Greater Efficiency Through Innovative Hairpin Technology
As part of the HAPIDA research project, Additive Drives is developing a highly efficient three-phase asynchronous motor for industrial applications based on hairpin technology. The goal of the project is to significantly exceed the efficiency of existing electric motors while enabling cost-effective manufacturing. This is intended to reduce energy consumption, CO₂ emissions, and operating costs.
So far in the project, market and requirements analyses were first conducted, and various motor and cooling concepts were examined. Building on this, winding schemes for a solid-copper winding were developed, and the electromagnetic design of the rotor and stator was optimized with regard to copper losses and efficiency. In addition, various concepts for efficient air cooling were investigated and further developed through thermo-fluid dynamic simulations.
The design and conceptualization phase was completed on schedule. Subsequently, the first test segments, functional prototypes, and stators were manufactured. At the same time, a versatile test bench was developed for measuring and analyzing induction motors. Manufacturing processes—including those for laminated core stacks, rotors, and hairpins—were also further developed and partially automated.
The project is funded by the European Union and is being supported by the Sächsische Aufbaubank (SAB) as part of the funding program.
