Sustainability Aspects of Electrical Machines For E-Mobility Applications Part II: Aluminium Hairpin vs. Copper Hairpin

Sustainability aspects of electrical machines are in today’s e-mobility market one of the main requirements together with high efficiency, high power density and low cost. In this paper the environmental impact of the electrical machine is being lowered looking at aluminium hairpin stator winding instead of the conventional copper hairpin winding. Two machines are designed using a multi-objective genetic optimization process with different objectives and compared with a copper hairpin machine design. The increase in resistivity has a non negligible impact on the joule losses, however it tends to mitigate AC effects. Overall, the aluminium hairpin solution is shown to be a sustainable and valid alternative for e-mobility applications.