Flexible Printed Circuit Board with Temperature Sensor, Stator and Motor

Abstract

The present invention relates to the field of motors, and discloses a flexible printed circuit board and a stator with a temperature sensor. The flexible printed circuit board includes a first part and a second part. A temperature sensor is mounted on the surface of the first part, and the communication line of the temperature sensor extends to the second part. The second part is used for connecting to the control device of the motor stator, and the temperature sensor can be electrically connected to the control device of the stator through the second part; the first part is used for connecting the coil windings of the stator; the second part extends radially in a direction away from the first part. By combining the flexible PCB embedded with the temperature sensor with the lead frame, the present invention reduces the space envelope for the coil windings and the inverter of the motor / generator, and moreover, the present invention can accurately measure the temperature of each group of coil windings, improving the safety performance of the motor.

Description

Technical Field

[0001] The present invention relates to the field of motors, and in particular to a flexible printed circuit board with a temperature sensor, a stator and a motor. Background Art

[0002] A motor system generally includes a motor, and its control unit is arranged to control the power of the motor. Since driving a vehicle requires high torque, the most commonly used motor is a three-phase motor. A three-phase motor generally includes three coil windings, and each coil winding is arranged to generate a magnetic field related to one of the three phases of an alternating voltage. In order to increase the number of magnetic poles formed in the motor, each coil winding usually has some coil subgroups distributed around the motor, and these coil subgroups are driven to generate a rotating magnetic field. Chinese Patent CN201710715959.7 provides a three-phase permanent magnet brushless DC hub motor.

[0003] As Figure 1 shown, a typical three-phase motor has three coil groups 14, 16, 18. Each coil group is composed of four serially connected coil subgroups. Among them, for a given coil group, the magnetic fields generated by the coil subgroups will have a common phase. The three coil groups of a three-phase motor are usually configured in a delta or star configuration. The control unit of a three-phase motor with a DC power supply usually includes an inverter that generates three-phase power by a three-phase bridge to drive the motor. Each respective voltage phase is applied to a respective coil group of the motor. A three-phase bridge inverter includes a number of switching devices, such as power electronic switches, such as insulated gate bipolar transistor (IGBT) switches, for generating an alternating voltage from a DC power supply. In the context of an electric vehicle motor, a more and more popular drive design is a motor design integrated within a wheel, where the motor and its associated control system are integrated within the wheel. However, due to the space limitation within the vehicle wheel where the electric motor and its associated control system are integrated, it is difficult to accurately measure the temperature of each coil, and it is impossible to determine whether the electric motor is operating within the optimal temperature range. Summary of the Invention

[0004] In view of the fact that the existing hub motors cannot stably measure the temperature of each coil and provide a large power, the present invention provides a flexible printed circuit board with a temperature sensor, a stator and a motor.

[0005] In order to solve the above technical problems, the present invention is solved by the following technical solutions:

[0006] Flexible printed circuit board with temperature sensor, the flexible printed circuit board includes a first part and a second part. A temperature sensor is mounted on the surface of the first part, and the communication line of the temperature sensor extends to the second part. The second part is used to connect to the control device of the motor stator, and the temperature sensor can be electrically connected to the control device of the stator through the second part; the first part is used to connect to the coil winding of the stator.

[0007] Preferably, the second part extends radially in a direction away from the first part.

[0008] Preferably, the flexible printed circuit board is composed of two semi-circular flexible printed circuit boards. Each semi-circular flexible printed circuit board includes a first part and a second part, and each semi-circular flexible printed circuit board is provided with a sensor for measuring the temperature of the winding coil.

[0009] The present invention also provides a stator, which further includes a lead frame and a circumferential support for mounting the winding coil. A plurality of stator teeth are provided on the circumferential side surface of the circumferential support, and the coil winding is mounted on the stator teeth. The first part of the flexible printed circuit board is mounted between the lead frame and the circumferential support. The upper end surface of the first part is in contact with the lower end surface of the lead frame, and the lower end surface of the first part is in contact with the upper end surface of the circumferential support. The lead frame includes a printed circuit board with a plurality of circuit board layers. The temperature sensor is mounted on the end surface of the first part close to the coil winding. A jack for the second part of the flexible printed circuit board to pass through is provided on the lead frame, and the second part passes through the jack after being bent; the end of the coil winding passes through the flexible printed circuit board and is electrically connected to the lead frame.

[0010] Preferably, the cross-sectional shape and size of the first part of the flexible printed circuit board are substantially the same as those of the lead frame, and the flexible printed circuit board is arranged to electrically isolate the coil winding from the lead frame.

[0011] Preferably, the lead frame is an integral circular shape, or two semi-circular lead frames are joined together to form an integral circular lead frame.

[0012] Preferably, each circuit board layer of the printed circuit board includes an insulating substrate; a conductive layer is formed on the insulating substrate; the printed circuit board has at least a first circuit board layer, a second circuit board layer, a third circuit board layer, and a fourth circuit board layer; the first circuit board layer includes a first conductive layer, and the first conductive layer is arranged to be electrically coupled to the first coil winding of the first set of coil windings and the first branch of the first inverter; the second circuit board layer includes a second conductive layer, and the second conductive layer is arranged to be electrically coupled to the second coil winding of the first set of coil windings and the second branch of the first inverter; the third circuit board layer includes a third conductive layer, and the third conductive layer is arranged to be electrically coupled to the third coil winding of the first set of coil windings and the third branch of the first inverter; the fourth circuit board layer includes a fourth conductive layer having multiple conductive layers, and the fourth conductive layer is arranged to be coupled to the first coil winding, the second coil winding, and the third coil winding of the first set of coil windings to form a neutral point between the first coil winding, the second coil winding, and the third coil winding.

[0013] The present invention also provides a motor including the above stator.

[0014] Due to the adoption of the above technical solutions, the present invention has remarkable technical effects:

[0015] The arrangement of the lead frame of the present invention enables a large current to be provided between the inverter and the coil windings of the motor or generator, thereby generating large torque and power values, while allowing a reduction in the space envelope for the coil windings and the inverter of the motor / generator. Moreover, the present invention can accurately measure the temperature of each set of coil windings, improving the safety performance of the motor. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 Illustrates a three-phase motor of the prior art;

[0017] Figure 2 Illustrates an exploded view of the motor including the present invention;

[0018] Figure 3 Is a schematic diagram of the control device;

[0019] Figure 4 Illustrates the electrical connections provided by the lead frame according to an embodiment of the present invention;

[0020] Figure 5 Illustrates the lead frame according to Embodiment 2 of the present invention;

[0021] Figure 6 Illustrates the lead frame arrangement according to Embodiment 2 of the present invention;

[0022] Figure 7 Illustrates the lead frame according to Embodiment 1 of the present invention;

[0023] Figure 8Illustrated is the lead frame arrangement according to Embodiment 1 of the present invention;

[0024] Figure 9 Describe the conductive layer on the circuit board layer of the lead frame according to an embodiment of the present invention;

[0025] Figure 10 Describe the lead frame according to an embodiment of the present invention;

[0026] Figure 11 Illustrate the conductive layer on the circuit board layer of the lead frame according to an embodiment of the present invention;

[0027] Figure 12 Describe the conductive layer on the circuit board layer of the lead frame according to an embodiment of the present invention;

[0028] Figure 13 Describe the conductive layer on the circuit board layer of the lead frame according to an embodiment of the present invention.

[0029] Figure 14 Describe the conductive layer on the circuit board layer of the lead frame according to an embodiment of the present invention;

[0030] Figure 15 Illustrate the lead frame according to an embodiment of the present invention;

[0031] Figure 16 Is a schematic diagram of the cooperation between the coil end and the lead frame according to an embodiment of the present invention;

[0032] Figure 17 Illustrated is the stator core, coil winding and lead frame according to an embodiment of the present invention;

[0033] Figure 18 Is a schematic diagram of the structure of the flexible circuit board;

[0034] Figure 19 Is a schematic diagram of the structure of the stator coil winding and the stator core;

[0035] Figure 20 Is an exploded view of the stator coil winding unit and the stator core. Detailed implementation manners

[0036] Embodiment 1

[0037] Such as Figure 18As shown, this embodiment provides a flexible printed circuit board with a temperature sensor. The flexible printed circuit board 500 includes a first part 501 and a second part 502. A temperature sensor 503 is mounted on the surface of the first part 501. The communication line of the temperature sensor 503 extends to the second part 502. The second part 502 is used to connect to the control device of the motor stator. The temperature sensor 503 can be electrically connected to the control device of the stator through the second part 502. The first part 501 is used to connect to the coil winding 60 of the stator. The second part 502 of the flexible printed circuit board 500 extends radially in a direction away from the first part 501 when not bent.

[0038] Generally, the flexible printed circuit board 500 will include a flexible plastic substrate, such as polyimide, PEEK, or transparent conductive polyester. As is well known to those skilled in the art, at least one temperature sensor 503 is mounted on the flexible plastic substrate. In this embodiment, the number of temperature sensors 503 is six.

[0039] The flexible printed circuit board 500 includes a first part 501 and a second part 502. The first part 501 is mounted between the lead frame 255 and the coil 400. The second part 502 extends radially from the first part 501 and is arranged to bend in a direction perpendicular to the first part 501.

[0040] When the second part 502 bends in a direction perpendicular to the first part 501, the second part 502 is configured to extend through the jack 810 formed in the lead frame 255. Preferably, the first part 501 of the flexible printed circuit board 500 is substantially flat, and the surface of the flexible printed circuit board 500 near the lead frame 255 has a surface area configuration similar to the corresponding surface of the lead frame 255, so as to facilitate the connection of the lead coil winding 60 to the lead frame 255. When the lead frame 255 is mounted on the stator core 600, the first part 501 of the flexible printed circuit board 500 is arranged to be mounted between the coil 400 and the lead frame 255. When the second part 502 of the flexible printed circuit board 500 bends to extend perpendicular to the first part 501 and extends through the jack 810 formed in the lead frame 255, the end of the second part 502 of the flexible printed circuit board 500 is arranged to be coupled to the control device 400 mounted on the stator.

[0041] Communication lines are formed on the substrate of the flexible printed circuit board 500. The communication lines extend from the temperature sensor 503 to the end of the second part 502 of the substrate of the flexible printed circuit board 500 to allow the control device to monitor the coil temperature measured by the temperature sensor 503 on the flexible printed circuit board 500. The temperature sensor 503 is arranged to be mounted on the first part 501 of the first flexible printed circuit board 500, and the temperature sensor 503 is arranged on the end face of the first part 501 close to the coil.

[0042] To enable the control device to monitor the temperature readings measured by the temperature sensor 503 mounted on the substrate of the flexible printed circuit board 500, the communication line formed on the substrate of the flexible printed circuit board 500 extends from the temperature sensor 503 to the end of the second part 502 of the flexible printed circuit board 500 and is coupled to the control device mounted near the second surface of the lead frame 255.

[0043] The material of the substrate of the flexible printed circuit board 500 is arranged to electrically isolate the coil winding 60 from the lead frame 255. In this embodiment, the flexible printed circuit board 500 includes two flexible printed circuit boards 500, as Figure 2 shown, each flexible printed circuit board 500 is substantially semi-circular in shape and has three temperature sensors 503 mounted on the substrate of the flexible printed circuit board 500. Each temperature sensor 503 is located on the side of the first part 501 of the substrate of the flexible printed circuit board 500 close to the coil.

[0044] Each temperature sensor 503 is substantially located at the intermediate position between the front and rear of the coil winding 60 and at the intermediate position between two of the three coil windings 60 that make up a set of coil windings 60.

[0045] The communication line extends from each temperature sensor 503 to the end of the second part 502 of the flexible printed circuit board 500 to allow the control device to monitor the temperature readings measured by each temperature sensor 503 mounted on the substrate of the flexible printed circuit board 500.

[0046] Any number of flexible printed circuit boards 500 are mounted between the lead frame 255 and the coil to measure the temperature of the coil. The flexible printed circuit board 500 can take any shape.

[0047] This embodiment provides a lead frame 255 for coupling an inverter of a motor or a generator to a DC power supply; the motor in this embodiment is a hub motor for an automotive wheel. The motor includes at least a set of coils as part of the stator, the stator is radially surrounded by a rotor, and the rotor carries a set of magnets connected to the wheel. For the avoidance of doubt, the various aspects of the present invention are equally applicable to a generator having the same arrangement. Therefore, the definition of a motor is intended to include a generator.

[0048] As Figure 2As shown, the in-wheel motor includes a stator 252 which comprises a circumferential bracket 253 serving as a radiator, a plurality of coils 254, and two control devices 300 (not shown) which are mounted on the circumferential bracket 253 at the rear of the stator and are used to drive the coils. A capacitor and a lead frame 255 are mounted between the axial flange formed by the axial edges of the coils 254 and the circumferential bracket 253 for connecting the control devices to the coils 254. The coils 254 are embedded in the stator teeth 800 to form a coil winding 60; a stator cover is mounted at the rear of the stator 252 to enclose the control devices and the annular capacitor to form the stator 252, and then it is fixed to the vehicle and will not rotate relative to the vehicle during use.

[0049] As Figure 3 shown, each control device 300 includes an inverter 310, and one of the control devices 300 includes a controller regulator 320. In this embodiment, the control device 300 includes a processor for controlling the operation of the two inverters 310. As Figure 3 shown, each control device 300 includes an inverter 310, and one of the control devices includes control logic 320 which, in this embodiment, includes a processor for controlling the operation of the two inverters 310. As described below, each inverter is coupled to three sets of coil windings 60, and the coil windings 60 are electrically parallel to form a set of three sub-motors.

[0050] The annular capacitor is coupled between the inverter 310 and the DC power supply of the motor to reduce the voltage fluctuations on the motor power line, also known as the DC bus, and to reduce the voltage overshoot during motor operation. To reduce the inductance, the capacitor is mounted near the control device 300. The rotor 240 includes a front portion 220 and a cylindrical portion 221 forming a cover which substantially encloses the stator 252. The rotor includes a plurality of permanent magnets 242 which are arranged around the inside of the cylindrical portion 221. For the purposes of this embodiment, 32 pairs of magnets are mounted inside the cylindrical portion 221. However, any number of magnet pairs can be used.

[0051] The magnet approaches the coil winding 60 on the stator 252, so the magnetic field generated by the coil interacts with the magnet 242 arranged inside the cylindrical portion 221 of the rotor 240, causing the rotor 240 to rotate. Since the permanent magnet 242 is used to generate the driving torque of the drive motor, the permanent magnet is usually referred to as the drive magnet. In this embodiment, the motor includes six coil windings 60, and each coil winding 60 has three coil subgroups, which are also called coil phase windings in this embodiment; these three coil subgroups are coupled in a Y-shaped structure to form a three-phase sub-motor, so that the motor has six three-phase sub-motors. As described above, each coil of the six coil groups is wound around each stator tooth 800 as part of the stator. As described below, the operation of each sub-motor is controlled by one of the two control devices 300. Although this embodiment describes a motor with six coil groups (i.e., six sub-motors), the motor can equally have one or more coil groups with associated control devices. Similarly, each coil group can have any number of coil subgroups, allowing each sub-motor to have two or more phases.

[0052] Figure 3 The connection between each coil group 60 and the control device 300 is illustrated, where three coil groups 60 are connected to the corresponding three-phase inverters 310 on the control device 300. As is well known to those skilled in the art, a three-phase inverter contains six switches, and three-phase AC voltage can be generated by the controlled operation of the six switches. However, the number of switches will depend on the number of voltage phases applied to the respective sub-motors, and any number of phases can be constructed on these sub-motors. Each control device 300 communicates with other control devices 300 via a communication bus.

[0053] One of the control devices 300 includes a processor 320 for controlling the operation of the inverter switches in the two control devices 300. The control device is also electrically connected to a temperature sensor 503 for receiving the signal of the temperature sensor 503 to determine whether the motor is operating within an acceptable temperature range. In addition, each control device 300 includes an interface arrangement that allows communication between the respective control devices 300 via a communication bus 330, and one of the control devices 300 is arranged to communicate with a vehicle controller installed outside the motor.

[0054] The processor 320 is used to control the operation of the inverter switches installed in each control device 300 to allow each motor coil group 60 to be equipped with a three-phase voltage power supply, so that each coil subgroup can generate a rotating magnetic field. As described above, although this embodiment describes each coil group 60 as having three coil subgroups, the present invention is not limited thereto, and it should be understood that each coil group 60 can have one or more coil subgroups.

[0055] Under the control of the processor, each three-phase bridge inverter 310 is set to provide pulse-width modulation voltage control in respective subsets of coils, thereby generating currents in the respective subsets of coils to provide the torques required for the respective sub-motors.

[0056] The working principle of PWM control is to utilize the motor inductance to average the applied pulsed voltage, thereby driving the required current into the motor coils. With pulse-width modulation control, the applied voltage is switched between the motor windings. During the period when the voltage is switched through the motor coils, the current in the motor coils rises at a rate determined by its inductance and the applied voltage. The pulse-width modulation voltage control is turned off before the current increases beyond the required value, thereby achieving precise control of the current.

[0057] For a given coil group 60, the three-phase bridge inverter 310 switches are arranged to apply a single voltage phase across each subset of coils. Using PWM switching, multiple switches are arranged to apply an alternating voltage across the respective subsets of coils. The voltage envelope and phase angle of the electrical signal are determined by the modulating voltage pulses.

[0058] The inverter formed on one control device is coupled to three coil groups to form a first group of three sub-motors, and the inverter formed on another control device is coupled to other coil groups to form a second group of three sub-motors.

[0059] The two inverters 310 are coupled to their respective coil groups through a lead frame 255, where each leg of the respective inverter 310 is coupled to the lead frame 255 through a respective phase winding bus. For this embodiment, the different voltage phases generated by the three legs of the inverter are designated as W, V, and U. The coil windings 60 are coupled to the lead frame 255 to allow current to flow from the DC power supply through the respective inverters 310 in the control device to the coil windings 60, thereby allowing the motor to generate driving torque.

[0060] Figure 4 The electrical connection provided by the lead frame 255 between the phase winding bus of one of the control devices and the coil windings 60 mounted on the stator is shown, where the lead frame 255 is arranged in a Y-shaped configuration for coupling the phase windings of the corresponding subsets of coils. However, the lead frame 255 can be configured to couple the phase windings of the corresponding subsets of coils in a different configuration. As described above, each coil winding 60 includes three subsets of coils (i.e., phase windings) to form a three-phase sub-motor. Figure 4Shows the electrical connection provided by the lead frame 255 between the phase winding busbars of one of the control devices and the coil windings mounted on the stator, where the lead frame 255 is arranged in a Y-shaped configuration for coupling the phase windings of the corresponding coil subgroups. However, the lead frame 255 can be configured to couple the phase windings of the corresponding coil subsets in a different configuration. As described above, each coil winding includes three coil subgroups (i.e., phase windings) to form a three-phase sub-motor. The first coil winding, the second coil winding, and the third coil winding of the first set of coil windings in this embodiment correspond one by one to the first sub-motor, the second sub-motor, and the third sub-motor below.

[0061] For this embodiment, each coil group forming a coil subgroup is formed by three separate coils, which are coupled by the circuit board layer of the lead frame 255.

[0062] Reference Figure 4 , coil 401 forms the first phase winding of the first sub-motor 411, coil 402 forms the second phase winding of the first sub-motor 411, and coil 403 forms the third phase winding of the first sub-motor 411. For the second sub-motor 412, coil 404 forms the first phase winding of the second sub-motor 412, coil 405 forms the second phase winding of the second sub-motor 412, and coil 406 forms the third phase winding of the second sub-motor 412. For the third sub-motor 413, coil 407 forms the first phase winding of the third sub-motor 413, coil 408 forms the second phase winding of the third sub-motor 413, and coil 409 forms the third phase winding of the third sub-motor 413. Figure 4 Each coil 400 shown in corresponds to the coil on a single stator tooth 800, where the ends of each coil are arranged to be coupled to the lead frame 255 to achieve the coupling of the coils according to the Figure 4 configuration shown.

[0063] The lead frame 255 is used to connect the W-phase inverter busbar to the first coil 400 of the first phase winding 401 of the first sub-motor 411, the first phase winding 404 of the second sub-motor 412, and the first phase winding 407 of the third sub-motor 413. The lead frame 255 also connects the V-phase inverter busbar to the first coil 400 of the second phase winding 402 of the first sub-motor 411, the second phase winding 405 of the second sub-motor 412, and the second phase winding 408 of the third sub-motor 413, and connects the U-phase inverter to the first coil 400 of the third phase winding 403 of the first sub-motor 411, the third phase winding 406 of the second sub-motor 412, and the third phase winding 409 of the third sub-motor 413.

[0064] As Figure 4As shown, the lead frame 255 connects the last coil 400 of the first-phase winding 401 of the first sub-motor 411 to the last coils 400 of the second-phase winding 402 and the third-phase winding 403 of the first sub-motor 411. Similarly, the lead frame 255 also connects the last coil 400 of the first-phase winding 404 of the second sub-motor 412 to the last coils 400 of the second-phase winding 405 and the third-phase winding 406 of the second sub-motor 412, and connects the last coil 400 of the first-phase winding 407 of the third sub-motor 413 to the last coils 400 of the second-phase winding 408 and the third-phase winding 409 of the third sub-motor 413. These connections serve as the star points for each sub-motor.

[0065] In addition, the lead frame 255 is arranged to electrically connect the respective coils 400 of each phase winding to form a serial connection between the respective coils 400 of each phase winding. Accordingly, the lead frame 255 provides an electrical connection between the W, V, U-phase inverter buses and the respective coils 400 to form a three-sub-motor driven by a single inverter 310, where the coil windings 60 of the respective sub-motors are coupled in a Y configuration.

[0066] Similarly, the lead frame 255 also connects the phase-winding busbars of the inverter 310 of another control device 300 and the coils mounted on the stator in the same way to form a three-sub-motor driven by the inverter 310 in the second control device 300.

[0067] Now, the structure of the lead frame 255 will be described. In the first embodiment, as Figure 5 shown, a substantially circular lead frame 255 is used to supply current from two control devices to the corresponding coil groups.

[0068] As Figure 6 shown, the substantially circular lead frame 255 is mounted on the axial mounting surface of the stator core 600, which surface is close to the coils that form part of the stator 252. The stator windings are plugged onto the stator teeth 800 formed on the stator core 600 and form a reliable mating relationship with the stator teeth 800. The stator includes a circumferential support and the stator windings mounted on the circumferential support. The stator windings are composed of stator winding units 550, which are teeth wound with coils. Tooth grooves 801 are provided on the inner side surfaces of each tooth. The outer circumference of the circumferential support is provided with stator teeth 800. The tooth grooves 801 are press-fitted into the stator teeth 800. The stator winding units 550 form a circumferential stator winding on the outer circumference of the stator core. In this embodiment, the number of stator winding units 550 is 54 because there are 2 groups of coil windings, each group of coil windings includes 3 coil windings, each coil winding includes 3 coil phase windings (subsets), and each coil phase winding includes 3 coils.

[0069] The lead frame 255 includes a first set of three holes 660 for receiving respective bus bar lead frame pins that couple the lead frame 255 to the inverter 310 in the first control device 300, and a second set of three holes 660 for receiving respective bus bar lead frame pins for coupling the lead frame 255 to the inverter 310 in the second set.

[0070] The lead frame 255 has fixing holes formed at predetermined positions, and the heat stakes 630 are inserted into the fixing holes. In this embodiment, the heat stakes 630 are arranged at the ends of the teeth of the stator winding unit 550, which ends are close to the lead frame 255. The heat stakes 630 are designed on the inner and outer sides of the stator winding unit 550, and the heat stakes 630 are arranged to extend through holes formed in the lead frame 255. Once the lead frame 255 is mounted on the stator core 600 and the respective heat stakes 630 pass through the corresponding fixing holes formed in the lead frame 255, the heat stakes 630 melt, thereby fixing the lead frame 255 to the stator core 600. However, any suitable method can be used to connect the lead frame 255 to the stator core.

[0071] As Figure 6 shown, the lead frame 255 includes a plurality of grooves 640 formed on the inner and outer radial edges of the lead frame 255 for receiving the ends of the coils wound around the stator teeth 800 for coupling the coils 400 to the lead frame 255, as described below. For each coil wound around the stator teeth 800, a part is mounted in the groove 640 formed on the inner radial edge of the lead frame 255, and another part is mounted in the groove 640 formed on the outer radial edge of the lead frame 255.

[0072] The single circumferential lead frame 255 serves as a current path from the respective inverters 310 within the control device 300 to the respective coil windings 60, where the lead frame 255 is a basic circumferential printed circuit board having a plurality of circuit board layers. Its layers have conductive layers printed on each circuit board layer. Each circuit board layer includes an insulating substrate; a conductive layer is formed on the insulating substrate. In this embodiment, the number of inverters is 2. In other words, half of the circumference of the lead frame printed circuit board is allocated for coupling the first control device 300 to a set of coil windings 60 to form a three-submotor formed by the first set of coil windings 60, and the other half of the circumference of the lead frame printed circuit board is allocated for coupling the second control device 300 to the second set of coil windings 60 to form three submotors. The plurality of circuit board layers are separated by respective insulating substrates.

[0073] To allow a large current to flow from the inverter 310 to the coil windings 60, thereby allowing the motor to generate sufficient torque to drive the vehicle, the conductive layers on each circuit board layer are arranged to extend over most of each circuit board, where each conductive layer is arranged to correspond to a specific circuit path between each inverter 310 and the coil windings 60 and between different subsets of coils that make up each sub-motor. Thus, each circuit board layer is optimized for current flow.

[0074] To achieve Figure 4 the circuit configuration shown, the configuration of the printed circuit board layers and the conductive layers printed on the circuit board layers will now be described. Each circuit board layer includes two sets of electrical connections for coupling a first set of three coil windings 60 to one inverter and another set of three coil windings 60 to another inverter, but each circuit board layer can include any number of conductive layers based on the number of inverters. For example, if one inverter is used to drive all the coil windings 60 mounted on the stator, the conductive layers printed on each circuit board layer will be arranged to form a specific circuit path between the inverter and the coil windings 60 and between different subsets of coils that make up each respective sub-motor, forming each respective sub-motor.

[0075] In this embodiment, the lead frame 255 includes a first lead frame 701 and a second lead frame 702, where both the first lead frame 701 and the second lead frame 702 are semi-circumferential. When mounted on the stator 252, the first lead frame 701 and the second lead frame 702 form a substantially circular lead frame 255.

[0076] Both the first lead frame and the second lead frame 702 include a set of three holes 660 for receiving respective bus bar lead frame pins for coupling the first lead frame 701 and the second lead frame 702 to the inverters 310 in the first control device 300 and the second control device 300, respectively.

[0077] The first lead frame 701 and the second lead frame 702 are mounted to the stator core 600 by connecting to heat studs 630 at predetermined positions, and the heat studs 630 are arranged to extend through holes formed in the first lead frame 701 and the second lead frame 702. Once the first lead frame 701 and the second lead frame 702 are mounted on the stator core 600 and their respective heat studs 630 pass through the respective holes formed in the first lead frame 701 and the second lead frame 702, the heat studs 630 melt, thereby holding the first lead frame 701 and the second lead frame 702 fixed to the stator core 600. However, any suitable method can be used to connect the first lead frame 701 and the second lead frame 702 to the stator core 600.

[0078] As Figure 8As shown, the first lead frame 701 and the second lead frame 702 include a plurality of grooves 640 formed on the inner and outer radial edges of the first lead frame 701 and the second lead frame 702 for receiving the end portions of the coils 400 wound around the stator teeth 800 for coupling, and the coils 400 are respectively connected to the first lead frame 701 and the second lead frame 702. For each coil wound around the stator teeth 800, one end is mounted in the groove 640 formed on the inner radial edge of the first lead frame 701 or the second lead frame 702, and the other end is mounted in the groove 640 formed on the outer radial edge of the corresponding lead frame 255 portion 701.

[0079] The circuit board layer of the first printed circuit board on the first lead frame and the circuit board layer of the second printed circuit board on the second lead frame are in a mirror image relationship. The first printed circuit board is responsible for three sub-motors formed by the first set of coil windings 60 (the first sub-motor, the second sub-motor, the third sub-motor or expressed as sub-motors 1 / 2 / 3), and the second printed circuit board is responsible for three sub-motors formed by the second coil winding 60 (the fourth sub-motor, the fifth sub-motor, the sixth sub-motor or expressed as sub-motors 4 / 5 / 6).

[0080] The circuit board layer and circuit connection of the first lead frame will be described below as an example.

[0081] The first printed circuit board includes a first circuit board layer, and the first circuit board layer has a first conductive layer as Figure 9 shown. The first conductive layer basically extends to the first half circumferential portion of the circumferential circuit board, and the first half circumferential portion is arranged to be electrically coupled to the W-phase inverter 310 bus bar and the first coil of the first phase winding 401 of the first sub-motor 411 of the first coil, the first coil of the first phase winding 404 of the second sub-motor 412, and the first coil of the first phase winding 407 of the third sub-motor 413. As described above, the printed circuit board on the second lead frame 702 has a circuit board layer corresponding to the first circuit board layer, and the conductive layer on this circuit board layer is arranged to be electrically coupled to the W-phase inverter bus bar of the second inverter and electrically coupled to the coil windings 60 corresponding to the second set of coil windings 60 mounted on the stator.

[0082] As Figure 10As shown, the bus of the W-phase inverter 310 is coupled to the first circuit board layer through the bus lead frame pin 1010. The bus lead frame 255 pin is a cylindrical conductive element coupled to the bus of the W-phase inverter 310, and the bus lead frame 255 pin extends through the relevant lead frame 255 pin hole 660 formed in the printed circuit board. The W bus lead frame pin 1010 is electrically coupled to the first conductive layer 900 at position 910. In order to couple the first coils of the first-phase windings 401 of the first sub-motor 411, the first coils of the first-phase windings 404 of the second sub-motor 412, and the first coils of the first-phase windings 405 of the third sub-motor 413 to the first conductive layer 900 at positions 920, 930, and 940, the ends of the relevant coils are installed in the grooves 640 formed within the inner and outer radial edges of the lead frame 255 as described above. Among them, the ends of the coil windings 60 are installed in the grooves 640 formed within the inner radial edge of the lead frame 255, and the positions of the grooves are 920, 930, and 940, and are electrically coupled to the first conductive layer 900. The other ends of the first coils of the first-phase windings of the first, second, and third sub-motors and the ends of the remaining coil windings 60 are installed in the respective grooves formed within the inner and outer radial edges of the lead frame 255 and are electrically isolated from the first conductive layer 900.

[0083] The first printed circuit board includes a second circuit board layer, which has a second conductive layer 1100 as Figure 11 shown. The second conductive layer generally extends to the first semi-circumferential portion of the circumferential circuit board, and the circumferential circuit board is arranged to be electrically coupled to the bus of the U-phase inverter 310 and the first coils of the second-phase windings 402 of the first sub-motor 411, the first coils of the second-phase windings 405 of the second sub-motor 412, and the first coils of the second-phase windings 408 of the third sub-motor 413. The printed circuit board on the second lead frame 702 has a circuit board layer corresponding to the second circuit board layer, and the conductive layer on this circuit board layer is arranged to be electrically coupled to the bus of the U-phase inverter of the second inverter and is electrically coupled to the coil windings 60 corresponding to the second group of coil windings 60 installed on the stator.

[0084] As Figure 10As shown, the bus of the U-phase inverter 310 is coupled to the second circuit board layer through the bus lead frame pin 1010, which is a cylindrical conductive element coupled to the bus of the U-phase inverter 310 and extends through the relevant lead frame 255 pinholes 660 formed in the printed circuit board. The U-shaped bus lead frame pin 1010 is electrically coupled to the second conductive layer 1100 at position 1110. In order to couple the first coil of the second-phase winding 402 of the first sub-motor 411, the first coil of the second-phase winding 405 of the second sub-motor 412, and the first coil of the second-phase winding 408 of the third sub-motor 413 to positions 1120, 1130, and 1140 of the second conductive layer respectively, and as described above, the relevant coils are installed in the grooves 640 formed within the inner and outer radial edges of the lead frame 255, where the ends of the coil windings 60 installed in the grooves formed within the inner radial edge of the lead frame 255 are electrically coupled to the second conductive layer at 1120, 1130, and 1140. The other ends of the first coils of the second-phase windings of the first, second, and third sub-motors and the ends of the remaining coil windings 60 are installed in the respective grooves formed within the inner and outer radial edges of the lead frame 255 and are electrically isolated from the second conductive layer.

[0085] The printed circuit board includes a third circuit board layer 1200, and the third circuit board layer has a third conductive layer as Figure 12 shown, and the third conductive layer substantially extends to the first semi-circumferential portion of the circumferential circuit board, and the first semi-circumferential portion is arranged to be electrically coupled to the bus of the V-phase inverter 310 and the first coil of the third coil of the first sub-motor 411 of the phase winding 403, the first coil of the third-phase winding 406 of the second sub-motor 412, and the first coil of the third-phase winding 409 of the third sub-motor 413. As described above, the printed circuit board on the second lead frame 702 has a circuit board layer corresponding to the third circuit board layer, and the conductive layer on this circuit board layer is arranged to be electrically coupled to the V-phase inverter bus of the second inverter and is electrically coupled to the coil windings 60 corresponding to the second group of coil windings 60 installed on the stator. As Figure 10As shown, the busbar of the V-phase inverter 310 is coupled to the third circuit board layer through the busbar lead frame pin 1010, which is a cylindrical conductive element coupled to the busbar of the V-phase inverter 310 and extends through the relevant lead frame 255 pinhole 660 formed in the printed circuit board. The V-busbar lead frame pin 1010 is arranged to be electrically coupled to the third conductive layer 1200 of the printed circuit board at position 1210. In order to couple the first coil of the third-phase winding 403 of the first sub-motor 411, the first coil of the third-phase winding 406 of the second sub-motor 412, and the first coil of the third-phase winding 409 of the third sub-motor 413 to the third conductive layer, the ends of the relevant coils are arranged as described above, in the groove 640 formed within the inner and outer radial edges of the lead frame 255. The ends of the coil windings 60 installed in the grooves formed at 1220, 1230, and 1240 of the lead frame 255 are electrically coupled to the third conductive layer. The other ends of the first coils of the third-phase windings of the first, second, and third sub-motors, as well as the ends of the remaining coil windings 60, are installed in their respective grooves formed within the inner and outer radial edges of the lead frame 255 and are electrically isolated from the third conductive layer.

[0086] The printed circuit board includes a fourth circuit board layer having a fourth conductive layer 1310, a fifth conductive layer 1320, and a sixth conductive layer 1330, as Figure 13 shown, where the fourth conductive layer 1310, the fifth conductive layer 1320, and the sixth conductive layer 1330 together extend over the first half circumferential portion of the annular circuit board. The fourth conductive layer 1310, the fifth conductive layer 1320, and the sixth conductive layer 1330 are electrically isolated from each other.

[0087] The fourth conductive layer 1310 is arranged to be electrically coupled to the last coil of the first-phase winding 401 of the first sub-motor 411, the last coil of the second-phase winding 402 of the first sub-motor 411, and the last coil of the third-phase winding 403 of the first sub-motor 411. A neutral point (i.e., star point) is formed between the first coil winding 60401, the second coil winding 60402, and the third coil winding 60403 of the first sub-motor 411. In order to couple the last coil of the first-phase winding 401 of the first sub-motor 411, the last coil of the second-phase winding 402 of the first sub-motor 411, and the last coil of the third-phase winding 403 of the first sub-motor 411, the ends of the relevant coils are mounted on the inner and outer radial edges of the lead frame 255 formed as described above, where the ends of the coil winding 60 mounted in the grooves formed in the outer radial edge of the lead frame 255 are electrically coupled to the fourth conductive layer 1310 at 1311, 1312, and 1313. The other end of the last coil of the first-phase winding 401 of the first sub-motor 411, the last coil of the second-phase winding 402 of the first sub-motor 411, the last coil of the third-phase winding 403 of the first sub-motor 411, and the ends of the remaining coil windings 60 are mounted in the corresponding grooves formed therein. The inner radial edge and the outer radial edge of the lead frame 255 are electrically isolated from the fourth conductive layer 1310.

[0088] The fifth conductive layer 1320 is arranged to be electrically coupled to the last coil of the first-phase winding 404 of the second sub-motor 412, the last coil of the second-phase winding 405 of the second sub-motor 412, and the last coil of the third-phase winding 406 of the second sub-motor 412. A neutral point (i.e., star point) is formed between the first coil winding 60404 of the second sub-motor 412, the second coil winding 60405 of the second sub-motor 412, and the third coil winding 60405 of the second sub-motor 412. In order to couple the last coil of the first-phase winding 404 of the second sub-motor 412, the last coil of the second-phase winding 405 of the second sub-motor 412, and the last coil of the third-phase winding 406 of the second sub-motor 412, the ends of the relevant coils are arranged to be mounted on the inner and outer radial edges of the lead frame 255 as described above, wherein the ends of the coil windings 60 mounted in the grooves formed within the outer radial edge of the lead frame 255 are electrically coupled to the fifth conductive layer 1320 at 1321, 1322, 1323. The other end of the last coil of the first-phase winding 404 of the second sub-motor 412, the last coil of the second-phase winding 405 of the second sub-motor 412, the last coil of the third-phase winding 406 of the second sub-motor 412, and the ends of the remaining coil windings 60, which are mounted in the corresponding grooves 640 formed to thin the inner and outer radial edges of the lead frame 255, are electrically isolated from the fifth conductive layer 1320. The sixth conductive layer 1330 is arranged to be electrically coupled to the last coil of the first-phase winding 407 of the third sub-motor 413, the last coil of the second-phase winding 408 of the third sub-motor 413, and the last coil of the third-phase winding 409 of the third sub-motor 413. A neutral point (i.e., star point) is formed between the first coil winding 60407 of the third sub-motor 413, the second coil winding 60408 of the third sub-motor 413, and the third coil winding 60409 of the third sub-motor 413.

[0089] The printed circuit board of the second lead frame 702 has a circuit board layer structure identical to that of the fifth circuit board layer for connecting the corresponding coils of the second set of coil windings 60, thereby forming a second set of sub-motors.

[0090] To couple the last coil of the first-phase winding 401 of the first sub-motor 411, the last coil of the second-phase winding 402 of the first sub-motor 411, and the last coil of the third-phase winding 403 of the first sub-motor 411, the ends of the relevant coils are mounted on the inner and outer radial edges formed in the lead frame 255 as described above. Specifically, the ends of the coil winding 60 within the groove formed within the outer radial edge of the lead frame 255 are electrically coupled to the fourth conductive layer 1310 at 1311, 1312, and 1313. Another end of the last coil of the first-phase winding 407 of the third sub-motor 413, the last coil of the second-phase winding 408 of the third sub-motor 413, the last coil of the third-phase winding 409 of the third sub-motor 413, and the ends of the remaining coil winding 60, which are mounted in the corresponding respective grooves 640, are electrically isolated from the sixth conductive layer 1330 at the inner and outer radial edges of the lead frame 255.

[0091] The printed circuit board includes a fifth circuit board layer that has Figure 14 the multiple conductive layers shown, for electrically coupling the coils 400 that form the first-phase winding 401 of the first sub-motor 411, the coils 400 that form the second-phase winding 402 of the first sub-motor 411, and the coils 400 that form the third-phase winding 402 of the first sub-motor 411. Relative to the second sub-motor, the multiple conductive layers are arranged for electrically coupling the coils 400 that form the first-phase winding 404 of the second sub-motor 412, the coils 400 that form the second-phase winding 405 of the second sub-motor 412, and the coils 400 that form the third-phase winding 406 of the second sub-motor 412. Relative to the third sub-motor, the multiple conductive layers are arranged to electrically couple the coils 400 that form the first-phase winding 407 of the third sub-motor 413, the coils 400 that form the second-phase winding 408 of the third sub-motor 413, and the coils 400 that form the third-phase winding 409 of the third sub-motor 413.

[0092] The multiple conductive layers on the fifth circuit board layer are arranged to allow the multiple coils of each respective coil subgroup to be coupled, such that each coil within the coil winding 60 generates a magnetic field that is anti-parallel to its adjacent coil in a given current direction and has a common phase.

[0093] The second printed circuit board includes a circuit board layer corresponding to the fifth circuit board layer, the circuit board layer having a plurality of conductive layers, the plurality of conductive layers being arranged to electrically couple a first coil winding 60, a second coil winding 60, and a third coil winding 60 of a second set of coil windings 60, a first-phase winding, a second-phase winding, and a third-phase winding; the first-phase winding, the second-phase winding, and the third-phase winding each include a plurality of coils, and the plurality of conductive layers are arranged to allow the plurality of coils of each corresponding phase winding to be coupled relative to each other so that each sub-group of coils generates a magnetic field that is antiparallel to adjacent coils in a given current direction and has a common phase. The connection of the circuit board layer corresponding to the fifth circuit board layer of the second printed circuit board to the second set of coil windings 60 is a mirror image of the connection of the fifth circuit board to the first coil winding 60.

[0094] Among the plurality of conductive layers formed on the fifth printed circuit board layer, two conductive layers 1501, 1502 are used to form a coupling coil 400 of a first-phase winding 401 of a first sub-motor 411, two conductive layers 1503, 1504 are used to form a coupling coil 400 of a second-phase winding 402 of the first sub-motor 411, and two conductive layers 1505, 1506 are used to couple a coil 400 forming a third-phase winding 403 of the first sub-motor 411. In the second sub-motor, two conductive layers 1507, 1508 are used to form a coupling coil 400 of a first-phase winding 404 of the second sub-motor 412, two conductive layers 1509, 1510 are used to couple a coil 400 forming a phase winding 405 of the second sub-motor 412 of the second sub-motor 412, and two conductive layers 1511, 1512 are used to couple a coil 400 that forms a third-phase winding 406 of the second sub-motor 412. For the third sub-motor, two conductive layers 1513, 1514 are used to form a coupling coil 400 of a first-phase winding 407 of the third sub-motor 413, two conductive layers 1515, 1516 are used to couple. A coil 400 forming a second-phase winding 408 of the third sub-motor 413 and two conductive layers 1517, 1518 are used to couple a coil 400 that forms a third-phase winding 409 of the third sub-motor 413. As described above, one end of a first coil of a coil group forming a first-phase winding 401 of a first sub-motor 411 is mounted in a groove 640 at a position 920 formed on an inner radial edge of a lead frame 255. Electrically coupled to a first conductive layer 900 formed on a first circuit board layer while being electrically isolated from any other conductive layers on other circuit board layers. The other end of the first coil is mounted in a relative groove formed on an outer radial edge of the lead frame 255 at a position 950 and is electrically coupled to a conductive layer 1502 on the fifth circuit board layer.

[0095] One end of the second coil of the coil group forming the first-phase winding 401 of the first sub-motor 411 is mounted in the groove at the position 951 formed at the outer radial edge of the lead frame 255 and is electrically coupled to the layer 1502 on the conductive fifth circuit board layer, so that the second coil is electrically connected to the W-phase bus bar pin through the first coil. The other end of the second coil is mounted in the opposite groove, which is formed at the position 952 on the inner radial edge of the lead frame 255 and is electrically coupled to the conductive layer 1501 on the fifth circuit board layer, and the conductive layer 1501 is electrically isolated from the conductive layer 1502. One end of the third coil of the coil group forming the first-phase winding 401 of the first sub-motor 411 is mounted in the groove at the position 953 formed at the inner radial edge of the lead frame 255 and is electrically coupled to the layer 1501 on the conductive fifth circuit board layer, so that the third coil is electrically connected to the W-phase bus bar pin through the first and second coils. The other end of the third coil is mounted in the opposite groove formed at the outer radial edge of the lead frame 255 at the position 954 and is electrically connected to the fourth conductive layer 1310 on the fourth circuit board layer for coupling the third coil to the corresponding coils for forming the second-phase winding 402 and the third-phase winding 403 of the first sub-motor 411.

[0096] The next group of two conductive layers 1503, 1504 on the fifth circuit board layer are used to couple the coils 400 forming the second-phase winding 402 of the first sub-motor 411 to the V-phase bus bar pin, and the next group of two conductive layers 1505, 1506 on the fifth circuit board layer are used to couple the coils 400 forming the third-phase winding 403 of the first sub-motor 411 to the U-phase bus bar pin. The next group of two conductive layers 1507, 1508 on the fifth circuit board layer are used to couple the coils 400 forming the first-phase winding 404 of the second sub-motor 412 to the W-phase bus bar pin of the next group of two conductive layers 1509, 1510 on the fifth circuit board layer are used to couple the coils 400 forming the second-phase winding 405 of the second sub-motor 412 to the V-phase bus bar pin, and the next group of two conductive layers 1511, 1512 on the fifth circuit board layer are coupled to couple the coils 400 forming the third-phase winding 406 of the second sub-motor 412 to the U-phase bus bar pin. The next group of two conductive layers 1513, 1514 on the fifth circuit board layer are used to couple the coils 400 forming the first-phase winding 407 of the third sub-motor 413 to the W-phase bus bar pin of the next group of two conductive layers 1515, 1516 on the fifth circuit board layer are used to couple the coils 400 forming the second-phase winding 408 of the third sub-motor 413 to the V-phase bus bar pin, and the next group of two conductive layers 1517, 1518 on the fifth circuit board layer are coupled to couple the coils 400 forming the third-phase winding 409 of the third sub-motor 413 to the U-phase bus bar pin.

[0097] Now, the electrical connections for coupling the W, U, V phase busbar pins and the corresponding coils to the lead frame 255 will be described. For the electrical connections for coupling the phase busbar pins 1010 to the corresponding conductive layers printed on the circuit board layer of the lead frame 255, the conductive sleeves 1600 are inserted into the corresponding holes formed in the lead frame 255 of the W, U, V phase busbar pins 1010, as Figure 15 shown. When the W, U, V phase busbar pins are inserted into the corresponding conductive sleeves 1600, the phase busbar pins 1010 are arranged to be in electrical contact with the sleeves 1600. To improve the electrical contact between the pins 1010 and the sleeves 1600, solder or other conductive materials can be used.

[0098] For any conductive layer formed on the corresponding circuit board layer that needs to be electrically connected to the phase busbar pins 1010, the corresponding conductive layer is arranged to extend and be in electrical contact with the conductive sleeve 1600. For any conductive layer formed on each circuit board layer that is electrically isolated from the phase busbar pins 1010, each conductive layer is arranged to be electrically isolated from the conductive sleeve 1600. For example, referring to Figure 15 , the lead frame 255 includes ten circuit boards. The first two circuit board layers 1611, 1612 correspond to the first circuit board layer for coupling the W busbar lead frame pins to the lead frame 255 as described above. The next two circuit board layers 1613, 1614 correspond to the second circuit board layer for connecting the U busbar lead frame pins to the lead frame 255. The next two circuit board layers 1615, 1616 correspond to or apply to the third circuit board layer for coupling the V busbar lead frame pins to the lead frame 255. The next two circuit board layers 1617, 1618 correspond to the fourth circuit board layer for coupling the first phase winding, the second phase winding, and the third phase winding of each sub-motor. The next two circuit board layers 1619, 1620 correspond to the fifth circuit board layer for coupling the coils of each phase winding. As Figure 15 shown, the first conductive layer on the first two circuit board layers 1611, 1612 is in contact with the conductive sleeve for coupling the W busbar lead frame pins to these two conductive layers. In contrast, the conductive layers printed on the other circuit board layers are electrically isolated from the conductive sleeve.

[0099] Although this embodiment uses the conductive sleeve 1600 to electrically couple the bus bar lead frame pins 1010 to the lead frame 255, any mechanism can be used to couple the corresponding inverter legs to the lead frame 255. Regarding the respective end portions of the coils, an arrangement similar to the coil used to electrically couple the phase bus bar pins 1010 can be used to electrically couple the respective end portions of the coil 400 to the desired conductive layer printed on one or more circuit board layers, where the semi-circular conductive sleeve is placed in the respective grooves formed in the inner radial edge and the outer radial edge of the lead frame 255. Alternatively, the ends of the respective coils 400 can be directly placed in the grooves 640 formed in the inner radial edge and the outer radial edge of the lead frame 255, and a conductive material is placed between the ends of the coil and the associated conductive layer for improving the conductivity between the ends of the respective coils and the conductive layer, which are electrically connected to the conductive layer. A preferred process for mounting the ends of the coil 400 in the inner radial groove 640 and the outer radial groove 640 of the lead frame 255 will now be described.

[0100] Before mounting the lead frame 255 to the stator core 600, the ends of the coils are arranged to extend radially away from the stator core 600 and are in the same plane as the axial mounting surface of the stator core 600. In this configuration, the ends of the coils on the outer radial edge of the stator core 600 are arranged to extend radially away from the center of the stator core 600 and the ends of the coils. The inner radial edge of the stator core 600 is arranged to extend radially towards the center of the stator core 600. Preferably, by using heat studs, the grooves formed in the inner radial edge and the outer radial edge of the lead frame 255 are arranged to align with the ends of the coils, such that the respective grooves 640 formed in the inner and outer diameters are positioned on the respective end sections of the coils of the lead frame 255. Where Figure 16 A coil end 1610 is shown that extends radially, and then the ends of the respective coils are rotated 90 degrees to extend into the printed circuit board grooves and the lead frame 255 grooves 640 located above the respective ends of the coils, resulting in the coil end 1620 extending axially. Any device can be used to rotate the ends into the respective grooves formed in the inner radial edge and the outer radial edge of the lead frame 255. Figure 17 A portion of the stator core is shown, showing six coils 400, the respective ends of which extend into the inner radial grooves 640 and the outer radial grooves 640 formed in the lead frame 255 for coupling the respective coils to the lead frame 255. To improve the electrical contact between the ends of the respective coils and the lead frame 255, solder or some other conductive material can be used between the ends of the coils and the lead frame 255. For this embodiment, since each portion of the lead frame 255 forms only a semi-circular portion, this has the advantage of reducing the manufacturing cost of the entire lead frame 255 arrangement compared to the manufacturing cost of a single circular lead frame 255.

[0101] Example 2

[0102] The lead frame of this embodiment is a complete circumferential frame, on which there is a circumferential printed circuit board. Each conductive layer of each circuit board layer on the circumferential printed circuit board includes two semi-circular conductive layers. One of the two semi-circular conductive layers is used to connect with the first controller, the first inverter, and the first group of coil windings 60 to form the sub-motor 1 / 2 / 3; the other is used to connect with the second controller, the second inverter, and the second group of coil windings 60 to form the sub-motor 4 / 5 / 6; and the two conductive layers are electrically isolated from each other in different regions of the circuit board layer. The stator includes a single flexible printed circuit board 500, where the flexible printed circuit board 500 is annular. The flexible printed circuit board 500 includes six temperature sensors 503 mounted on the substrate of the flexible printed circuit board 500.

[0103] Example 3

[0104] The difference between this embodiment and Embodiment 1 is that in order to allow for increased current and thus increased torque, one or more circuit board layers can be replicated. In this embodiment, the printed board further includes a sixth circuit board layer, and the sixth circuit board layer includes a ninth conductive layer, and the structure of the sixth circuit board layer is the same as that of the first circuit board layer; it also includes a seventh circuit board layer, and the seventh circuit board layer includes a tenth conductive layer, and the structure of the tenth circuit board layer is the same as that of the second circuit board layer; it also includes an eighth circuit board layer, and the eighth circuit board layer includes an eleventh conductive layer, and the structure of the eighth circuit board layer is the same as that of the third circuit board layer; it also includes a ninth circuit board layer, and the ninth circuit board layer includes a twelfth conductive layer, and the structure of the ninth circuit board layer is the same as that of the fourth circuit board layer; the printed circuit board further includes a tenth circuit board layer, and the tenth circuit board layer includes multiple conductive layers, and the function of the tenth circuit board layer is the same as the structure of the fifth circuit board layer. Therefore, the first circuit board layer is replaced by two circuit board layers having the same configuration as the first circuit board layer, thereby doubling the conductive area provided by the first circuit board. Similarly, the second circuit board layer is replaced by two circuit board layers having the same configuration as the second circuit board layer, the third circuit board layer is replaced by two circuit board layers having the same configuration as the third circuit board layer, the fourth circuit board layer is replaced by two circuit board layers having the same configuration as the fourth circuit board layer, and the fifth circuit board layer is replaced by two circuit board layers having the same configuration as the fifth circuit board layer.

[0105] Example 4

[0106] Compared with Embodiment 1, it has the following differences. To improve current flow, if there are portions of the conductive layer on one or more printed circuit board layers, these portions of the conductive layer can be isolated from the rest of the conductive layer and used as additional current paths for the conductive layer on other printed circuit board layers when current flow is not required. For example, since the right portion of the conductive layer 900 on the first printed circuit board is not required for current flow between the W-phase bus bar pin and the first-phase windings of the first, second, and third sub-motors, this portion of the conductive layer can be used to support current flow in other conductive layers. In this embodiment, this portion of the first conductive layer is electrically isolated from the rest of the first conductive layer and is used to support current flow in the sixth conductive layer on the fourth printed circuit board layer.

[0107] Embodiment 5

[0108] This embodiment provides a motor or a generator, including the stator of Embodiment 1.

[0109] In summary, the above are only the preferred embodiments of the present invention. All equivalent changes and modifications made according to the scope of the patent application of the present invention shall fall within the scope covered by the patent of the present invention.

Claims

1. Stator, characterized in that It includes a flexible printed circuit board which comprises a first part and a second part. A temperature sensor is surface-mounted on the first part, and the communication line of the temperature sensor extends to the second part. The second part is used to connect to the control device of the motor stator, and the temperature sensor can be electrically connected to the control device of the stator through the second part; The first part is used to connect to the coil winding of the stator; The second part extends radially in a direction away from the first part; the flexible printed circuit board is composed of two semi-circular flexible printed circuit boards. Each semi-circular flexible printed circuit board includes a first part and a second part, and each semi-circular flexible printed circuit board is provided with a sensor for measuring the temperature of the winding coil; The stator further includes a lead frame and a circumferential support for mounting the winding coil. A plurality of stator teeth are provided on the circumferential side surface of the circumferential support. The coil winding of the stator is mounted on the stator teeth. The first part of the flexible printed circuit board is mounted between the lead frame and the circumferential support. The upper end surface of the first part is in contact with the lower end surface of the lead frame, and the lower end surface of the first part is in contact with the upper end surface of the circumferential support. The lead frame includes a printed circuit board having a plurality of circuit board layers. The temperature sensor is mounted on the end surface of the first part close to the coil winding. A jack for the second part of the flexible printed circuit board to pass through is provided on the lead frame. The second part passes through the jack after being bent; the end of the coil winding passes through the flexible printed circuit board and is electrically connected to the lead frame; the cross-sectional shape of the first part of the flexible printed circuit board is substantially the same as the cross-sectional shape and size of the lead frame; the lead frame is an integral circular shape, or two semi-circular lead frames are assembled into an integral circular lead frame.

2. The stator according to claim 1, characterized in that: Each circuit board layer of the printed circuit board includes an insulating substrate; a conductive layer is formed on the insulating substrate; the printed circuit board has at least a first circuit board layer, a second circuit board layer, a third circuit board layer, and a fourth circuit board layer; the first circuit board layer includes a first conductive layer which is arranged to be electrically coupled to the first coil winding of the first group of coil windings and the first branch of the first inverter; the second circuit board layer includes a second conductive layer which is arranged to be electrically coupled to the second coil winding of the first group of coil windings and the second branch of the first inverter; the third circuit board layer includes a third conductive layer which is arranged to be electrically coupled to the third coil winding of the first group of coil windings and the third branch of the first inverter; the fourth circuit board layer includes a fourth conductive layer having multiple conductive layers, and the fourth conductive layer is arranged to be coupled to the first coil winding, the second coil winding, and the third coil winding of the first group of coil windings to form a neutral point between the first coil winding, the second coil winding, and the third coil winding.

3. The stator according to claim 2, characterized in that: The first coil winding, the second coil winding, and the third coil winding each include three coil subgroups, namely the first-phase winding, the second-phase winding, and the third-phase winding; the printed circuit board further includes a fifth circuit board layer, and the fifth circuit board layer has a plurality of conductive layers, and the plurality of conductive layers are arranged to electrically couple the first-phase winding, the second-phase winding, and the third-phase winding of the first coil winding, the second coil winding, and the third coil winding; the first-phase winding, the second-phase winding, and the third-phase winding each include a plurality of coils, and the plurality of conductive layers on the fifth circuit board are arranged to allow the plurality of coils for each corresponding phase winding to be coupled relative to each other, so that each coil subgroup coil generates a magnetic field that is antiparallel to the adjacent coil in a given current direction and has a common phase at the same time.

4. The stator according to claim 3, wherein: The printed circuit board further includes a set of circuit board layers identical to those of claim 3 for electrically connecting to a second set of three sub-motors formed by the second set of coil windings, and this set of circuit board layers is electrically isolated from the circuit board layers described in claim 3.

5. Electric motor, characterized in that: Including the stator according to any one of claims 1 to 4, a plurality of grooves are formed on the inner and outer edges of the printed circuit board, and each groove is arranged to receive a respective coil winding for electrically coupling the coil winding to the printed circuit board.

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