorRotorStatorResolver, terminal block Rear inverterPower modu...

Market & Tech Reports  Updated at: 2024/08/27

t, assist-driven motors. In recent years, the inserter-type distributed winding using round wire (enameled wire with a round cross section) has been decreasing, and distributed winding using "SC winding," in which flat rectangular wire (enameled wire with a rectangular cross section) is inserted as hairpin-shaped segments into the stator slots, formed, and welded to form a wave-wound coil, has become more common. Flat wire, as opposed to round wi...

Market & Tech Reports  Updated at: 2024/08/22

otor and new generation silicon carbide (SiC) power module   The motor of the electric drive system uses 0.25mm ultra-thin silicon steel sheets. The high-speed low-leakage magnetic rotor structure and dual-split (V-shaped) magnet design are optimized. Motor slot full rate reaches 92%. It also uses hairpin flat wire coil technology. The motor rotation speed is 23,000 rpm. As of May 2024, this is the highest rotation speed in the world for a mass-...

Market & Tech Reports  Updated at: 2024/07/16

peak power of 738 hp, and peak torque of 3,689 lb-ft. Accelera Gen 4.5 14Xe eAxle with ELFA 3 v3.2 inverter Accelera 1CS2022 traction motor with two ELFA 3 v3.0 inverters   ZF highlighted the AxTrax 2 e-axle which debuted at ACT Expo 2023. AxTrax 2 is a modular system which integrates a hairpin electric motor, silicon carbide inverter, ECU, electric actuator and three-speed transmission. The AxTrax2 produces 282 hp of continuous power...

Market & Tech Reports  Updated at: 2024/07/05

or, with a small outer diameter of 150 mm and an active length of 175 mm, has a peak performance of 250 kW and a rotational speed of 155 m per second. It has a total active mass of less than 20 kg and uses standard magnets, that are optimized in terms of weight and efficiency. The stator features a hairpin winding with a copper fill factor of 60%. Specifications and cooling principle of the e-motor (45th International Vienna Motor Symposiu...

Market & Tech Reports  Updated at: 2024/07/03

Since the 1-motor hybrid transmission is a 1M2C (1 motor, 2 clutch) system, it does not have the power split mechanism used in THS, and the clutch is located inside the motor.   Although the motor's axial dimension is limited, the motor is not a concentrated winding type, but uses a segment coil (hairpin) type distributed winding motor similar to those used in the 5th generation Prius and BZ4X.   The starting clutch is large, capable of withst...

Market & Tech Reports  Updated at: 2024/06/12

but with a closed design. The laminate offset is not a sequential step design and only has two positions. The keeper plate for the permanent magnet motor is not as large, exposing the magnet tops and laminate for what Sandy Munro speculated was cooling purposes. Finally, the motor stators use a new hairpin design which can be wound using one machine instead of multiple. The Cybertruck is the first Tesla model to use a 48-V low-voltage system inst...

Market & Tech Reports  Updated at: 2024/05/21

or weld seam deep learning inspectionMotor weld seam deep learning inspection explanation panelDisplay screen of inspection results   Cognex Corporation's (Cognex) motor weld seam deep learning inspection device uses the In-Sight D900 smart camera to measure the weld seam at the point where the hairpin type conductor is welded in a hairpin type (SC winding) motor, and performs deep learning and rule-based inspection to make a pass/fail judgme...

Market & Tech Reports  Updated at: 2024/03/07

connecting 2 units in parallel. Full view of the "J3 Series" SiC/Si power module exhibit for xEVs J3 Series exhibit   A prototype of the J3 series (J3-HEXA-L) mounted on an e-Axle was also on display at the venue. The motor part of the e-Axle was said to be made by Himeji Works, and the hairpin type (SC) windings are visible, but no detailed explanation was provided.   The xEV power module panel introduced the transition of automotiv...

Market & Tech Reports  Updated at: 2024/02/29

exhibits reports Analysis Reports: EV/HV Drive Motors   BorgWarner: e-Axle, motor, high-voltage fan   BorgWarner Inc. displayed two types of motors for BEVs at the front of its booth.   The SW180 S-winding drive motor uses the "S stator winding technology" method, which is the same as the normal hairpin type winding in that it uses flat square wire, but by using continuous forming wire, welding points are eliminated and the height of the coil ...

Market & Tech Reports  Updated at: 2024/02/15

t dissipation efficiency exceeds 50%.   Xiaomi designed a new stator and rotor. The combination of a 54-slot 6-pole configuration reduces the AC frequency of the magnetic field and iron loss compared to the standard 48-slot 8-pole configuration, further improving efficiency. It also adopts 8-layer hairpin flat wire winding technology, with a winding coefficient of 77%. Filling more copper wire in the same space generates even larger currents and...

Market & Tech Reports  Updated at: 2024/02/07

oling and lubrication technology, low-resistance technology, and direct connection between the P1 motor and the engine. Two-system cooling lubrication system: Precise injection to the high temperature points of the motor to achieve dynamic and accurate control of motor temperature. The 10-layer hairpin flat wire technology produces motor products with ultra-high power density (7kW/kg), high efficiency (97.8%), high sustained power (70%), and ...

Market & Tech Reports  Updated at: 2024/01/17