Winding structure of motor for electric vehicle

Abstract

The application relates to a winding structure of a motor for an electric vehicle, comprising a stator, the stator comprising tooth bars, tooth slots and windings, the windings being wound on the tooth bars in clockwise or counterclockwise directions, the windings on the same tooth bar being wound in batches, the winding directions of the windings on the same tooth bar being the same, and the windings on the same tooth bar being connected in series. The winding structure of the application increases the conductor wire diameter of the motor winding, the windings on the same tooth are wound in batches, the crowded position of the copper wire is effectively avoided, the idle tooth slot space is utilized, the slot fill factor is greatly improved, the current carrying capacity of the motor is improved, the copper consumption is reduced, the motor efficiency is improved, the output torque and the cruising range are increased.

Description

Technical Field

[0001] This invention relates to the field of electric vehicle technology, and in particular to a winding structure for an electric vehicle motor. Background Technology

[0002] With the encouragement of national policies and the increasing emphasis on environmental issues in human society, and the need to mitigate the greenhouse effect, electric vehicles, as green and pollution-free transportation tools, have become an indispensable part of people's daily lives. As the core component of electric vehicles, the performance and quality of the motor directly affect the personal safety and user comfort of consumers. Most existing electric vehicle motors use hub motors with a large number of pole slots. To improve the utilization rate of copper wire in the stator windings, most adopt fractional-slot concentrated windings. However, in the existing winding structure, the winding on each tooth can only be wound to the required number of turns at a time before winding the next tooth. Due to the large diameter of hub motors, the stator outer diameter is also large, which inevitably causes the stator slots to become wider towards the outside and narrower towards the center. This results in a very crowded winding structure at the root of the slots, inevitably causing friction and crushing between conductors. This greatly increases the probability of inter-turn and withstand voltage issues in the stator windings. Furthermore, due to the limitation at the root of the slots, the utilization rate of the slots is limited, and the slot opening is very wide and cannot be fully wound, resulting in a large unused slot area. Therefore, the existing motors with their wide outer and narrow inner slots and the one-time sequential winding structure of the stator have a small winding cross-sectional area, limited current overload capacity, low motor efficiency and torque, high copper losses, and high motor temperature rise.

[0003] Therefore, those skilled in the art are dedicated to developing a winding structure for electric vehicle motors to improve the slot fill factor and product yield of the motor stator windings, enhance motor efficiency and output torque, reduce motor temperature rise, improve motor overload capacity and power density, achieve industrial automated winding of the windings, and improve production efficiency. Solving the existing technical problems and achieving the above objectives is the motivation behind this invention. Summary of the Invention

[0004] In view of the above-mentioned deficiencies of the prior art, the technical problem to be solved by the present invention is:

[0005] 1. Electric vehicle motors have a large outer diameter, a stator slot shape that is wider on the outside and narrower on the inside, a winding structure that is relatively crowded at the bottom of the slot, a lot of unused space at the slot opening, and a low stator winding slot fill factor.

[0006] 2. Electric vehicle motors have a large number of slots. In order to reduce waste at the winding ends and improve the sinusoidal characteristics of the motor's back electromotive force waveform, most of them adopt fractional slot concentrated windings, with the winding on each tooth formed in one go, and the teeth following the sequential winding in the cross-line direction.

[0007] 3. The high crowding at the bottom of the stator slots makes the conductor insulation layer susceptible to compression and friction, resulting in a high number of inter-turn and withstand voltage failures, and the pass rate of the stator winding cannot be guaranteed.

[0008] 4. The stator winding cross-sectional area is small, resulting in low overload capacity for current, low power density of the motor, high copper loss, high temperature rise, and low efficiency.

[0009] 5. With a large number of stator slots, the parallel connection pattern of motors is complex, prone to errors, and cannot guarantee the parallel connection qualification rate.

[0010] To achieve the above objectives, the present invention provides a winding structure for an electric vehicle motor, the technical solution of which is as follows:

[0011] A winding structure for an electric vehicle motor includes a stator, which comprises toothed ribs, slots, and windings. The windings are characterized in that they are wound clockwise or counterclockwise around the toothed ribs, with the windings on the same toothed rib being wound in several batches, all winding in the same direction, and connected in series. This design arranges the windings on the same toothed rib in different batches while avoiding crowded positions on adjacent toothed ribs. This allows for the winding of thicker conductors, improves the utilization rate of the slots, effectively enhances the motor's current overload capacity, reduces copper loss, and improves motor efficiency, output torque, and driving range.

[0012] This invention provides a winding structure for an electric vehicle motor, which also includes the following auxiliary technical solutions:

[0013] The windings are composed of windings on several toothed ribs forming a unit winding. The windings on each toothed rib within a unit winding are connected in series. The stator is composed of several unit windings, which are connected in series or parallel. This design scheme ensures the continuity of winding production for each batch of windings on each toothed rib within a unit winding, simplifies the production process, improves production efficiency and winding qualification rate. At the same time, the flexible use of series and parallel connections between unit windings improves the adjustability of motor parameters, optimizes the motor winding process, and reduces costs while increasing efficiency.

[0014] In this design, at least one tooth in a unit winding consists of windings from different batches that are spaced apart from windings on any other tooth in the same unit winding. This scheme aims to avoid congestion in the tooth slots and improve the winding yield.

[0015] The stator can have 27 tooth slots with windings on 3 tooth ribs as unit windings, or 36 tooth slots with windings on 3 tooth ribs as unit windings, or 45 tooth slots with windings on 3 tooth ribs as unit windings, or 48 tooth slots with windings on 4 tooth ribs as unit windings, or 54 tooth slots with windings on 3 tooth ribs as unit windings, or 63 tooth slots with windings on 3 tooth ribs as unit windings.

[0016] In this design, the windings can be arranged in layers with a single conductor or in layers with multiple conductors. This scheme optimizes the range of selectable conductor diameters for the windings, allowing for the rational selection of a single thick wire or multiple thin wires based on actual operating conditions. This enables cost control as well as improved product yield and efficiency.

[0017] The diameter of a single conductor wire in the winding is 0.3mm to 3.3mm.

[0018] In this design, the winding directions of adjacent tooth ribs within the same unit winding are opposite. This reduces waste of stator end conductors and lowers costs.

[0019] In this design, the number of turns and the order of windings on each tooth within a unit winding are arbitrary. This scheme breaks the limitations of conventional continuous winding rules, rationally arranges the wire positions according to the tooth structure, improves tooth utilization, increases slot fill factor, and enhances motor performance.

[0020] Furthermore, the present invention also proposes a motor for electric vehicles, including the winding structure of the electric vehicle motor described in any one of the claims.

[0021] Furthermore, the present invention also proposes an electric vehicle, including the aforementioned electric vehicle motor.

[0022] Compared with the prior art, the advantages and beneficial effects of the present invention are:

[0023] This invention provides a winding structure for an electric vehicle motor. The windings on the same tooth rib of the motor stator are arranged in batches within a unit winding according to actual winding parameter requirements. The number of turns and winding sequence of each batch of windings on the same tooth rib can be flexibly designed based on the structure and quantity of the stator's tooth slots and tooth ribs. This reasonably avoids congestion during wiring of windings on adjacent tooth ribs. Furthermore, different batches of windings on the same tooth rib can be connected in series. In contrast, existing winding structures require each tooth rib to be wound continuously before moving to the next tooth rib. This prevents multiple batches of windings from being wound at intervals within a single unit winding. Moreover, existing winding structures can only achieve sequential tooth winding in the stator winding direction within a unit winding. Compared with the prior art, the winding structure of the present invention greatly improves the slot fill factor of the stator winding, significantly improves the pass rate of the stator winding, realizes the specification improvement of the winding wire diameter, improves the current overload capacity and power density of the motor, improves the efficiency and output torque of the motor, increases the driving range of electric vehicles, and has good consistency of motor products.

[0024] The electric vehicle motor provided by this invention, compared with existing motors, innovates the winding method through optimized design of the winding structure, enabling the winding of conductors with larger unit cross-sectional area. The effective cross-sectional area of ​​the motor winding is increased, effectively reducing copper loss and motor temperature rise, significantly improving stator slot fill factor, stator winding qualification rate, and production efficiency, and significantly optimizing motor performance. It is particularly effective when applied to the case of multiple branches of a single conductor being wound in parallel.

[0025] The present invention provides an electric vehicle that uses an optimized motor, which significantly improves the driving range and reduces the cost of the motor compared with existing products of the same specifications.

[0026] The following description, in conjunction with the accompanying drawings, further illustrates the concept, specific structure, and technical effects of the present invention, so as to provide a full understanding of the purpose, features, and effects of the present invention. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the winding structure of an electric vehicle motor according to a preferred embodiment of the present invention, which uses a 4-tooth winding group to form a unit winding in batches.

[0028] Figure 2 This is a schematic diagram of a 48-slot stator winding structure for an electric vehicle motor according to a preferred embodiment of the present invention.

[0029] Figure 3 A schematic diagram of the winding structure of a preferred embodiment of an electric vehicle motor, wherein the motor is composed of a unit winding scheme with a 3-tooth winding group wound in batches.

[0030] Figure 4 This is a schematic diagram of a 54-slot stator winding structure for an electric vehicle motor according to a preferred embodiment of the present invention.

[0031] Figure 5 This is a performance comparison curve table between the electric motor of this invention and existing motors.

[0032] In the diagram, 1 represents the winding; 2 represents the tooth rib; 3 represents the tooth slot; 4 represents the phase parallel connection node; 5 represents the winding Y-type connection node; 11 represents the unit winding; 21 represents the first tooth rib; 22 represents the second tooth rib; 23 represents the third tooth rib; and 24 represents the fourth tooth rib. It is particularly important to note that the arrows placed on the conductors in the diagram indicate the winding direction of the stator winding structure. Detailed Implementation

[0033] The following are specific embodiments of the present invention, and the technical solution of the present invention will be further described in detail with reference to the accompanying drawings. It should be noted that the described embodiments are only intended to facilitate the understanding of the present invention by those skilled in the art, and do not limit the scope of protection of the present invention in any way.

[0034] Example 1:

[0035] like Figures 1 to 2 As shown in the preferred embodiment of the winding structure of an electric vehicle motor provided in this embodiment, the stator includes winding 1, tooth ribs 2, and tooth slots 3. Specifically, wherein... Figure 1 This embodiment describes a stator for an electric vehicle motor where a unit winding 11 is constructed by winding four-tooth windings in batches. The unit winding 11 includes windings 1 on a first tooth rib 21, a second tooth rib 22, a third tooth rib 23, and a fourth tooth rib 24. The windings 1 on the first tooth rib 21, second tooth rib 22, and third tooth rib 23 are each wound in two or more batches. All windings 1 on the same tooth rib 2 have the same winding direction. All windings 1 on each tooth rib 2 within the unit winding 11 are connected in series. The stator's unit windings 11 can be connected in series, in parallel, or a combination of both. Specifically, in this embodiment, the windings on the first tooth rib 21, second tooth rib 22, and third tooth rib 23 within the unit winding 11 are each wound in two batches, while the winding 1 on the fourth tooth rib 24 is wound in one operation. The unit windings 11 of each phase are connected in parallel.

[0036] like Figure 2 As shown, this embodiment is a DC brushless 3-phase motor with 48 slots in the stator. Each phase winding 1 of the stator contains 4 parallel branches, and the 4 parallel branches of each phase intersect at the phase line parallel node 4. The winding structure of this embodiment is a "Y" type connection, and all parallel branches of the three-phase windings intersect at the "Y" type connection point. In particular, the "Y" type connection point in this embodiment is divided into 4 "Y" type connection sub-nodes 5.

[0037] like Figure 1 As shown, in the winding structure scheme of the 4-tooth unit winding in this embodiment, the number of turns of the winding 1 on each tooth 2 in the unit winding 11 between batches is arbitrary, and the winding sequence of each batch on each tooth 2 in the unit winding 11 is as follows: "the first batch of winding 1 on the first tooth 21 is wound → the first batch of winding 1 on the second tooth 22 is wound → the first batch of winding 1 on the third tooth 23 is wound → the first batch of winding 1 on the fourth tooth 24 is wound → the second batch of winding 1 on the second tooth 22 is wound → the second batch of winding 1 on the first tooth 21 is wound → the second batch of winding 1 on the third tooth 23 is wound." In this embodiment, the distribution order of the first tooth rib 21, the second tooth rib 22, the third tooth rib 23, and the fourth tooth rib 24 in the stator circumferential direction can be defined clockwise or counterclockwise, and the clockwise and counterclockwise winding directions on each tooth rib follow the principle that the winding directions of the windings 1 on adjacent tooth ribs 2 in the unit winding 11 are opposite. The winding direction on the first tooth rib 21 can be arbitrarily defined. In particular, the winding structure scheme in this embodiment is applicable to all cases of winding structures in which the unit winding 11 is composed of 4 tooth ribs 2.

[0038] Example 2:

[0039] The technical solution in this embodiment is mostly the same as that in embodiment 1. This embodiment only describes the different parts in detail, and the parts that are the same as those in embodiment 1 will not be described again.

[0040] like Figures 3 to 4 As shown in this embodiment, another preferred embodiment of the winding structure of an electric vehicle motor is provided, particularly in that... Figure 3 This is an embodiment of a scheme in which the stator is wound in batches with 3-tooth windings to form a unit winding 11. In this scheme, the unit winding 11 includes windings 1 on the first tooth rib 21, the second tooth rib 22, and the third tooth rib 23, wherein the windings 1 on the first tooth rib 21, the second tooth rib 22, and the third tooth rib 23 are each wound in two batches. For example... Figure 4 As shown, the stator has 54 slots. Each phase winding 1 of the stator contains 3 parallel branches. Each parallel branch is connected in series by 2 unit windings 11. The 3 parallel branches of each phase intersect at the phase line parallel node 4. In this embodiment, the winding structure is a "Y" type connection. All parallel branches of the three-phase windings intersect at the "Y" type connection point. In particular, the "Y" type connection point in this embodiment is divided into 3 "Y" type connection sub-nodes 5.

[0041] like Figure 4As shown, in the winding structure scheme of the unit winding 11 formed by the batch winding of the 3-tooth winding group in this embodiment, the number of turns of the winding 1 on each tooth 2 in the unit winding 11 between batches is arbitrary, and the winding sequence of each batch on each tooth 2 in the unit winding 11 is as follows: "the first batch of winding 1 on the first tooth 21 is wound → the first batch of winding 1 on the second tooth 22 is wound → the first batch of winding 1 on the third tooth 23 is wound → the second batch of winding 1 on the second tooth 22 is wound → the second batch of winding 1 on the first tooth 21 is wound → the second batch of winding 1 on the third tooth 23 is wound." In this embodiment, the distribution order of the first tooth rib 21, the second tooth rib 22, and the third tooth rib 23 in the stator circumferential direction can be defined clockwise or counterclockwise, and the clockwise and counterclockwise winding directions on each tooth rib follow the principle that the winding directions of the windings 1 on adjacent tooth ribs 2 within the unit winding 11 are opposite. The winding direction on the first tooth rib 21 can be arbitrarily defined. In particular, the winding structure scheme in this embodiment is applicable to all cases where the winding structure of the unit winding 11 is composed of the windings on the three tooth ribs 2.

[0042] Example 3:

[0043] The technical solution in this embodiment is mostly the same as that in embodiment 2. This embodiment only describes the different parts in detail, and the parts that are the same as those in embodiment 2 will not be described again.

[0044] like Figures 3 to 4 As shown in this embodiment, another preferred embodiment of the winding structure of an electric vehicle motor is provided, particularly in that... Figure 3 This is an embodiment of a scheme in which the stator is constructed by winding a unit winding 11 in batches using three tooth windings. In this scheme, the unit winding 11 includes windings 1 on the first tooth rib 21, the second tooth rib 22, and the third tooth rib 23, wherein the windings on the first tooth rib 21, the second tooth rib 22, and the third tooth rib 23 are all wound in one operation. For example... Figure 4 As shown, the stator slot 3 has 54 slots. Each phase winding 1 of the stator contains 3 parallel branches. Each parallel branch is connected in series by 2 unit windings 11. The 3 parallel branches of each phase intersect at the phase line parallel node 4. In this embodiment, the winding structure is a "Y" type connection. All parallel branches of the three-phase windings intersect at the "Y" type connection point. In particular, the "Y" type connection point in this embodiment is divided into 3 "Y" type connection sub-nodes 5.

[0045] like Figure 4As shown, in the winding structure scheme of the 3-tooth unit winding in this embodiment, the number of turns of the winding 1 on each tooth 2 in the unit winding 11 is arbitrary. The winding sequence of each batch on each tooth 2 in the unit winding 11 is "the first batch of winding 1 on the first tooth 21 is wound → the first batch of winding 1 on the third tooth 23 is wound → the first batch of winding 1 on the second tooth 22 is wound". The above windings 1 are directly connected in series. In particular, the winding structure scheme in this embodiment is applicable to all cases of winding structure in which the unit winding 11 is composed of 3 teeth 2.

[0046] Example 4:

[0047] The technical solution in this embodiment is largely the same as that in embodiment 2. This embodiment only details the differences, while the parts that are the same as those in embodiment 2 will not be repeated. In this embodiment, winding 1 consists of 6 parallel branches connected in parallel. The 6 parallel branches of each phase intersect at the phase line parallel connection point 4. The winding structure in this embodiment is a "Y" type connection, and all parallel branches of the three-phase winding intersect at the "Y" type connection point. In particular, the "Y" type connection point in this embodiment is divided into 6 "Y" type connection sub-nodes 5.

[0048] Example 5:

[0049] The technical solution in this embodiment is largely the same as that in embodiment 3. This embodiment only details the differences, while the parts that are the same as those in embodiment 3 will not be repeated. In this embodiment, winding 1 consists of 6 parallel branches connected in parallel. The 6 parallel branches of each phase intersect at the phase line parallel connection point 4. The winding structure in this embodiment is a "Y" type connection, and all parallel branches of the three-phase winding intersect at the "Y" type connection point. In particular, the "Y" type connection point in this embodiment is divided into 6 "Y" type connection sub-nodes 5.

[0050] The above-described embodiments are merely preferred embodiments of the present invention and are only used to illustrate the technical solutions of the present invention. They are not intended to limit the patent scope of the present invention. Any modifications or equivalent substitutions made to the technical solutions of the present invention based on the description and drawings of the present invention, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

[0051] Although this document frequently uses terms such as winding 1, tooth rib 2, tooth slot 3, phase line parallel node 4, winding Y-type connection node 5, unit winding 11, first tooth rib 21, second tooth rib 22, third tooth rib 23, and fourth tooth rib 24, the possibility of using other terms is not excluded. The use of these terms is merely for the convenience of describing and explaining the essence of this invention; interpreting them as any additional limitation would contradict the spirit of this invention.

Claims

1. A winding structure for an electric vehicle motor, comprising a stator, said stator including tooth ribs, tooth slots, and windings, characterized in that: The windings are wound clockwise or counterclockwise on the toothed ribs. The windings on the same toothed rib are divided into several batches and wound in the same direction. The windings on the same toothed rib are connected in series. The windings on several toothed ribs form a unit winding. The windings on each toothed rib within the unit winding are connected in series. The stator is composed of several unit windings. The unit windings are connected in series or in parallel. The windings on different batches on at least one toothed rib within the unit winding are separated from the windings on any other toothed rib within the same unit winding. The windings are arranged in layers with a single conductor or in layers with multiple conductors.

2. The winding structure of the electric vehicle motor according to claim 1, characterized in that: The stator has 27 tooth slots with windings on 3 tooth ribs as unit windings, or 36 tooth slots with windings on 3 tooth ribs as unit windings, or 45 tooth slots with windings on 3 tooth ribs as unit windings, or 48 tooth slots with windings on 4 tooth ribs as unit windings, or 54 tooth slots with windings on 3 tooth ribs as unit windings, or 63 tooth slots with windings on 3 tooth ribs as unit windings.

3. The winding structure of the electric vehicle motor according to claim 2, characterized in that: The diameter of a single conductor wire in the winding is 0.3mm to 3.3mm.

4. The winding structure of the electric vehicle motor according to claim 3, characterized in that: The winding directions of the windings on adjacent toothed ribs within the same unit winding are opposite.

5. The winding structure of the electric vehicle motor according to claim 4, characterized in that: The number of turns and the order of windings on each tooth of the unit winding are arbitrary.

6. A motor for an electric vehicle, characterized in that: Including the winding structure of an electric vehicle motor as described in any one of claims 1-5.

7. An electric vehicle, characterized in that: Including the electric vehicle motor as described in claim 6.

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