Integral slot concentrated full-pitch flat wire winding structure and flat wire motor

Abstract

The invention discloses an integer slot concentrated full-pitch flat wire winding structure and a flat wire motor, and relates to the technical field of motors. Each branch of each phase of the integral-slot concentrated whole-pitch flat wire winding structure comprises one or more coil units, each coil unit is composed of four coil groups, each of the first coil group and the third coil group comprises a same-layer hairpin, the second coil group comprises N / 2-1 cross-layer hairpins, and each cross-layer hairpin comprises N / 2-1 cross-layer hairpins. The two effective conductors of the cross-layer hairpin are located on the adjacent layers of flat wires in different grooves, the fourth coil assembly is obtained by rotating the second coil assembly by m stator grooves in the circumferential direction, and m is the phase number of the winding motor. According to the invention, the stator adopts an integral pitch winding and is matched with a concentrated winding scheme that the number of slots per pole per phase is 1, so that the motor can obtain the maximum winding coefficient; only N / 2 + 1 types of hairpins are needed, and the types of the hairpins are reduced, so that the purposes of reducing the processing difficulty, the assembly complexity, the manufacturing cost and the maintenance difficulty of the flat wire winding are achieved.

Description

Technical Field

[0001] The present invention relates to the field of motor technology, in particular to the field of flat wire motor technology, and more specifically to an integer-slot concentrated full-pitch flat wire winding structure and a flat wire motor. Background Art

[0002] As a device that realizes the mutual conversion between electrical energy and mechanical energy based on the principle of electromagnetic induction, the motor plays a vital role in various electrical and mechanical fields, such as household appliances, electric vehicles and electric vehicles. It can provide power sources for these devices and also act as a power generation device. According to the type of working power supply, motors can be divided into two categories: DC motors and AC motors, and AC motors can be further divided into single-phase motors and multi-phase motors. The motor is mainly composed of two parts: the stator and the rotor, in which the winding is arranged in the stator core slot of the stator.

[0003] At present, there are mainly two types of motor windings: wave winding and stacked winding. For motors with segmented hairpin windings that use flat copper wire or rectangular copper wire, if stacked winding is used, there will be too many crossover conductors between stacked coils, which will increase the amount of ineffective copper. Therefore, wave winding is usually used for such motors.

[0004] For example, in the invention patent application publication text entitled "A Flat Wire Winding Structure" with application publication number CN118659564A and application publication date September 17, 2024, the flat wire winding structure involved includes a stator core, the upper and lower sides of which are respectively set as the connection side and the insertion side of the flat wire. On the inner side surface of the stator core, a number of evenly distributed axial slots are opened along the circumferential direction. The number of winding poles of this flat wire winding structure is 2p, the number of slots of the axial slot is m, and each axial slot is provided with 2n layers of conductors, and a flat wire U-shaped hairpin is inserted in the axial slot. The flat wire U-shaped hairpin here covers three pitch structures of full pitch Y1=m / 2p, long pitch Y2≥Y1+1, and short pitch Y3≤Y1-1, and satisfies the relationship Y2-Y3=m / 2p / 3, and adopts a cross-layer structure of two adjacent layers. This invention patent application adopts a single-branch triangle connection method, a single-branch star connection method, or a double-branch star connection method. Through these three connection methods, it can ensure that the electric potential remains balanced, there is no circulating current problem, and its winding structure is relatively simple, and there are no special-shaped wires.

[0005] However, the flat wire winding structure disclosed in the prior art is only applicable to motors with single-branch or double-branch windings. At the same time, since it involves three pitch structures, namely, full pitch, long pitch and short pitch, the types of flat wire hairpins related thereto increase accordingly, which undoubtedly increases the difficulty of processing the flat wire winding and the flat wire motor, the complexity of the assembly process, the manufacturing cost and the difficulty of subsequent maintenance. Summary of the invention

[0006] In order to overcome the defects and shortcomings in the above-mentioned prior art, the present invention provides an integer slot concentrated full-pitch flat wire winding structure and a flat wire motor. The invention aims to solve the problem that the flat wire winding structure in the above-mentioned prior art uses a variety of flat wire hairpins, which leads to the difficulty of flat wire winding processing, high assembly complexity, high manufacturing cost and high maintenance difficulty.

[0007] The integer-slot concentrated full-pitch flat wire winding structure of the present invention has 1 slot number per phase per stage, all stator windings under a single rotor pole of a certain phase are in the same stator slot, and there are N layers of flat wires in each stator slot, N is an even number, and N≥4; the flat wires under the same phase but different rotor poles are connected by hairpins, and each branch of each phase contains one or more coil units, each coil unit consists of four coil groups, the first coil group and the third coil group each contain a same-layer hairpin, the second coil group is an oblique span area, containing N / 2-1 cross-layer hairpins, and the two effective conductors of the cross-layer hairpins are located in adjacent layers of flat wires in different slots, and the fourth coil group is obtained by rotating the second coil group along the circumferential direction by m stator slots, where m is the number of phases of the winding motor; all hairpins are full-pitch hairpins, and the spans of the two effective conductors of all welding parts of the four coils are full-pitch. The stator of the present invention adopts a full-pitch winding, and with a concentrated winding scheme with 1 slot per pole per phase, the motor can obtain the maximum winding coefficient; the winding connection scheme can form a head-to-tail closed loop, that is, a winding branch can be formed by disconnecting any welding end position; the present invention only requires N / 2+1 types of hairpins, reducing the number of hairpins, thereby achieving the purpose of reducing the difficulty of flat wire winding processing, assembly complexity, manufacturing cost and maintenance difficulty.

[0008] In order to solve the above problems existing in the prior art, the present invention is implemented through the following technical solutions.

[0009] A first aspect of the present invention provides an integer-slot concentrated full-pitch flat wire winding structure, comprising a stator core, wherein the upper and lower sides of the stator core are respectively a connection side and an insertion side of the flat wire, the stator core is an integer-slot stator core, and the number of slots per level and per phase of the flat wire winding structure is 1; All stator windings under a single rotor pole of a certain phase are in the same stator slot, and there are N layers of flat wires in each stator slot, N is an even number, and N ≥ 4; the flat wires under different rotor poles of the same phase are connected by hairpins; each branch of each phase contains one or more coil units, and each coil unit consists of four coil groups, namely the first coil group, the second coil group, the third coil group and the fourth coil group, and the adjacent coil groups are connected in sequence end to end through the welding ends of two adjacent hairpins in the circumferential direction; wherein the first coil group and the third coil group each contain a hairpin of the same layer , the two effective conductors of the same-layer hairpins are located in the same layer of flat wires in different slots, and belong to the first layer or the Nth layer of flat wires respectively; the second coil group and the fourth coil group are both oblique span areas, including N / 2-1 cross-layer hairpins, and the two effective conductors of the cross-layer hairpins are located in adjacent layers of flat wires in different slots, and the cross-layer hairpins are connected end to end in sequence; the fourth coil group is composed of the second coil group rotated along the circumferential direction of the stator core by m stator slots, where m is the number of winding phases; the same-layer hairpins and cross-layer hairpins are all full-pitch hairpins; the spans of the two effective conductors of all welding parts of the four coil groups are the same, which are all full-pitch.

[0010] Further preferably, the coil unit is rotated clockwise or counterclockwise along the circumferential direction of the stator core by m stator slots in sequence, where m is the number of winding phases; p coil units are formed, where p is the number of pole pairs; in the order of the slot numbers of the stator slots, the outlet of the outgoing wire segment of the previous coil unit in adjacent coil units is connected to the inlet of the next coil unit to form one branch of one-phase winding; the head and tail are spaced an entire distance apart in adjacent layers.

[0011] More preferably, according to different outgoing line positions and the corresponding welding ends of the busbar disconnection, a plurality of coil units are connected in series and parallel to form k branches, where k is a divisor of the number of pole pairs p.

[0012] More preferably, all branches of one phase winding are rotated clockwise or counterclockwise by 1 to m-1 stator slots to obtain a connection mode of other m-1 phase windings.

[0013] Further preferably, the same-layer hairpin and the cross-layer hairpin both include effective conductors in two slots and a hairpin end for connection and two welding ends for welding.

[0014] More preferably, the two effective conductors on the hairpin are in different slots of the same phase winding, and the difference in the number of stator slots bridged by the hairpin is the span of the hairpin, and the span is an integral span.

[0015] Further preferably, the effective conductors of the hairpins on the same layer located at the upper layer are all located clockwise of the effective conductors on the lower layer, and the effective conductors of the hairpins across layers located at the upper layer are all located clockwise of the effective conductors on the lower layer.

[0016] Further preferably, the effective conductors of the hairpins on the same layer located at the upper layer are all located counterclockwise to the effective conductors on the lower layer, and the effective conductors of the hairpins across layers located at the upper layer are all located counterclockwise to the effective conductors on the lower layer.

[0017] Further preferably, the cross-layer hairpins are connected end to end in sequence, with the first layer of flat wires close to the inner side of the stator being radially plugged into the Nth layer of flat wires outside the stator along the stator core, or the Nth layer of flat wires close to the outer side of the stator being radially plugged into the first layer of flat wires inside the stator along the stator core.

[0018] A second aspect of the present invention provides an integer-slot concentrated-pitch flat wire motor, which comprises the integer-slot concentrated-pitch flat wire winding structure and a rotor, wherein the rotor is coaxially arranged in a stator core of the flat wire winding structure.

[0019] Compared with the prior art, the beneficial technical effects brought by the present invention are as follows: 1. In the manufacturing process of the flat wire motor stator winding, it is usually necessary to open molds for different types of hairpins. A major outstanding advantage of the present invention is that the types of hairpins required in its manufacturing process are very few, and only N / 2+1 hairpins are needed to meet the construction requirements of the entire stator winding. Compared with the traditional manufacturing process that may require a variety of complicated hairpin types, this greatly reduces the number of molds. The mold development of each hairpin involves high cost investment, including mold design, raw material procurement, processing and manufacturing, and subsequent debugging. The present invention directly saves a large number of unnecessary mold opening processes and related costs by streamlining the types of hairpins, so that the mold opening cost is significantly reduced, saving enterprises considerable capital expenditures in the production and manufacturing links. For example, if a similar flat wire motor stator winding is manufactured in a traditional way, 10 different hairpins may be required, and the mold opening cost of each hairpin is assumed to be 50,000 yuan, then the mold opening cost alone is as high as 500,000 yuan. However, the present invention only requires, for example, 5 types of hairpins (assuming N is 8), and the mold opening cost is only 250,000 yuan, and the cost reduction effect is very obvious.

[0020] 2. Different types of hairpins often mean different shapes, sizes, torsion angles, and assembly requirements, which makes the manufacturing process extremely complicated. When embedding the hairpins into the stator slots and performing subsequent connection and assembly operations, a variety of complex hairpin types will increase many operating steps and precision requirements. However, the present invention greatly simplifies this process because it only requires N / 2+1 types of hairpins. Production personnel no longer need to face a wide variety of hairpins with different characteristics. In the processing and manufacturing links, such as forming, cutting, twisting, etc., they can focus more on these limited types of hairpins, and it is easier to master the key points of their processing technology to ensure the stability of processing quality. In the assembly stage, it is also a crucial link to accurately install the hairpins into the stator slots and complete the correct connection. Under traditional processes, the many different types of hairpins require assemblers to remember the placement position, connection method, and other complex information of various hairpins. A little carelessness may lead to assembly errors, affecting the performance of the motor or even normal operation. The present invention simplifies the types of hairpins, and assemblers only need to be familiar with the assembly requirements of these few hairpins to complete the assembly of stator windings more efficiently and accurately, effectively reducing the difficulty of the manufacturing process and improving production efficiency and product quality.

[0021] 3. The present invention has unique advantages. It can realize motor solutions with different numbers of parallel branches by cleverly combining different stator winding coil groups in series and parallel. This flexibility is of great significance in the research and development and production of flat wire motors, and it lays a solid foundation for the platform development of flat wire motors. By establishing such a platform that can flexibly adjust the number of parallel branches, enterprises can quickly develop flat wire motor products with various specifications and performance requirements on the same infrastructure according to the needs of different customers, different application scenarios and different market positioning. For example, for some small electrical appliance application scenarios that are more sensitive to cost, flat wire motors with lower power and fewer parallel branches may be required; while for application scenarios with higher power requirements such as large industrial equipment, high-power flat wire motors with more parallel branches are required. This feature of the present invention enables enterprises to meet these diverse needs by simply adjusting the series and parallel combination of different stator winding coil groups without redesigning the entire motor structure, greatly improving the versatility and scalability of the product, and promoting the development of flat wire motors in the direction of platformization.

[0022] 4. In the traditional flat wire motor production process, if you want to produce motors with different numbers of parallel branches, you often need to redesign the motor winding structure, re-open the mold, readjust the production process and other cumbersome operations, which will undoubtedly lead to a significant extension of the production cycle. The present invention realizes motor solutions with different numbers of parallel branches through the above-mentioned unique series-parallel combination method, avoiding these repetitive and time-consuming tasks. Once the basic stator winding coil group is determined, its series-parallel combination can be quickly adjusted according to specific needs, so as to quickly obtain a motor product with the required number of parallel branches. This efficient production method greatly shortens the time interval from design to finished product, effectively reduces the production cycle of the motor, and enables enterprises to respond to market demand more quickly and improve market competitiveness.

[0023] 5. The winding coefficient of the flat wire motor of the present invention reaches 1, which is a very ideal state. The winding coefficient is an important indicator to measure the efficiency of the motor winding in utilizing the magnetic field energy. The closer its value is to 1, the more fully the winding utilizes the magnetic field energy. In the present invention, a winding coefficient of 1 means that the motor winding can convert the input electrical energy into magnetic field energy in the most efficient way, and in the process of generating and interacting with the magnetic field, there is no waste or loss of energy due to factors such as the winding structure. From the perspective of electromagnetic principles, when the winding coefficient is 1, the magnetic field strength generated by the current passing through the winding is completely consistent with the theoretically optimized magnetic field strength, which enables the motor to generate torque more stably and efficiently during operation, providing a solid foundation for the high-performance operation of the motor.

[0024] 6. Since the winding coefficient of the flat wire motor of the present invention is 1, this directly leads to an increase in its torque density. Torque density refers to the torque that the motor can generate per unit volume, and it is a key indicator for measuring the power performance of the motor. In practical applications, a larger torque density means that the motor can output a larger torque at the same volume, which has great advantages for many application scenarios. For example, in the field of electric vehicles, the motor that needs to drive the vehicle forward or backward requires a higher torque density so that when the vehicle starts, climbs a hill, and other situations that require greater power, it can quickly provide sufficient torque to enable the vehicle to run smoothly. The flat wire motor of the present invention, with its large torque density, can better meet these application scenarios with higher power requirements, thereby improving the applicability and practicality of the motor.

[0025] 7. Compared with the flat wire winding structure involved in the prior art document CN118659564A cited in its background technology, the present application has significant advantages and characteristics in multiple key technical points.

[0026] First, in terms of the number of slots per phase per level, the existing technology can only adapt to full-pitch windings with 2 slots per phase per level, while the present application takes a unique approach and sets the number of slots per phase per level to 1. This difference makes the present application more autonomous and flexible in the structural planning of the winding and the matching of electromagnetic performance, and can perform more precise optimization design according to different application requirements.

[0027] Secondly, regarding the number of flat wire clips, when faced with N layers of flat wires, the existing technology requires as many as 2N-1 types of flat wire clips. Such a large number of clips undoubtedly brings a heavy burden to the entire manufacturing process, including increasing processing difficulty, extending production cycle, and increasing manufacturing costs. In stark contrast, this application only requires N / 2+1 types of clips. The sharp reduction in the number of clips greatly reduces the manufacturing burden, simplifies the production process, and thus improves production efficiency, while also achieving good results in cost control.

[0028] Third, from the perspective of welding process, the welding end of the prior art has welding operations in each adjacent layer. This frequent welding arrangement makes the welding process extremely complicated. Not only that, it also causes the end height of the welding end to remain high, which has a certain negative impact on the overall structural compactness and performance stability of the product. However, this application adopts the method of adjacent welding of welding ends every two layers, and keeps the welding direction consistent. Through this optimized design, the welding process becomes simple and easy to operate, and the end height of the welding end is effectively reduced, thereby improving the comprehensive performance and process aesthetics of the product.

[0029] Fourthly, in terms of the application scope of branch windings, the existing technology has shown strong limitations and can only be used for single-branch windings. Once double-branch windings are used, additional buses must be added, which undoubtedly brings additional burdens in terms of system complexity and cost. On the contrary, the present application has a wide range of applicability and can be used for any k-branch windings (k is a multiple of p), and there is no need to add buses, which provides a more convenient, flexible and economical solution for the design and application of motors in different application scenarios. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 A schematic diagram of a stator structure of an example of the present invention; Figure 2 It is a schematic diagram of the distribution of a certain phase winding in a stator slot of an integer slot concentrated full-pitch flat wire winding structure of the present invention; Figure 3 It is a schematic diagram of the flat wire hairpin structure of the integer slot concentrated full-pitch flat wire winding structure of the present invention; Figure 4 It is a connection plan view of a coil unit of the integer slot concentrated full-pitch flat wire winding structure of the present invention; Figure 5 It is a plan view of all branches of a certain phase winding of the present invention; Figure 6 This is a schematic diagram of the connection structure of a 60-slot, 20-pole, 10-layer flat wire 1-branch winding; Figure 7 This is a schematic diagram of the connection structure of a 60-slot, 20-pole, 10-layer flat wire 5-branch winding; Figure 8 This is a schematic diagram of the connection structure of a 48-slot, 16-pole, 8-layer flat wire, 4-branch winding; Fig. 9 This is a schematic diagram of the connection structure of the 60-slot, 20-pole, 10-layer flat wire A-phase winding in an example of the present invention; Fig.10 This is a schematic diagram of the connection structure of the 60-slot, 20-pole, 10-layer flat wire B-phase winding in an example of the present invention; Fig.11 This is a schematic diagram of the connection structure of a 60-slot, 20-pole, 10-layer flat wire C-phase winding in an example of the present invention; Fig.12 This is a schematic diagram of the distribution of 6 types of hairpin positions of 10 layers of flat wires of the present invention; Fig.13 for Fig.12 Schematic diagram of 6 types of hairpin structures of 10 layers of flat wire; Figure numerals: 1, stator core, 2, stator slot, 201, first layer of flat wire, 202, second layer of flat wire, 203, third layer of flat wire, 204, fourth layer of flat wire, 205, fifth layer of flat wire, 206, sixth layer of flat wire, 207, seventh layer of flat wire, 208, eighth layer of flat wire, 209, ninth layer of flat wire, 210, tenth layer of flat wire, 3, inner edge of stator core, 4, outer edge of stator core, 5 , hairpin, 501, effective conductor, 502, hairpin end, 503, welding end; 504, the first type of hairpin, 505, the second type of hairpin, 506, the third type of hairpin, 507, the fourth type of hairpin, 508, the fifth type of hairpin, 509, the sixth type of hairpin, 6, coil unit, 601, the first coil group, 602, the second coil group, 603, the third coil group, 604, the fourth coil group. DETAILED DESCRIPTION

[0031] The following will be combined with the drawings of the present invention specification to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0032] Example 1 As a preferred embodiment of the present invention, this embodiment discloses an integer slot concentrated full-pitch flat wire winding structure, Figure 1 As shown, it includes a stator core 1, the upper and lower sides of the stator core 1 are the connection side and the insertion side of the flat wire respectively, the stator core 1 is an integer slot stator core, and the number of slots per level and per phase of the flat wire winding structure is 1.

[0033] All stator windings under a single rotor pole of a certain phase are in the same stator slot 2, and each stator slot 2 has N layers of flat wires, N is an even number, and N ≥ 4. The flat wires under different rotor poles of the same phase are connected by hairpins 5. Each branch of each phase contains one or more coil units 6, and each coil unit 6 is composed of four coil groups, namely the first coil group 601, the second coil group 602, the third coil group 603, and the fourth coil group 604. The adjacent coil groups are connected end to end in sequence through the welding ends 503 of two adjacent hairpins 5 in the circumferential direction.

[0034] Among them, the first coil group 601 and the third coil group 603 each include a same-layer hairpin, and the two effective conductors 501 of the same-layer hairpin are located in the same layer of flat wires in different slots, respectively, the first layer of flat wires 201 or the Nth layer of flat wires (here, for example, the 10th layer of flat wires 210). The second coil group 602 and the fourth coil group 604 are both oblique spanning areas, including N / 2-1 cross-layer hairpins (which can be regarded as different types such as the second type of hairpin 505, the third type of hairpin 506, etc., depending on the cross-layer situation), and the two effective conductors 501 of the cross-layer hairpin are located in adjacent layers of flat wires in different slots, and each cross-layer hairpin is connected end to end in sequence. The fourth coil group 604 is rotated by m stator slots 2 along the circumferential direction of the stator core 1 by the second coil group 602, where m is the number of winding phases. Both the same-layer hairpins and cross-layer hairpins are full-pitch hairpins. The spans of the two effective conductors 501 of all welding parts of the four coil groups are the same and are all full pitch, which means that they can better meet the requirements of the electromagnetic performance of the motor in design, making the magnetic field generated when current passes through more evenly distributed, which is beneficial to improving the performance indicators such as the motor's operating efficiency and torque output.

[0035] As an example, refer to the attached Figure 1 As shown, the flat wire winding is radially distributed in the stator slot 2 of the stator core 1. Figure 1 Ten layers of flat wires are shown, which are radially arranged from the inner edge 3 of the stator core to the outer edge 4 of the stator core in order: the first layer of flat wires 201, the second layer of flat wires 202, the third layer of flat wires 203, the fourth layer of flat wires 204, the fifth layer of flat wires 205, the sixth layer of flat wires 206, the seventh layer of flat wires 207, the eighth layer of flat wires 208, the ninth layer of flat wires 209, and the tenth layer of flat wires 210.

[0036] The stator core 1 has Q stator slots 2 evenly distributed along the circumference. For an m-phase winding, the number of slots per phase per level in the stator core 1 is 1, that is, q=Q / (2mp)=1, where q is the number of slots per phase per level, Q is the number of stator slots, m is the number of winding phases, and p is the number of motor pole pairs. Figure 2 As shown in FIG. 1 , a schematic diagram of the distribution of the stator slots of a certain phase winding is shown. The stator core 1 has 60 slots. If the flat wire winding is a 3-phase winding, the number of motor pole pairs is 10 and the number of motor poles is 20. Figure 2 In the 60-slot stator core 1 shown in the figure, taking a certain phase winding of the winding as an example, all stator windings under a single rotor pole of the phase winding are assembled in the same stator slot 2, and there are 10 layers of flat wires in each stator slot 2. The flat wires under different rotor poles of the same phase are connected by hairpins 5. Figure 4 As shown, the phase winding includes one or more coil units 6, each of which is composed of four coil groups, namely the first coil group 601, the second coil group 602, the third coil group 603, and the fourth coil group 604. The adjacent coil groups are connected end to end in sequence through the welded ends 503 of two adjacent hairpins 5 along the circumferential direction of the stator core 1. The first coil group 601 and the third coil group 603 include a hairpin on the same layer, and the two effective conductors 501 of the hairpin on the same layer are located in the same layer of flat wires in different slots, and belong to the 1st layer of flat wires 201 and the 10th layer of flat wires 210 respectively; the second coil group 602 and the fourth coil group 604 are both oblique span areas, including N / 2-1 cross-layer hairpins, and the two effective conductors 501 of the cross-layer hairpins are located in adjacent layers of flat wires in different slots, and each cross-layer hairpin is connected end to end in sequence; the fourth coil group 604 is composed of The second coil group 602 rotates m stator slots 2 along the circumferential direction of the stator core 1, where m is the number of winding phases; both the same-layer card-spinning and the cross-layer card-spinning are full-pitch card-spinning; the spans of the two effective conductors 501 of all welding parts of the four coil groups are the same, which are all full-pitch. In this example, the span is the number of winding phases, that is, spanning 3 stator slots 2; this unified full-pitch setting further ensures the consistency and stability of the electromagnetic performance of the motor winding, so that the entire flat wire winding structure can function more coordinated during operation.

[0037] In this embodiment, refer to the attached manual. Figure 4 As shown, attached Figure 4The solid line in the middle represents the hairpin end 502, and the dotted line represents the welding end 503. Specifically, the first coil group 601 is a hairpin on the same layer, and the hairpin on the same layer is the flat wire 210 on the 10th layer. The two effective conductors 501 of the hairpin on the same layer are located in the 3rd slot (denoted by 10-3) and the 6th slot (denoted by 10-6) on the 10th layer. The connection structure of a coil unit 6 is specifically represented as follows: 10-3 is the head end of the coil, and 10-3 to 10-6 is a hairpin located on the same layer of the 10th layer of flat wire 210, i.e., the first coil group 601; the welding end 503 of 10-6 is connected to 9-9, 9-9 is connected to 8-12, 9-9 to 8-12 is a cross-layer hairpin, 8-12 is connected to 7-15, 7-15 to 6-18 is a cross-layer hairpin, 6-18 is connected to 5-21, 5-21 to 4-24 is a cross-layer hairpin, 4-24 is connected to 3-27, 3-27 to 2-30 are cross-layer hairpins, 2-30 is connected to 1-33, the above 9-9 to 2-30 are all the second coil group 602, 1-33 to 1-36 are the same-layer hairpins, that is, the third coil group 603, refer to the connection method of the second coil group 602, rotate 3 stator slots 2 along the circumference of the stator core 1, that is, the fourth coil group 604, that is, 1-36 is connected to 2-33, 2-33 to 3-30 are cross-layer hairpins, 3-30 is connected to 4-27, 4-27 to 5-24 are cross-layer hairpins, 5-24 is connected to 6-21, 6-21 to 7-18 are cross-layer hairpins, 7-18 is connected to 8-15, 8-15 to 9-12 are cross-layer hairpins, 9-12 is the end of the coil unit 6, the end of the coil unit 6 is connected in series with the head end of the adjacent coil unit 6 belonging to the same phase winding, and the result can be obtained as shown in the attached manual. Figure 6 The 60-slot, 20-pole, 10-layer flat wire 1-branch winding connection structure shown.

[0038] Example 2 As another preferred embodiment of the present invention, this embodiment further supplements and elaborates on the technical solution of the present invention on the basis of the above-mentioned embodiment 1.

[0039] In this embodiment, further operations are performed on the coil unit 6 to construct a complete winding structure. The coil unit 6 is rotated clockwise or counterclockwise along the circumference of the stator core 1 by m stator slots 2, where m is the number of winding phases. Through such a rotation operation, p coil units 6 can be formed, where p is the number of pole pairs.

[0040] For example, take a specific case as an example, refer to the attached manual Figure 6 As shown, for a three-phase winding (m=3 at this time), we rotate the coil unit 6 along the circumferential direction of the stator core 1 clockwise or counterclockwise by three stator slots 2 in sequence, thus forming 10 coil units 6 (assuming that the number of pole pairs p=10 at this time, according to the previously mentioned rule for forming p coil units 6).

[0041] Then, according to the slot number sequence of the stator slots 2, the outlet of the outgoing wire segment of the previous coil unit 6 in the adjacent coil units 6 is connected to the inlet of the next coil unit 6, and through such a connection method, a branch of a phase winding is formed. In addition, in this connection process, it should be noted that the head and tail are separated by a full distance in adjacent layers. This full distance setting plays an important role in ensuring the electromagnetic performance of the motor winding. It can make the magnetic field generated when the current passes through the winding more uniformly distributed, which is conducive to improving the performance indicators such as the motor's operating efficiency and torque output.

[0042] Just like in the Figure 6 In the example of the 60-slot, 20-pole, 10-layer flat wire 1-branch winding connection structure shown, the specific situation of a branch of a single-phase winding formed under this connection method is clearly demonstrated. The coil units 6 are connected in order according to the above rules to form a complete current path, which provides a basis for the normal operation of the motor.

[0043] A further preferred solution is that we can disconnect the corresponding welding ends 503 according to different outlet positions and busbars to achieve series-parallel connection between multiple coil units 6, thereby forming k branches, where k is a divisor of the pole pair number p.

[0044] Specifically, by disconnecting any one welding end 503 of the coil unit 6, the disconnected welding end 503 can be used as the inlet and outlet of the outlet of the coil unit 6, so that one coil unit 6 can be used as a branch. This method provides us with the possibility of flexibly adjusting the number of branches of the motor, which can better meet the requirements of motor performance in different application scenarios.

[0045] Refer to the instruction manual Figure 5 As shown, it is a plan view of all branches of a phase winding. In this figure, we can clearly see how each coil unit 6 is connected in different series and parallel modes by disconnecting different welding ends 503, and finally forms 10 branches. Different connection modes will affect the current distribution, electromagnetic performance and other aspects of the motor, so in actual design and application, it is necessary to reasonably select and adjust according to specific needs.

[0046] As an example, refer to the attached Figure 7 As shown, according to the above scheme, the following can be obtained Figure 7 The schematic diagram of the connection structure of a 60-slot, 20-pole, 10-layer flat wire, 5-branch winding is shown.

[0047] As another example, refer to the attached Figure 8 As shown, according to the above scheme, the following can be obtained Figure 8The schematic diagram of the connection structure of the 48-slot, 16-pole, 8-layer flat wire, 4-branch winding is shown.

[0048] There is further a preferred solution, which is to rotate all branches of one phase winding clockwise or counterclockwise by 1 to m-1 stator slots 2 in sequence, so as to obtain the connection mode of other m-1 phase windings.

[0049] For example, for a three-phase winding (m=3), combined with Figure 5 and Figure 6 For the 60-slot stator core 1 structure shown in FIG. Fig. 9 The A-phase winding is shown. If we rotate the A-phase winding clockwise or counterclockwise by two stator slots 2, we can get the B-phase winding (refer to the instruction manual). Fig.10 Then, after rotating it by one stator slot 2, the C-phase winding can be obtained (refer to the attached manual). Fig.11 as shown).

[0050] Through such a rotation operation, the reasonable spatial distribution of the three-phase windings and the balance of electromagnetic performance can be ensured. Because the three-phase windings need to work together during the operation of the motor, the magnetic fields generated by each of them are superimposed and interact with each other to form a stable rotating magnetic field, thereby driving the motor's rotor to rotate. Therefore, ensuring that the connection method and distribution law between the three-phase windings meet the requirements is crucial for the normal operation and performance of the motor.

[0051] As an example of this embodiment, the effective conductors of the hairpins on the same layer at the upper layer are all located clockwise of the effective conductors on the lower layer, and the effective conductors of the hairpins on the cross-layer layer at the upper layer are all located clockwise of the effective conductors on the lower layer.

[0052] As another example of this embodiment, the effective conductors of the hairpins on the same layer located at the upper layer are all located counterclockwise to the effective conductors on the lower layer, and the effective conductors of the hairpins on the cross-layers located at the upper layer are all located counterclockwise to the effective conductors on the lower layer.

[0053] As another example of this embodiment, the cross-layer hairpins are connected end to end in sequence, with the first layer of flat wires close to the inner side of the stator being radially plugged into the Nth layer of flat wires on the outer side of the stator along the radial direction of the stator core, or the Nth layer of flat wires close to the outer side of the stator being radially plugged into the first layer of flat wires on the inner side of the stator along the radial direction of the stator core. Figure 5 A clockwise connection method is shown. When the connection method is counterclockwise, the connection method of the second coil group and the fourth coil group is replaceable, and the positions of the first coil group and the third coil group are replaceable, that is, the flat wire of the first layer is used as the same-layer hairpin, that is, the first coil group, and the flat wire of the tenth layer is used as the third coil group, and the oblique direction of the second coil group and the fourth coil group is counterclockwise.

[0054] In this embodiment, through the above-mentioned series of operations on the coil unit 6 and different connection mode adjustments, the integer-slot concentrated full-pitch flat wire winding structure of the present invention is further enriched and improved, so that it can more flexibly adapt to different application scenarios and meet diverse motor performance requirements.

[0055] Example 3 As another preferred embodiment of the present invention, this embodiment further supplements and elaborates on the technical solution of the present invention on the basis of the above-mentioned embodiment 1 or embodiment 2.

[0056] In this embodiment, refer to the attached manual. Figure 3 As shown, the hairpin 5 shown in the above-mentioned embodiment 1 or embodiment 2 includes an effective conductor 501 in two slots, a hairpin end 502 for connecting, and two welding ends 503 for welding.

[0057] According to the number of flat wire layers in the stator slot 2, the types of hairpins 5 required in the coil unit 6 are N / 2+1. Fig.13 As shown, when there are 10 layers of flat wires (such as the first layer of flat wires 201, the second layer of flat wires 202, the third layer of flat wires 203, the fourth layer of flat wires 204, the fifth layer of flat wires 205, the sixth layer of flat wires 206, the seventh layer of flat wires 207, the eighth layer of flat wires 208, the ninth layer of flat wires 209, and the tenth layer of flat wires 210), the required hairpin types are 10 / 2+1=6. For specific types, please refer to the attached manual. Fig.13 As shown, attached Fig.13 a is the first type of card 504, b is the second type of card 505, c is the third type of card 506, d is the fourth type of card 507, e is the fifth type of card 508, and f is the sixth type of card 509. Fig.12 middle: ——The first type of hairpin 504 is a hairpin on the same layer, i.e., the third coil group, and the two effective conductors 501 of the first type of hairpin 504 are respectively located in the 1-33 and 1-36 stator slots 2; - The two effective conductors 501 of the second hairpin 505 are respectively located in the 2-30 and 3-27 stator slots 2 in the second coil group 602, and the two effective conductors 501 of the second hairpin 505 are respectively located in the 2-33 and 3-30 stator slots 2 in the fourth coil group 604; - The two effective conductors 501 of the third type of hairpin 506 are respectively located in the 4-24 and 5-21 stator slots 2 in the second coil group 602, and the two effective conductors 501 of the third type of hairpin 506 are respectively located in the 4-27 and 5-24 stator slots 2 in the fourth coil group 604; - The two effective conductors 501 of the fourth type of hairpin 507 are respectively located in the 6-18 and 7-15 stator slots 2 in the second coil group 602, and the two effective conductors 501 of the fourth type of hairpin 507 are respectively located in the 6-21 and 7-18 stator slots 2 in the fourth coil group 604; - The two effective conductors 501 of the fifth type of hairpin 508 are respectively located in the 8-12 and 9-9 stator slots 2 in the second coil group 602, and the two effective conductors 501 of the fifth type of hairpin 508 are respectively located in the 9-12 and 8-15 stator slots 2 in the fourth coil group 604; ——The sixth type of hairpin 509 is a hairpin of the same layer, namely the first coil group. The two effective conductors 501 of the sixth type of hairpin 509 are respectively located in the 10-3 and 10-6 stator slots 2.

[0058] Example 4 As another preferred embodiment of the present invention, this embodiment discloses an integer-slot concentrated-pitch flat wire motor (not shown in the figure), which includes the integer-slot concentrated-pitch flat wire winding structure shown in the above-mentioned embodiment 1, embodiment 2 or embodiment 3 and a rotor, and the rotor is coaxially arranged in the stator core of the flat wire winding structure.

[0059] The above embodiments are only for illustrating the technical concept and features of the present invention, and their purpose is to enable people familiar with the technology to understand the content of the present invention and implement it accordingly, and they cannot be used to limit the protection scope of the present invention. Any equivalent changes or modifications made according to the spirit of the present invention should be included in the protection scope of the present invention.

Claims

1. An integer-slot concentrated full-pitch flat wire winding structure, comprising a stator core (1), wherein the upper and lower sides of the stator core (1) are respectively a connection side and an insertion side of the flat wire, and characterized in that: The stator core (1) is an integer-slot stator core, and the number of slots per phase per level of the flat wire winding structure is 1; All stator windings under a single rotor pole of a certain phase are in the same stator slot (2), and each stator slot (2) has N layers of flat wires, N is an even number, and N≥4; the flat wires under different rotor poles of the same phase are connected by hairpins (5); each branch of each phase includes one or more coil units (6), and each coil unit (6) is composed of four coil groups, namely a first coil group (601), a second coil group (602), a third coil group (603), and a fourth coil group (604), and adjacent coil groups are connected end to end in sequence through welding ends (503) of two adjacent hairpins (5) in a circumferential direction; wherein the first coil group (601) and the third coil group (603) each include A same-layer hairpin, two effective conductors (501) of the same-layer hairpin are located in different slots of the same layer of flat wire, respectively belonging to the first layer or the Nth layer of flat wire; the second coil group (602) and the fourth coil group (604) are both oblique spanning areas, comprising N / 2-1 cross-layer hairpins, the two effective conductors (501) of the cross-layer hairpin are located in adjacent layers of flat wire in different slots, and the cross-layer hairpins are connected end to end in sequence; the fourth coil group (604) is formed by rotating the second coil group (602) along the circumferential direction of the stator core (1) by m stator slots (2), where m is the number of winding phases; the same-layer hairpin and the cross-layer hairpin are both full-pitch hairpins; the spans of the two effective conductors (501) of all welding parts of the four coil groups are the same, and are all full-pitch.

2. The integral slot concentrated full-pitch flat wire winding structure according to claim 1, characterized in that: The coil unit (6) is rotated clockwise or counterclockwise along the circumferential direction of the stator core (1) through m stator slots (2), where m is the number of winding phases; p coil units (6) are formed, where p is the number of pole pairs; in the order of the slot numbers of the stator slots (2), the outlet of the outgoing wire segment of the previous coil unit (6) in adjacent coil units (6) is connected to the inlet of the next coil unit (6) to form a branch of a phase winding; the head and the tail are spaced an entire distance apart in adjacent layers.

3. The integral slot concentrated full-pitch flat wire winding structure according to claim 2, characterized in that: According to different outlet positions and the corresponding welding ends (503) of the busbar disconnection, a plurality of coil units (6) are connected in series and parallel to form k branches, where k is a divisor of the number of pole pairs p.

4. An integer-slot concentrated and uniform-pitch flat wire winding structure as claimed in any one of claims 1 to 3, characterized in that: All branches of one phase winding are rotated clockwise or counterclockwise by 1 to m-1 stator slots (2) to obtain the connection mode of other m-1 phase windings.

5. An integer-slot concentrated and uniform-pitch flat wire winding structure as claimed in any one of claims 1 to 3, characterized in that: The same-layer hairpin and the cross-layer hairpin both include effective conductors (501) in two slots, a hairpin end (502) for connection, and two welding ends (503) for welding.

6. The integral slot concentrated and integral pitch flat wire winding structure as claimed in claim 5, characterized in that: The two effective conductors (501) on the hairpin (5) are in different slots of the same phase winding, and the difference in the number of stator slots bridged by the hairpin (5) is the span of the hairpin (5), which is a full span.

7. An integer-slot concentrated and uniform-pitch flat wire winding structure according to any one of claims 1 to 3, characterized in that: The effective conductors (501) located at the upper layer of the hairpins on the same layer are all located in the clockwise direction of the effective conductors (501) at the lower layer, and the effective conductors (501) located at the upper layer of the hairpins across layers are all located in the clockwise direction of the effective conductors (501) at the lower layer.

8. An integer-slot concentrated and uniform-pitch flat wire winding structure according to any one of claims 1 to 3, characterized in that: The effective conductors (501) located at the upper layer of the hairpins on the same layer are all located in the counterclockwise direction of the effective conductors (501) at the lower layer, and the effective conductors (501) located at the upper layer of the hairpins across layers are all located in the counterclockwise direction of the effective conductors (501) at the lower layer.

9. An integer-slot concentrated and uniform-pitch flat wire winding structure according to any one of claims 1 to 3, characterized in that: The cross-layer hairpins are connected end to end in sequence, with the first layer of flat wires (201) close to the inner side of the stator being inserted radially along the stator iron core (1) into the Nth layer of flat wires outside the stator, or the Nth layer of flat wires close to the outer side of the stator being inserted radially along the stator iron core (1) into the first layer of flat wires (201) inside the stator.

10. An integer slot concentrated pitch flat wire motor, characterized in that: The flat wire motor comprises an integer-slot concentrated-pitch flat wire winding structure as claimed in any one of claims 1 to 9 and a rotor, wherein the rotor is coaxially arranged in a stator core (1) of the flat wire winding structure.

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