Ford/Chevy using BW HVH250-115 hairpin motor

[spinningmagnets]

I was researching motors recently, and I was surprised to find that the 2WD version of the Ford Mustang Mach-E (actually a 4-door SUV), was using a BorgWarner HVH250-115 motor, and that's the same motor the FWD Chevy Bolt uses. Further research revealed:

“… In May 2010, the U.S. Department of Energy finalized a $60.2 million American Recovery and Reinvestment Act grant for Indiana-based Remy to develop its HVH electric motor technology. This design can be used with either a permanent magnet rotor or AC-induction rotor…”

This was before Remy was bought by BorgWarner in 2015, so the research and patents are available to be used by a variety of American companies.

The Mach-E has a AWD version, and the rear motor (on the left) is the HVH250-115, and the smaller front motor (on the right) is a different model (HVH250-090?)





The hairpins use rectangular cross-section wire to improve copper-fill. Pic on the right shows a laser-weld by an industrial robot. they claim several reasons to use hairpin style, and I believe the main reason is the ease of rapid manufacture by assembly-line robots.

HVH stands for High Voltage Hairpin, I assume the 250 is 250mm diameter, and the 115 is 115mm length.

I found a reference for an HVH 350, and the HVH410 that is used in at least one hybrid bus.

At 400V, the motor was designed to work well with either a permanent magnet rotor (using neodymium magnets) or, an induction rotor that does not use any strategic rare earth metals that China could restrict.

One reference said that if using 800V, the back-EMF causes issues with a PM rotor, so the 800V applications use an induction rotor.

 

[1boris]

Latest Bosch cx4 250 w ebike motor also uses a hairpin motor. What are the advantages?

 

[spinningmagnets]

The hairpin style of winding can be assembled rapidly by industrial robots, with a very consistent quality.

There may be other benefits of the hairpin style over a traditional winding, but I'm not sure about any others.

 

[speedmd]

Rectangular wire can increase copper fill by some 15- 20% in theory and also allow significantly higher heat dissipation due to its added surface area. Also better with higher frequencies. Been the standard for high power transformers and motors for many years now.

 

[ganzey]

I know this threads old, just figured id throw it out there for anyone interested in a cheap source for these motors, there are 2 inside of the 2ml70 transmission, found in 2008-2013 GM 2mode hybrid trucks (tahoe, suburban, yukon, escalade, ect), most of which are non operational at this point due to it costing more to fix them than they are worth. That transmission also came in some bmw and mercedes as the Allsion Ahs-2.

Datasheet looks promising if you are using high voltage

 

[Hillhater]

Datasheet looks promising if you are using high voltage

I am surprised at the relatively low Torque ?
Without the advantage of a multi ratio transmission that a similar (more ?) torque ICE would have, ..up to 10:1 reduction....at first glance the epower version would seem compromised between torque and road speed.