A new winding technology maximizes all active copper components in the slots and/or in the air gap by adapted shaping of conductors while all passive copper components outside stator and air gap, e.g. in the winding heads, are minimized to the shortest possible length. This brings phase resistance as well as the axial length and weight of the motor to the bottom, while efficiency is at top. A topologically optimized design of the winding as well as several methods for its cost-effective manufacturing are presented. Example results of a) a very compact design of a wheel hub motor with gearbox for a cargo bicycle, b) a high efficiency design for a vehicle drive motor, and c) a lightweight design for a drone motor with air gap winding proves the power of the new technology. In this session, you will learn more about:

• New winding technology for high efficiency & lightweight e-motors,
• Super compact winding for high fill factors and small size
• New methods of cost-efficient high quality winding manufacturing,
• Adapted manufacturing methods for small, medium and large e-motor size,
• Adapted manufacturing methods for small, medium and high volume.