Multilayer flat wire winding, stator assembly and motor

Abstract

The present invention provides a multi-layer flat wire winding, a stator assembly, and a motor, specifically relating to the field of motor technology. The multi-layer flat wire winding is installed in the core slot of the motor stator, and each of the core slots is distributed with L layers of conductor coils, where L is an even number greater than or equal to 4. Each phase winding of the multi-layer flat wire winding includes a first coil group, a second coil group, and a third coil group distributed along the circumferential direction of the stator core, wherein the first coil group is located on the 1st or Lth layer of the conductor coil; the second coil group is located on the 2nd to L-1st layers of the conductor coil; the third coil group is distributed on the Lth or 1st layer of the conductor coil; and the first coil group, the second coil group, and the third coil group are connected at the welding end of the winding. There is no circulating current between the branches of each phase of the flat wire winding of the present invention, which can reduce losses and improve motor efficiency.

Description

Technical Field

[0001] The present invention relates to the technical field of motors, and in particular to a multi-layer flat wire winding, a stator assembly and a motor. Background Art

[0002] With the rapid development of new energy vehicle technology, the performance requirements for automotive drive motors are becoming increasingly higher. The main development trends of new energy vehicle motors are miniaturization and high speed, and miniaturization and high speed will inevitably require a significant improvement in motor efficiency.

[0003] Compared to round wire windings, flat wire windings can improve the motor's slot fill rate. This increased slot fill rate means that more copper wire can be packed into the motor while maintaining the same space, generating a stronger magnetic field and increasing power density. Consequently, an increasing number of flat wire motors are being used in new energy vehicle drive systems. Existing flat wire motors often use short-torque windings to reduce the winding's magnetic potential harmonics. For example, CN201520265436.3, "A Motor and Stator Thereof," uses short-pitch windings. Another example is CN202010193400.4, "Flat Wire Continuous Wave Winding Stator and Motor." While this flat wire continuous wave winding uses full-pitch windings, the staggered windings are used, making it equivalent to a double-layer short-pitch winding. This results in the conductors in a slot belonging to different phases. To ensure insulation reliability, additional interlayer insulating paper is required, reducing the winding's slot fill rate and lowering the motor's efficiency. Summary of the Invention

[0004] In view of the above shortcomings of the prior art, the present invention provides a multi-layer flat wire winding, a stator assembly and a motor to improve the circulating current problem of the stator winding.

[0005] To achieve the above objectives and other related objectives, the present invention provides a multi-layer flat wire winding, which is installed in the core slots of a motor stator. Each core slot is distributed with L layers of conductor coils, where L is an even number greater than or equal to 4. Each phase winding of the multi-layer flat wire winding includes a first coil group, a second coil group, and a third coil group. The first coil group is distributed in a chain-like manner along the circumferential direction of the motor stator and is located in the first or Lth layer of the conductor coils; the second coil group is distributed in a chain-like manner along the circumferential direction of the motor stator and is located in the second to L-1th layers of the conductor coils; the third coil group is distributed in a chain-like manner along the circumferential direction of the motor stator and is located in the Lth or 1st layer of the conductor coils, corresponding to the position of the first coil group. The first coil group, the second coil group, and the third coil group are connected at the welding end of the winding.

[0006] In an example of the present invention, the first coil group, the second coil group and the third coil group are all wave windings, the first coil group and the third coil group each include multiple first U-shaped coils and at least one second U-shaped coil, and the second coil group includes multiple first U-shaped coils.

[0007] In one example of the present invention, the first U-shaped coil includes a first U-shaped conductor and a second U-shaped conductor, the first U-shaped conductor is arranged on the outside of the second U-shaped conductor and is connected in series through a bent portion, and the bent portions on both sides of the first U-shaped coil extend with the same slot pitch along the circumferential direction of the stator core, and extend in opposite directions and away from each other.

[0008] In one example of the present invention, the second U-shaped coil includes a third U-shaped conductor and a fourth U-shaped conductor, the third U-shaped conductor is arranged around the outside of the fourth U-shaped conductor and is connected in series through the bent portions, and the bent portions on both sides of the second U-shaped coil extend with the same slot pitch along the circumferential direction of the stator core and extend in the same direction.

[0009] In one example of the present invention, the number of pole pairs of the motor is p, the number of core slots is Q, the pole pitch y = Q / (2p), the span of the first U-shaped coil is y+1 or y-1, and the span of the second U-shaped coil is y+1 or y-1.

[0010] In an example of the present invention, each phase winding of the multi-layer flat wire winding includes at least two branches.

[0011] In an example of the present invention, each phase winding of the multi-layer flat wire winding includes a first branch and a second branch, and the first branch and the second branch have the same winding direction.

[0012] In an example of the present invention, the lead end of the first branch and the lead end of the second branch are spaced apart by one core slot in the circumferential direction of the motor stator.

[0013] In an example of the present invention, the lead end and the outlet end of each branch of each phase winding differ by y core slots in the circumferential direction of the motor stator.

[0014] In an example of the present invention, the lead-in end and the outlet end of each branch of each phase winding are located in different flat wire conductor layers.

[0015] In an example of the present invention, the flat wire conductors of each branch in the slot are symmetrical, and all the flat wire conductors in the same slot belong to the winding of the same phase.

[0016] Another aspect of the present invention provides a stator assembly, which includes a stator core and a stator winding. The stator winding is the multi-layer flat wire winding of the present invention.

[0017] The present invention also provides a motor comprising the multi-phase flat wire winding or the stator assembly.

[0018] The multi-layer flat wire winding of the present invention, through the rational layout of the first, second, and third coil groups, ensures that the branches of each phase in the winding are completely equal in electrical parameters such as resistance, inductance, and potential. When connected in parallel, there is no circulating current between the branches, thereby improving motor efficiency and reducing motor vibration and noise. Furthermore, since all flat wire conductors within a slot belong to the same phase, interlayer insulating paper can be eliminated, increasing the slot fill rate of the flat wire conductors and further improving motor efficiency. The present invention has a simple and efficient manufacturing process, reduces the number of coil types, and reduces production costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0020] Figure 1 This is a schematic structural diagram of a multi-layer flat wire winding according to an embodiment of the present invention;

[0021] Figure 2 for Figure 1 A partial enlarged view of the middle region I;

[0022] Figure 3 This is a schematic structural diagram of a first coil group in an embodiment of a multi-layer flat wire winding according to the present invention;

[0023] Figure 4 This is a schematic structural diagram of a first U-shaped coil in an embodiment of a multi-layer flat wire winding according to the present invention;

[0024] Figure 5 This is a schematic structural diagram of a second U-shaped coil in an embodiment of a multi-layer flat wire winding according to the present invention;

[0025] Figure 6 This is a schematic structural diagram of a second coil group in an embodiment of a multi-layer flat wire winding according to the present invention;

[0026] Figure 7 This is a schematic structural diagram of a third coil group in an embodiment of a multi-layer flat wire winding according to the present invention;

[0027] Figure 8 Schematic diagram of the structure of a stator assembly in one embodiment of the present invention;

[0028] Figure 9 Schematic diagram of the expansion of the A-phase winding of the stator assembly in one embodiment of the present invention;

[0029] Figure 10 A schematic diagram of two branches of the A-phase winding connected in series to form a parallel branch in one embodiment of the present invention;

[0030] Figure 11 FIG. 1 is a schematic diagram of a stator assembly of the present invention in which two branches of the A-phase winding are connected in parallel to form two parallel branches in one embodiment.

[0031] Component number description

[0032] 100. Stator assembly; 110. Stator core; 111. Slot body; 120. Stator winding; 1201. Insertion end; 1202. Welding end; 121. First coil group; 122. Second coil group; 123. Third coil group; 124. First U-shaped coil; 125. Second U-shaped coil; 1241. First U-shaped conductor; 12411. First conductor body; 12412. First bend; 1242. Second U-shaped conductor; 12421. Second conductor body; 12422. Second bend; 1251. Third U-shaped conductor; 12511. Third conductor body; 12512. Third bend; 1252. Fourth U-shaped conductor; 12521. Fourth conductor body; 12522. Fourth bend. DETAILED DESCRIPTION

[0033] The following describes the embodiments of the present invention through specific examples. Those skilled in the art can easily understand other advantages and effects of the present invention from the contents disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and the details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of the present invention. It should be noted that the following examples and the features in the examples can be combined with each other unless they conflict. It should also be understood that the terms used in the examples of the present invention are for the purpose of describing specific embodiments, not for the purpose of limiting the scope of protection of the present invention. The test methods for which specific conditions are not specified in the following examples are generally carried out under conventional conditions or under the conditions recommended by the manufacturers.

[0034] It should be noted that the terms such as "upper", "lower", "left", "right", "middle" and "one" cited in this specification are only for the convenience of description and are not used to limit the scope of implementation of the present invention. Changes or adjustments to their relative relationships should be regarded as the scope of implementation of the present invention without substantially changing the technical content.

[0035] See also Figures 1 to 11 The present invention provides a multi-layer flat wire winding, a stator assembly and a motor to improve the circulating current problem of the stator winding.

[0036] See also Figure 1 and Figure 2 The multi-layer flat wire winding of the present invention is installed in the core slot of the stator. Each core slot is provided with L layers of conductor coils, where L is an even number greater than or equal to 4. Each phase winding of the flat wire winding includes a first coil group 121, a second coil group 122 and a third coil group 123. The first coil group 121 is distributed in a chain-like manner along the circumferential direction of the stator core, and the first coil group is located in the first layer or the Lth layer of the conductor coil; the second coil group 122 is distributed in a chain-like manner along the circumferential direction of the stator core, and the second coil group 123 is located in the first layer or the Lth layer of the conductor coil; 22 is located between the second and L-1 layers of the conductor coils. The third coil group 123 is arranged in a chain pattern along the circumference of the stator core. The third coil group 123 corresponds to the position of the first coil group 121, and is located in the Lth or 1st layer of the conductor coils. That is, when the first coil group 121 is located in the first layer of the conductor coils, the third coil group 123 is located in the Lth layer of the conductor coil layer; when the first coil group 121 is located in the Lth layer of the conductor coils, the third coil group 123 is located in the first layer of the conductor coil group. The first, second, and third coil groups 121, 122, and 123 are connected at the welding end 1202 of the winding to form a multi-layer flat wire winding. This winding method ensures that each branch of each phase winding has equal electrical parameters such as resistance, inductance, and potential. When connected in parallel, there is no circulating current between the branches, thereby improving motor efficiency and reducing vibration and noise. Furthermore, the conductors in each slot belong to a specific phase, eliminating the need for interlayer insulating paper, increasing the slot fill rate of the winding, and further improving motor efficiency.

[0037] See also Figure 1 、 Figures 3 to 7The first coil group 121, the second coil group 122, and the third coil group 123 are all wave windings, forming a chain structure with multiple conductor coils arranged in sequence along the circumference of the stator core. The first coil group 121 includes multiple first U-shaped coils 124 and at least one second U-shaped coil 125. The multiple first U-shaped coils 124 of the first coil group 121 are arranged in sequence along the circumference of the stator core from the starting end and connected in series via a bend. The second U-shaped coil 125 is located at the end of the first coil group and is connected to the last first U-shaped coil 124 via a bend. The first U-shaped coil 124 includes a first U-shaped conductor 1241 and a second U-shaped conductor 1242. The first and second U-shaped conductors 1241 and 1242 have the same structure, but different sizes of their open ends. The first U-shaped conductor 1241 is arranged around the outside of the second U-shaped conductor 1242. The first U-shaped conductor 1241 includes a first conductor body 12411 and first bends 12412 connected to both ends of the first conductor body 12411. The first bends 12412 at both ends of the first conductor body 12411 extend along the circumference of the stator core by the same slot pitch, in opposite directions, and away from each other. The second U-shaped conductor 1242 is located inside the first U-shaped conductor 1241. The second U-shaped conductor 1242 includes a second conductor body 12421 and second bends 12422 connected to both ends of the second conductor body 12421. The two second bends 12422 extend along the circumference of the stator core by the same slot pitch. The extension direction and slot pitch of the two second bends 12422 are the same as those of the corresponding first bends 12412. The first and second U-shaped conductors 1241 and 1242 are connected in series via the first and second bends 12412 and 12422. The second U-shaped coil 125 includes a third U-shaped conductor 1251 and a fourth U-shaped conductor 1252. The third U-shaped conductor 1251 and the fourth U-shaped conductor 1252 have identical structures, but differ in the size of their opening ends. The third U-shaped conductor 1251 is disposed outside the fourth U-shaped conductor 1252. The third U-shaped conductor 1251 includes a third conductor body 12511 and third bent portions 12512 connected to both ends of the third conductor body 12511. The third bent portions 12512 at both ends of the third conductor body 12511 extend along the circumference of the stator core by the same slot pitch and in the same direction. The fourth U-shaped conductor 1252 is located on the inner side of the third U-shaped conductor 1251. The fourth U-shaped conductor 1252 includes a fourth conductor body 12521 and fourth bends 12522 connected to both ends of the fourth conductor body 12521. The extension direction and slot pitch of the two fourth bends 12522 are the same as those of the third bends 12512 on the corresponding side. The third U-shaped conductor 1251 and the fourth U-shaped conductor 1252 are connected in series via the third bends 12512 and the fourth bends 12522.Second coil assembly 122 includes multiple first U-shaped coils 124, and third coil assembly 123 includes multiple first U-shaped coils 124 and multiple second U-shaped coils 125. The structures of the first and second U-shaped coils in second and third coil assemblies 122, 123 are identical to those in first coil assembly 121. During flat wire winding, the conductor bodies of the U-shaped coils in first, second, and third coil assemblies 121, 122, and 123 are first inserted into the core slots of the stator core at one end. The conductors are then bent at the other ends along the circumference of the stator core in their respective bending directions to form a bend. The inserted end of the U-shaped coil forms the insertion end of the winding, and the U-shaped coils are welded together at the bends to form the welded ends of the winding.

[0038] See also Figure 9The specific winding method of the multi-layer flat wire winding is as follows: When winding the first coil group 121, when the lead end enters from the slot body No. 27, the first U-shaped coil (the first U-shaped coil 124, whose span can be y+1 or y-1, where y is the motor pole pitch) is wound in the slot bodies No. 27 and No. 34. Since the bent portion of the U-shaped coil extends a certain slot pitch along the circumferential direction of the stator core, for example, the bent portion of the U-shaped coil extends outward for 3 slot pitches, the two U-shaped coils are separated by 6 slot pitches, so the second U-shaped coil is wound between No. 40 and No. 45. Winding in the slot body, the first U-shaped coil and the second U-shaped coil are connected in series through their respective bends. The series connection method is that the bend on the outside of the first U-shaped coil (the first bend or the third bend) is connected to the bend on the inside of the second U-shaped coil (the second bend or the fourth bend), and the bend on the inside of the first U-shaped coil (the second bend or the fourth bend) is connected to the bend on the outside of the second U-shaped coil (the first bend or the third bend), until one circle is wound along the circumference of the stator core, and the winding of the first coil group 121 is completed. Among them, the last U-shaped coil of the first coil group 121 is the second U-shaped coil, with a pole pitch of y+1 or y-1. The U-shaped coils of the two spans are arranged alternately. For example, if the span of the first U-shaped coil is y+1, the span of the second U-shaped coil is y-1, the span of the third U-shaped coil is y+1, and the span of the fourth U-shaped coil is y-1, and so on. The second coil group 122 is disposed in the middle layer of the coil layer and includes multiple first U-shaped coils with a span of y+1 or y-1. The first U-shaped coils within the second coil group 122 are wound sequentially along the circumference of the stator core. The first U-shaped coils within the second coil group 122 are cross-layer coils, with both sides located in adjacent conductor layers. Because the second coil group 122 comprises multiple layers, half of the coils are first wound in the winding direction of the first coil group 121, followed by the third coil group 123. The winding method of the third coil group 123 is the same as that of the first coil group 121, except that the winding direction is opposite. The remaining second coil group 122 is then wound in the winding direction of the third coil group 123. At the end of the winding, the bent sections of each coil are welded at the welding end to form a multi-layer flat wire winding. It should be noted that "slot pitch" in the present invention refers to the difference between slot numbers. For example, the slot pitch between slots 3 and 9 is 6.

[0039] See also Figure 9Each phase of the multi-layer flat wire winding of the present invention includes at least two branches, and the winding direction of each branch is the same. The lead-in end and the outlet end of each branch differ by y core slots in the circumferential direction of the motor stator; the lead-in end and the outlet end of each branch are located on different conductor layers. Taking the example of each phase of the multi-phase winding including two branches, the two branches are respectively denoted as the first branch and the second branch. The winding direction of the first branch and the second branch is the same, that is, when the first branch is wound clockwise along the circumferential direction of the stator core, the second branch is also wound clockwise along the circumferential direction of the stator core; when the first branch is wound counterclockwise along the circumferential direction of the stator core, the second branch is also wound counterclockwise along the circumferential direction of the stator core. The lead-in terminal (input terminal) of the first branch and the lead-out terminal of the second branch are separated by one core slot in the circumferential direction of the stator core. The lead-out terminal and the output terminal of the first branch are separated by y core slots in the circumferential direction of the stator core, and the lead-out terminal and the output terminal of the second branch are separated by y core slots in the circumferential direction of the stator core. The lead-out terminals of the first and second branches are located in different conductor coil layers. For example, if the lead-out terminal is located in the sixth conductor coil layer, the output terminal is located in the fifth conductor coil layer.

[0040] See also Figure 8 Another aspect of the present invention provides a stator assembly 100, comprising a stator core 110 and a stator winding 120. The stator core 110 comprises an overall cylindrical main body. The inner ring of the cylindrical main body is uniformly circumferentially provided with multiple slots 111 for winding wiring. The slots 111 are radially inwardly open. The stator winding 120 is mounted within the multiple slots 111 of the stator core 110. Each slot contains L layers of flat wire conductors, where L is an even number of layers greater than or equal to 4. Preferably, the stator winding 120 is a multi-layer flat wire winding according to the present invention. The stator winding 120 includes an insertion end 201 and a welding end 1202, respectively, disposed at opposite ends of the stator core 110. In one embodiment, the downward end is the insertion end 1201, and the upward end is the welding end 1202.

[0041] The following describes in detail the winding method of the multi-layer flat wire winding of the present invention, taking a three-phase winding as an example. In this embodiment, the three-phase windings are defined as phase A, phase B, and phase C, respectively. An example is provided with eight poles, 48 slots, six layers of flat wire conductors within each slot, and two branches per pole and phase. For example, the number of slots Q = 48, the number of conductor layers L = 6, the number of pole pairs P = 4, the pole pitch y = Q / (2p) = 6, the span of the coils in the first coil group 121 is 5 or 7, the span of the coils in the second coil group 122 is 5 or 7, and the span of the coils in the third coil group 123 is 5 or 7. The coil bends in each coil group extend three slot pitches circumferentially along the stator core.

[0042] In order to express the wiring of the present invention more clearly, Figure 9The winding expansion diagram only shows the winding of Phase A, not Phase B and Phase C. Phase B and Phase C are wound in the same manner as Phase A, differing only in the slot numbers where the incoming and outgoing wires are located. For example, Phase A consists of a first branch, A1X1, and a second branch, A2X2. A1 and A2 are the incoming wires, and X1 and X2 are the outgoing wires. The incoming wires of Phase A are located in slots 27 and 28, while those of Phase B can be located in slots 31 and 32, and those of Phase C can be located in slots 35 and 36. Figure 2 From left to right, each slot has 6 layers, 5 layers, 4 layers, 3 layers, 2 layers, and 1 layer. In the first and second branches of phase A, the first coil group 121 is located in the outermost layer (the 6th layer), the second coil group 122 is located in the second to the second outermost layers (the 2nd to 5th layers), and the third coil group 123 is located in the innermost layer (the 1st layer).

[0043] See also Figure 1 、 Figure 3 、 Figure 6 、 Figure 7 and Figure 9The specific winding method of the A-phase winding is as follows: the first branch enters from slot body No. 27, and the first U-shaped coil of the first coil group 121 enters from the 6th layer of slot body No. 27 and exits from the 6th layer of slot body No. 34; since the bending portion of each coil extends 3 slot pitches along the circumferential direction of the stator core, the second U-shaped coil enters from the 6th layer of slot body No. 40 and exits from the 6th layer of slot body No. 45; the third U-shaped coil enters from the 6th layer of slot body No. 3 and exits from the 6th layer of slot body No. 10; the fourth U-shaped coil enters from the 6th layer of slot body No. 16 and exits from the 6th layer of slot body No. 21, and the winding of the first coil group 121 is completed; the spans of the U-shaped coils in the first coil group 121 are 5 and 7, appearing alternately, the first three U-shaped coils are the first U-shaped coils, and the fourth U-shaped coil is the second U-shaped coil. The first U-shaped coil of the second coil group 122 enters from the 5th layer of slot No. 27 and comes out from the 4th layer of slot No. 34; the second U-shaped coil enters from the 5th layer of slot No. 40 and comes out from the 4th layer of slot No. 45; the third U-shaped coil enters from the 5th layer of slot No. 3 and comes out from the 4th layer of slot No. 10; the fourth U-shaped coil enters from the 5th layer of slot No. 16 and comes out from the 4th layer of slot No. 21 to complete one circle of winding; then the fifth U-shaped coil enters from the 3rd layer of slot No. 27 and comes out from the 2nd layer of slot No. 34; the sixth U-shaped coil enters from the 3rd layer of slot No. 40 and comes out from the 2nd layer of slot No. 45; the seventh U-shaped coil enters from the 3rd layer of slot No. 3 and comes out from the 2nd layer of slot No. 10; the eighth U-shaped coil enters from the 3rd layer of slot No. 16 and comes out from the 2nd layer of slot No. 21 The third coil group 123 is then wound in the opposite direction to the first coil group 121. The first U-shaped coil enters the first layer of slot 27 and exits the first layer of slot 22. The second U-shaped coil enters the first layer of slot 16 and exits the first layer of slot 9. The third U-shaped coil enters the first layer of slot 3 and exits the first layer of slot 46. The fourth U-shaped coil enters the first layer of slot 40 and exits the first layer of slot 33, completing one winding. The U-shaped coils in the third coil group 123 are alternately arranged with U-shaped coils having a span of 5 and a span of 7. The first three U-shaped coils in the third coil group 123 are the first U-shaped coil 124, and the last one is the second U-shaped coil 125.Then, the third turn of the second coil group 122 is wound. The ninth U-shaped coil of the second coil group 122 enters from the second layer of the No. 27 slot and comes out from the third layer of the No. 22 slot; the tenth U-shaped coil enters from the second layer of the No. 16 slot and comes out from the third layer of the No. 9 slot; the eleventh U-shaped coil enters from the second layer of the No. 3 slot and comes out from the third layer of the No. 46 slot; the twelfth U-shaped coil enters from the second layer of the No. 40 slot and comes out from the third layer of the No. 33 slot to complete the winding of the third turn; then wind The fourth turn of the second coil assembly 122 is wound. The thirteenth U-shaped coil of the second coil assembly 122 enters the fourth layer of slot 27 and exits the fifth layer of slot 22. The fourteenth U-shaped coil enters the fourth layer of slot 16 and exits the fifth layer of slot 9. The fifteenth U-shaped coil enters the fourth layer of slot 3 and exits the fifth layer of slot 46. The sixteenth U-shaped coil enters the fourth layer of slot 40 and exits the fifth layer of slot 33. The winding of the first branch A1X1 is completed. The U-shaped coils in the second coil assembly 122 alternate between first U-shaped coils with a span of 5 and those with a span of 7.

[0044] The second branch follows the same winding direction as the first, with the U-shaped coils in each coil group alternating between two types of coils, spans 5 and 7. The second branch enters slot 28. The first U-shaped coil of first coil group 121 enters the sixth layer of slot 28 and exits the sixth layer of slot 33. The second U-shaped coil enters the sixth layer of slot 39 and exits the sixth layer of slot 46. The third U-shaped coil enters the sixth layer of slot 4 and exits the sixth layer of slot 9. The fourth U-shaped coil enters the sixth layer of slot 15 and exits the sixth layer of slot 22. The first U-shaped coil of the second coil group 122 enters from the 5th layer of slot body No. 28 and comes out from the 4th layer of slot body No. 33; the second U-shaped coil enters from the 5th layer of slot body No. 39 and comes out from the 4th layer of slot body No. 46; the third U-shaped coil enters from the 5th layer of slot body No. 4 and comes out from the 4th layer of slot body No. 9; the fourth U-shaped coil enters from the 5th layer of slot body No. 15 and comes out from the 4th layer of slot body No. 22 to complete one circle of winding; then the fifth U-shaped coil enters from the 3rd layer of slot body No. 28 and comes out from the 2nd layer of slot body No. 33; the sixth U-shaped coil enters from the 3rd layer of slot body No. 39 and comes out from the 2nd layer of slot body No. 46; the seventh U-shaped coil enters from the 3rd layer of slot body No. 4 and comes out from the The eighth U-shaped coil comes out from the second layer of slot body No. 9, enters from the third layer of slot body No. 15, and comes out from the second layer of slot body No. 22 to complete the second circle of winding; then the third coil group 123 is wound. The third coil group 123 is wound in the opposite direction of the first coil group 121. Its first U-shaped coil enters from the first layer of slot body No. 28 and comes out from the first layer of slot body No. 21; the second U-shaped coil enters from the first layer of slot body No. 15 and comes out from the first layer of slot body No. 10; the third U-shaped coil enters from the first layer of slot body No. 4 and comes out from the first layer of slot body No. 45; the fourth U-shaped coil enters from the first layer of slot body No. 39 and comes out from the first layer of slot body No. 34 to complete one circle of winding. Then, the third turn of the second coil group 122 is wound. The ninth U-shaped coil of the second coil group 122 enters from the second layer of the No. 28 slot and comes out from the third layer of the No. 21 slot; the tenth U-shaped coil enters from the second layer of the No. 15 slot and comes out from the third layer of the No. 10 slot; the eleventh U-shaped coil enters from the second layer of the No. 4 slot and comes out from the third layer of the No. 45 slot; the twelfth U-shaped coil enters from the second layer of the No. 39 slot and comes out from the third layer of the No. 34 slot to complete the winding of the third turn; then The fourth turn of the second coil group 122 is wound. The thirteenth U-shaped coil of the second coil group 122 enters from the 4th layer of slot No. 28 and comes out from the 5th layer of slot No. 21; the fourteenth U-shaped coil enters from the 4th layer of slot No. 15 and comes out from the 5th layer of slot No. 10; the fifteenth U-shaped coil enters from the 4th layer of slot No. 4 and comes out from the 4th layer of slot No. 45; the sixteenth U-shaped coil enters from the 4th layer of slot No. 39 and comes out from the 5th layer of slot No. 34. The winding of the second branch A2X2 is completed.Then, the U-shaped coil bends of the first coil group 121 , the second coil group 122 and the third coil group 123 are welded to each other at the welding end 1202 to form the A-phase winding.

[0045] The winding path of the first branch A1X1 of the A-phase winding is as follows:

[0046] A1->27(6)->34(6)->40(6)->45(6)->3(6)->10(6)->16(6)->21(6)->27(5)->34(4)->40(5)->45( 4)->3(5)->10(4)->16(5)->21(4)->27(3)->34(2)->40(3)->45(2)->3(3)->10(2)->16(3)->21(2 )->27(1)->22(1)->16(1)->9(1)->3(1)->46(1)->40(1)->33(1)->27(2)->22(3)->16(2)->9(3)- >3(2)->46(3)->40(2)->33(3)->27(4)->22(5)->16(4)->9(5)->3(4)->46(5)->40(4)->33(5)->X1

[0047] The winding path of the second branch A2X2 of the A-phase winding is as follows:

[0048] A2->28(6)->33(6)->39(6)->46(6)->4(6)->9(6)->15(6)->22(6)->28(5)->33(4)->39(5)->46(4 )->4(5)->9(4)->15(5)->22(4)->28(3)->33(2)->39(3)->46(2)->4(3)->9(2)->15(3)->22(2)-> 28(1)->21(1)->15(1)->10(1)->4(1)->45(1)->39(1)->34(1)->28(2)->21(3)->15(2)->10(3)-> 4(2)->45(3)->39(2)->34(3)->28(4)->21(5)->15(4)->10(5)->4(4)->45(4)->39(4)->34(5)->X2

[0049] The numbers outside the brackets represent the slot numbers, and the numbers inside the brackets represent the layer numbers.

[0050] From the above specific winding direction, it can be concluded that the lead ends (input ends A1 and A2) of the first branch A1XA and the second branch A2X2 are one slot apart in the circumferential direction; the lead end A1 of the first branch is in slot No. 27, and the output end X1 is in slot No. 33, so the lead end A1 and the output end X1 of the first branch are 6 slots apart in the circumferential direction; the lead end A2 of the second branch is in slot No. 28, and the output end is in slot No. 34, so the lead end and the output end of the second branch are 6 slots apart in the circumferential direction; the input ends of the first branch and the second branch are both located in the outermost layer (the 6th layer) of the conductor coil layer, and the output ends are both located in the second outermost layer (the 5th layer) of the conductor coil layer.

[0051] After winding phase A, phases B and C are wound sequentially using the same winding method. Phase B's inlet is slots 31 and 32, while phase C's inlet is slots 35 and 36. After winding, the two parallel branches of each phase have equal electrical parameters such as resistance, inductance, and potential. After parallel connection, there is no circulating current in the branches, thereby improving motor efficiency and reducing vibration and noise. Furthermore, the conductors in each slot belong to the same phase, eliminating the need for interlayer insulating paper, increasing the winding's slot fill rate, and further improving motor efficiency. The winding arrangement of the present invention simplifies the manufacturing process, reduces the number of coil types, and reduces production costs.

[0052] See also Figure 10 and Figure 11 , the two branches A1X1 and A2X2 of phase A can be connected in series to form a parallel branch, that is, the outlet end of the first branch is connected to the incoming end of the second branch; or they can be connected in parallel to form two parallel branches, such as Figure 9 A star connection is shown, but a delta connection may also be used in other embodiments.

[0053] On the other hand, the present invention further provides a motor comprising the multi-layer flat wire winding of the present invention or the stator assembly of the present invention. The multi-layer flat wire winding of the present invention can avoid circulating current, reduce loss, and improve motor efficiency.

[0054] It should be noted that the structures of the stator and the motor are not described in detail in the present invention and can be achieved through conventional technical means, which will not be described in detail here.

[0055] The multi-layer flat wire winding of the present invention utilizes rational winding routing to ensure that the parallel branches of each phase have equal parameters such as resistance, inductance, and potential. This eliminates circulating current between the parallel branches, improving motor efficiency and reducing vibration and noise. Furthermore, since conductors within the same slot belong to the same phase winding, interlayer insulation paper can be eliminated, increasing the slot fill rate and further improving motor efficiency. Therefore, the present invention effectively overcomes several practical problems of the prior art and has high utility value and practical significance.

[0056] The above embodiments are merely illustrative of the principles and effects of the present invention and are not intended to limit the present invention. Anyone skilled in the art may modify or alter the above embodiments without departing from the spirit and scope of the present invention. Therefore, all equivalent modifications or alterations made by one of ordinary skill in the art without departing from the spirit and technical principles disclosed herein are intended to be covered by the claims of the present invention.

Claims

1. A multi-layer flat wire winding installed in the core slot of a motor stator, characterized in that: Each of the core slots is provided with L layers of conductor coils, where L is an even number greater than or equal to 4. Each phase winding of the multi-layer flat wire winding includes: A first coil group is distributed in a chain-like manner along the circumferential direction of the motor stator, and the first coil group is located in the first layer or the Lth layer of the conductor coil; A second coil group is distributed in a chain-like manner along the circumferential direction of the motor stator, and the second coil group is located at the 2nd layer to the L-1 layer of the conductor coil; a third coil group, distributed in a chain-like manner along the circumferential direction of the motor stator, the third coil group corresponding to the position of the first coil group, and located in the Lth layer or the 1st layer of the conductor coil; The first coil group, the second coil group and the third coil group are connected at the welding ends of the windings.

2. The multi-layer flat wire winding according to claim 1, characterized in that: The first coil group, the second coil group and the third coil group are all wave windings. The first coil group and the third coil group each include a plurality of first U-shaped coils and at least one second U-shaped coil. The second coil group includes a plurality of first U-shaped coils.

3. The multi-layer flat wire winding according to claim 2, characterized in that: The first U-shaped coil includes a first U-shaped conductor and a second U-shaped conductor. The first U-shaped conductor is arranged outside the second U-shaped conductor and is connected in series through a bent portion. The bent portions on both sides of the first U-shaped coil extend with the same slot pitch along the circumferential direction of the stator core, extend in opposite directions and are away from each other.

4. The multi-layer flat wire winding according to claim 3, characterized in that: The second U-shaped coil includes a third U-shaped conductor and a fourth U-shaped conductor. The third U-shaped conductor is arranged on the outside of the fourth U-shaped conductor and is connected in series through a bent portion. The bent portions on both sides of the second U-shaped coil extend along the circumferential direction of the stator core with the same slot pitch and the same extension direction.

5. The multi-layer flat wire winding according to claim 2, characterized in that: The number of pole pairs of the motor is p, the number of core slots is Q, the pole pitch y=Q / (2p), the span of the first U-shaped coil is y+1 or y-1, and the span of the second U-shaped coil is y+1 or y-1.

6. The multi-layer flat wire winding according to claim 1, characterized in that: Each phase of the multi-layer flat wire winding includes at least two branches.

7. The multi-layer flat wire winding according to claim 6, characterized in that: Each phase winding includes a first branch and a second branch, and the first branch and the second branch are wound in the same direction.

8. The multi-layer flat wire winding according to claim 7, characterized in that: The lead end of the first branch and the lead end of the second branch are spaced apart by one core slot in the circumferential direction of the motor stator.

9. The multi-layer flat wire winding according to claim 6, characterized in that: The lead-in end and the outlet end of each branch of each phase winding differ by y core slots in the circumferential direction of the motor stator.

10. The multi-layer flat wire winding according to claim 6, characterized in that: The lead-in end and the outlet end of each branch of each phase winding are located in different conductor layers.

11. A stator assembly comprising a stator core and a stator winding, characterized in that: The stator winding is a multi-layer flat wire winding according to any one of claims 1 to 10.

12. A motor, characterized in that: It comprises the multi-layer flat wire winding according to any one of claims 1 to 10 or the stator assembly according to claim 11.

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