Magnetics Business & Technology - March/April 2020 - 34

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Advancements in motor design and magnetic technology are central to the stunning high performance of Porsche's first-ever electric
vehicle, Taycan. Along with other design achievements in the highpowered auto, they likely point the way to future engineering trends
for the EV market.
The key element is a pair of exceptionally efficient permanently excited synchronous permanent-magnet motors with hairpin winding,
one on the front axle and one on the rear axle, thus making the cars
all-wheel drive. Both the range and the continuous power of the drive
benefit from the high efficiency of the motors which constitute an
electric machine that also functions as a generator for the batteries
during braking..

of hairpin technology is complex, but it allows the wires to be packed
more densely and thus increase the amount of copper in the stator.
While conventional winding processes have a copper filling factor of
around 45 percent, it is just under 70 percent in this case. This increases power output and torque for the same volume. Another important
advantage for a high-performance car like the Taycan is that a hairpin
stator can be cooled considerably more efficiently.

This electric machine, transmission and pulse-controlled inverter are
combined into a compact drive module. The rear axle module is installed parallel to the axle. The pulse-controlled inverter is mounted
on this in a balcony configuration to increase the luggage compartment volume. Thanks to its coaxial design, the front axle module is
integrated into the front of the vehicle in a very small space.
Permanently excited synchronous motors have a rotor with high-quality permanent magnets that generate a natural magnetic field. The rotor thus moves in sync with the magnetic rotating field of the stator,
which is why it is known as a permanently excited synchronous motor. A pulse-controlled inverter specifies the frequency of the rotating
field in the stator, therefore determining rotor speed. On account of
their structure, functionality and their excellent thermal behavior, the
permanently excited synchronous motors are able to deliver the high
performance that Porsche engineers were seeking.
A special feature of the Taycan's electric motors is the hairpin winding
in which the solenoid coils of the stator consist of rectangular rather
than round magnet wires. The wires are bent and their shape, before
they are inserted into the stator's laminated core, is reminiscent of that
of hairpins, hence the name for the type of winding. The open ends
are welded together using a laser beam. The manufacturing process

Magnetics Business & Technology * March/April 2020

The liquid-cooled synchronous motor on the front axle has an active
length of 160 mm and an active diameter of 190 mm. Its counterpart
on the rear axle is 210 mm long and has a diameter of 245 mm. All in
all, the modules have the highest power density of any electric powertrains on the market today, says Porsche.
Continued on page 33...

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