Optimal Hairpin Winding Configuration for EV Traction Motors to Enhance Active CMV Cancellation Capability of NPL.X Inverter
Active common-mode voltage (CMV) cancellation in neutral-point-less (NPL.X) inverter is an effective approach for reducing common-mode electromagnetic interference and alleviating voltage stress associated with high-speed switching in EV traction drives. However, the existing hairpin winding configuration often exhibits impedance imbalance due to slot leakage inductance and manufacturing constraints, limiting the effectiveness of active CMV cancellation. This paper investigates symmetric hairpin winding configurations for a dual-three-phase EV traction machine to improve impedance symmetry. Considering the manufacturing constraints of six-layer hairpin windings, four feasible symmetric winding configurations are analyzed. Two-dimensional finite-element analysis is performed to extract the impedance parameters of each configuration. The extracted impedance parameters are used to quantify the impedance mismatch between complementary phase pairs and evaluate its influence on active CMV cancellation. The results show that the fully interleaved winding configuration achieves perfectly balanced phase impedances with 0 % mismatch, whereas the mismatch in the other configurations ranges from approximately 2.4 % to 0.8 %. Consequently, the resulting total CMV overshoot is significantly suppressed to near zero voltage under high-voltage and high switching frequency operating conditions, demonstrating the importance of winding symmetry for maximizing the active CMV cancellation capability of the NPL.X inverter.