Résumé
This chapter details the design of a new innovative solid bar winding for electrical machines (either motors or generators) dedicated to the electric propulsion. The goal of this new winding technique is to enhance the performance by better utilizing the stator slot and increasing the copper fill factor to higher than 75%, and also to reduce the inactive copper at the end-windings. Accordingly, many advantages arise from the application of this solid bar winding: higher torque-to-weight ratio, better thermal behavior, lower rotor losses, higher efficiency, higher reliability and lower cogging torque. However, the solid bar has its inherent constraints, which should be considered with care when designing an electric motor: the AC copper losses and the manufacturing process. The suggested winding technique aims at addressing these challenges.