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The traction and power generation motors of hybrid electric vehicles need to provide greater output densities. This can be achieved by increasing output and reducing the physical size and weight of the motors. However, there are limits on how much a motor’s output can be increased while simultaneously shrinking the motor’s size, as it is conventionally structured. To address this issue, the authors developed a stator with a new structure to increase motor output and reduce motor size. By simultaneously optimizing magnetic circuit design, they increased maximum torque by 2.6% and maximum output by 8.9% and reduced volume by 23% and weight by 23% compared to motors of conventional structure, all while maintaining the same level of efficiency. The result was top-of-class output and compactness.

Driving motors for hybrid vehicles and electric vehicles require magnet wires that can endure use at high voltages of 650 V or more. The magnet wire is a main motor component with the electromagnetic steel sheets and magnets. Conventional motors generally assure insulation by using the two parts of the magnet wire and insulate paper. But this increases the motor space factor and hinders weight reduction. A new magnet wire with high insulation performance was used by forming thermoplastic resin onto an enameled layer in order to reduce the number of insulating parts and enhance motor performance. The magnet wire (High-Voltage Wire: HVW) composed of polyetheretherketone (PEEK) resin . HVW can withstand the forming load during motor manufacture, secures durability for the automobile motor operating environment (Automatic Transmission Fluid: ATF), high temperatures) and can maintain high-voltage characteristics.