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:
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.
“… 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.