A Study on Improving the Power Density of Hairpin Motor using Fe-CoV based Soft Magnetic Steel Sheet

In response to climate change caused by carbon emissions, many studies and policy efforts have been implemented to reduce carbon emissions through various international agreements and policies. A policy for expanding the supply of eco-friendly vehicles is also a representative example. When an internal combustion engine vehicle is converted to an electric vehicle (xEV), the emission reduction effect is extremely high. However, xEV vehicles are difficult to distribute because of their shorter mileage compared with internal combustion engines. Recent studies have aimed to reduce the weight of a vehicle by improving the power density of the driving motor and securing a driving distance by improving the system efficiency accordingly. In this study, we aimed to improve the efficiency of the motor by improving the residual magnetic flux density and reducing iron loss by improving the performance of the iron core material. In addition, the power density of a vehicle motor was improved by applying a hairpin winding that maximized the fill factor of the stator. To verify the validity of the derived motor, efficiency and ripple maps for the entire driving range were extracted to confirm the output characteristics. The validity of this study was identified through manufacturing and testing.