Creating Two Hairpin Coils Connected with End-Tip and Leads

  1. Set Slots=18, Layers=6, CoilPitch=2, 2ndPitch=3, LayerSetIdx=0, and InfoCoil=4. These parameter settings will create a single hairpin coil located at the slot bottom, as shown by the pink-color coil in the figure below.

    Two hairpin coils with different coil pitch at different slot locations

  2. Make a copy of the coil, and change CoilPitch to 3, and LayerSetIdx to 1. The copied coil is modified to be located at the slot center, as shown by the blue-color coil in the above figure.

  3. Rotate the blue-color coil by 100deg, or 5 slot-angle, the bottom leg-span of the blue-color coil will align with the top leg-span of the pink-color coil, as shown in the figure below.

    Two hairpin coils at different slot locations connected with end-tip and leads

  4. Make a copy of the blue-color coil, and change LayerSetIdx to 0.5 (for end-tip between layer-set index of 0 and 1) and InfoCoil to 4. The copied coil is modified to an end tip, as shown by the green-color object in the above figure.
  5. Make a copy of the pink-color coil and change InfoCoil to 6, the copied coil is modified to a going lead; and make a copy of the blue-color coil and change InfoCoil to 7. The copied coil is modified to a returning lead, as shown by the golden-color objects in the figure.

The two hairpin coils, two leads, and one end-tip can thus be united to become a single connected coil set.

Note: In order for the end-tip and leads to be able to perfectly connect two hairpin coils, the parameter value of 2ndSpanExt for all components must be the same to keep the same axial span length. If you see a message such as: “HairpinCoil - 2ndSpanExt is modified from xxx to xxx”, you need to increase the value of 2ndSpanExt for all components to be at least the maximum modified value of all components.