A connection structure of a lead frame and a winding coil

Abstract

The application relates to the field of electric machines, and discloses a connecting structure of a lead frame and winding coils, which comprises a lead frame for placing a printed circuit board with multiple circuit board layers, and a stator core perpendicular to the axis of a rotating shaft of a generator or a motor, wherein the circumferential side surface of the stator core is uniformly provided with stator teeth, a first coil winding, a second coil winding and a third coil winding are installed on the stator teeth, and the two coil ends of the first coil winding, the second coil winding and the third coil winding extend radially outward or inward along the stator core, the coil ends of the first coil winding, the second coil winding and the third coil winding are finally arranged in grooves formed in the lead frame by rotating the coil ends from the radial direction to the axial direction, and the coil ends of the first coil winding, the second coil winding and the third coil winding are coupled to the lead frame.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of electric machines, and in particular to a connection structure of a lead frame and a winding coil. BACKGROUND

[0002] Electric motor systems typically include an electric motor, a control unit of which is arranged to control the power of the electric motor. Known electric machine types include induction machines, synchronous brushless permanent magnet machines, switched reluctance machines and linear machines. As high torque is required for driving a vehicle, the most commonly used electric motor is a three-phase electric motor. A three-phase electric motor typically includes three coil windings, each of which is arranged to generate a magnetic field associated with one of the three phases of an alternating voltage. To increase the number of magnetic poles formed within the electric machine, each coil winding typically has a number of coil sub-groups distributed around the electric machine, which are driven to generate a rotating magnetic field. Chinese patent CN201710715959.7 provides a three-phase permanent magnet brushless DC hub motor.

[0003] As shown in Figure 1 A typical three-phase electric motor has three coil groups 14, 16, 18. Each coil group is composed of four coil sub-groups in series, wherein, for a given coil group, the magnetic field generated by each coil sub-group will have a common phase. The three coil groups of a three-phase electric motor are typically configured in a delta or star configuration. The control unit of a three-phase electric motor with a direct current power supply typically includes an inverter driving the electric machine to generate a three-phase power supply. Each respective voltage phase is applied to a respective coil group of the electric motor. A three-phase bridge inverter includes a number of switching devices, such as power electronic switches, for example insulated gate bipolar transistor (IGBT) switches, for generating an alternating voltage from a direct current power supply. In the context of electric vehicle motors, an increasingly popular drive design is an electric machine design integrated within a vehicle wheel, in which the electric machine and its associated control system are integrated within the vehicle wheel. However, due to the space constraints within the vehicle wheel in which the electric motor and its associated control system are integrated, this can have an impact on the power generation capability of the electric motor. The present application provides an electric machine lead frame that can provide a large current. SUMMARY

[0004] The present application provides a connection structure of a lead frame and a winding coil according to the defect that the existing hub motor cannot provide large torque.

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

[0006] A connection structure of a lead frame and winding coils, comprising a lead frame in which a printed circuit board having a plurality of circuit board layers is disposed, each circuit board layer including an insulating substrate and a conductive layer formed on the insulating substrate, the circuit board layers including 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 including a first conductive layer arranged to be electrically coupled to a first coil winding of a first set of coil windings and a first leg of a first inverter, the second circuit board layer including a second conductive layer arranged to be electrically coupled to a second coil winding of the first set of coil windings and a second leg of the first inverter, the third circuit board layer including a third conductive layer arranged to be electrically coupled to a third coil winding of the first set of coil windings and a third leg of the first inverter, the fourth circuit board layer including a fourth conductive layer having a plurality of conductive layer structures configured 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, further comprising a circumferential support perpendicular to an axis of rotation of a generator or motor, the neutral point being located on a surface of the circumferential support, the circumferential support having stator teeth evenly distributed on a circumferential side of the circumferential support, the first coil winding, the second coil winding, and the third coil winding being mounted on the stator teeth, the coil ends of the first coil winding, the second coil winding, and the third coil winding extending radially outward from the circumferential support to ultimately rotate the coil ends of the first coil winding, the second coil winding, and the third coil winding from a radial direction to an axial direction to ultimately form the coil ends of the first coil winding, the second coil winding, and the third coil winding within a groove formed in the lead frame and couple the coil ends of the first coil winding, the second coil winding, and the third coil winding to the lead frame.

[0007] As a preference, the ends of the first coil winding are mounted in the groove of the lead frame such that the first coil winding is electrically connected to the first conductive layer.

[0008] As a preference, the ends of the second coil winding are mounted in the groove of the lead frame such that the second coil winding is electrically connected to the second conductive layer.

[0009] As a preference, the ends of the third coil winding are mounted in the groove of the lead frame such that the third coil winding is electrically connected to the third conductive layer.

[0010] As a preference, the lead frame is in a single circumferential shape or two half circumferential shapes that are pieced together to form a single circumferential shape.

[0011] As a preference, the circumferential support includes a means for positioning the lead frame at a predetermined location on the circumferential support, the ends of the first coil winding, the second coil winding, and the third coil winding being adjacent to the groove in the lead frame to allow the lead frame to couple the individual coil windings into a multi-phase coil winding.

[0012] As a preference, the means for positioning the lead frame on the circumferential support comprises a thermal stake, wherein the method further comprises melting the thermal stake when the lead frame has been mounted on the circumferential support to secure the lead frame to the circumferential support.

[0013] As a preference, the means for positioning the lead frame on the circumferential support comprises a thermal stake, wherein the method further comprises melting the thermal stake when the lead frame has been mounted on the circumferential support to secure the lead frame to the circumferential support.

[0014] As a preference, the means for positioning the lead frame on the circumferential support comprises a thermal stake, wherein the method further comprises melting the thermal stake when the lead frame has been mounted on the circumferential support to secure the lead frame to the circumferential support.

[0015] As a preference, the means for positioning the lead frame on the circumferential support comprises a thermal stake, wherein the method further comprises melting the thermal stake when the lead frame has been mounted on the circumferential support to secure the lead frame to the circumferential support.

[0016] The present invention, due to the adoption of the above technical solutions, has the following technical effects:

[0017] The present invention has the advantage of simplifying the manufacturing process of mounting the lead frame on the stator, the arrangement of the lead frame allows providing a large current between the inverter of the motor or generator and the coil winding, thereby generating a large torque and power value, while allowing reducing the space envelope of the motor / generator coil winding and inverter. BRIEF DESCRIPTION OF DRAWINGS

[0018] Figure 1 A three-phase motor of the prior art is illustrated;

[0019] Figure 2 An exploded view of a motor comprising the present invention is illustrated;

[0020] Figure 3 is a schematic view of a control device;

[0021] Figure 4 An electrical connection provided by a lead frame according to an embodiment of the present invention is illustrated;

[0022] Figure 5 A lead frame according to an embodiment of the present invention is illustrated;

[0023] Figure 6 A lead frame arrangement according to an embodiment of the present invention is illustrated;

[0024] Figure 7 A lead frame according to an embodiment of the present invention is illustrated;

[0025] Figure 8 A lead frame arrangement according to an embodiment of the present invention is illustrated;

[0026] Figure 9 FIG. 6 illustrates a conductive layer on a circuit board layer of a lead frame according to an embodiment of the present application;

[0027] Figure 10 FIG. 7 illustrates a lead frame according to an embodiment of the present application;

[0028] Figure 11 FIG. 8 illustrates a conductive layer on a circuit board layer of a lead frame according to an embodiment of the present application;

[0029] Figure 12 FIG. 9 illustrates a conductive layer on a circuit board layer of a lead frame according to an embodiment of the present application;

[0030] Figure 13 FIG. 10 illustrates a conductive layer on a circuit board layer of a lead frame according to an embodiment of the present application.

[0031] Figure 14 FIG. 11 illustrates a conductive layer on a circuit board layer of a lead frame according to an embodiment of the present application;

[0032] Figure 15 FIG. 12 illustrates a lead frame according to an embodiment of the present application;

[0033] Figure 16 FIG. 13 is a schematic diagram of a coil end cooperating with a lead frame according to an embodiment of the present application;

[0034] Figure 17 FIG. 14 illustrates a stator core, a coil winding, and a lead frame according to an embodiment of the present application;

[0035] Figure 18 FIG. 15 is a schematic diagram of a cooling structure according to an embodiment of the present application;

[0036] Figure 19 FIG. 16 is a schematic diagram of a structure of a stator coil winding and a stator core;

[0037] Figure 20 FIG. 17 is an exploded schematic diagram of a stator coil winding unit and a stator core. DETAILED DESCRIPTION

[0038] Embodiment 1

[0039] A connection structure of a lead frame and a winding coil includes a lead frame in which a printed circuit board having a plurality of circuit board layers is placed, and further includes a circumferential support 550 perpendicular to an axis of a rotating shaft of a generator or a motor, and a plurality of stator teeth 800 are uniformly distributed on a circumferential side surface of the circumferential support 550, and a first coil winding, a second coil winding, and a third coil winding are installed on the stator teeth 800, and coil end portions of the first coil winding, the second coil winding, and the third coil winding are extended radially outward of the circumferential support 550, and are finally rotated from a radial direction to an axial direction to be finally accommodated in grooves formed in the lead frame, and the coil end portions of the first coil winding, the second coil winding, and the third coil winding are coupled to the lead frame.

[0040] Specifically, Figure 16 A coil end portion 1610 is shown extending radially, and then the end portion of each coil is rotated 90 degrees to extend into a printed circuit board groove and a lead frame 255 groove 640 formed above each end portion of each coil, resulting in an axial extension of the coil end portion 1620. Any means can be used to rotate the end portion into the corresponding groove formed on the inner radial edge and the outer radial edge of the lead frame 255.

[0041] As Figure 17 A portion of the stator core is shown, showing six coils 400, each having a coil end portion extending into an inner radial groove 640 and an outer radial groove 640 formed in the lead frame 255 for coupling the respective coil to the lead frame 255. To improve electrical contact between the end portion of each coil and the lead frame 255, solder or some other conductive material can be used between the end portion of the coil and the lead frame 255.

[0042] The present embodiment provides a lead frame 255 for coupling an inverter of a motor or a generator to a direct current power source; the motor in the present embodiment is a hub motor for a vehicle wheel. As Figure 2 shown, the hub motor includes a stator 252 including a circumferential support as a heat sink 253, a plurality of coils 254, and two control devices 300 not shown, which are installed on the circumferential support 253 at the rear of the stator, for driving the coils. Capacitors and a lead frame 255 are installed between the axial edges of the coils 254 and the axial flanges formed on the circumferential support 253, for connecting the control devices to the coils 254. The coils 254 are embedded on the stator teeth 800 to form coil windings; a stator cover is installed at the rear of the stator 252, surrounding the control devices and the ring capacitors to form the stator 252, which is then fixed to the vehicle and does not rotate relative to the vehicle during use.

[0043] The stator includes a circumferential support and stator windings mounted on the circumferential support, the circumferential support being a stator core 600, the stator windings being comprised of stator winding units 550, the stator winding units 550 being teeth with coils wound thereon, each tooth having a tooth slot 801 formed therein, the circumferential support having a plurality of stator teeth 800 formed on an outer circumference thereof, the tooth slots 801 being interference fit within the stator teeth 800. In the present embodiment, the stator winding units 550 are 54 in number, with 2 sets of coil windings, each set of coil windings including 3 coil windings, each coil winding including 3 coil phase windings (subsets), each coil phase winding including 3 coils.

[0044] As shown in FIG. 3, each control device 300 includes an inverter 310, with one control device 300 including a controller regulator 320, in the present embodiment, the control device 300 includes a processor for controlling the operation of both inverters 310. As shown in FIG. 4, each control device 300 includes an inverter 310, with one control device including control logic 320, the control logic 320 including a processor in the present embodiment for controlling the operation of both inverters 310. As described below, each inverter is coupled to three sets of coil windings, the coil windings being electrically connected in parallel to form a set of three sub-machines. Figure 3 Figure 3 As shown in FIG. 3, each control device 300 includes an inverter 310, with one control device 300 including a controller regulator 320, in the present embodiment, the control device 300 includes a processor for controlling the operation of both inverters 310. As shown in FIG. 4, each control device 300 includes an inverter 310, with one control device including control logic 320, the control logic 320 including a processor in the present embodiment for controlling the operation of both inverters 310. As described below, each inverter is coupled to three sets of coil windings, the coil windings being electrically connected in parallel to form a set of three sub-machines.

[0045] A ring capacitor is coupled between the inverter 310 and the DC power supply for the motor to reduce voltage ripple on the motor power supply line, also known as the DC bus, and to reduce voltage overshoot during motor operation. To reduce inductance, the capacitor is mounted proximate the control device 300.

[0046] The magnets are proximate the coil windings on the stator 252, so the magnetic field generated by the coils interacts with the magnets 242 disposed on the inside of the cylindrical portion 221 of the rotor 240 to cause the rotor 240 to rotate. Since the permanent magnets 242 are used to generate the drive torque that drives the motor, the permanent magnets are commonly referred to as drive magnets. In the present embodiment, the motor includes six coil windings, each coil winding having three coil subsets, the coil subsets also being referred to as coil phase windings in the present embodiment; the three coil subsets are coupled in a Y configuration to form a three phase sub-machine, so the motor has six three phase sub-machines. As described below, the operation of each sub-machine is controlled by one of the two control devices 300. Although the present embodiment describes a motor having six coil windings (i.e., six sub-machines), the motor can equally have one or more coil sets with associated control devices. Likewise, each coil set can have any number of coil subsets, allowing each sub-machine to have two or more phases.

[0047] Figure 3 ​The connection between each coil set 60 and the control device 300 is illustrated, wherein three coil sets 60 are connected to a respective three-phase inverter 310 on the control device 300. As is well known to those skilled in the art, a three-phase inverter comprises six switches, wherein a three-phase alternating voltage can be generated by controlled operation of the six switches. However, the number of switches will depend on the number of voltage phases applied to the respective sub-machines, which can be built with any number of phases. Each control device 300 communicates with other control devices 300 via a communication bus.

[0048] One of the control devices 300 comprises a processor 320 for controlling the operation of the inverter switches in both control devices 300, and is also electrically connected to a temperature sensor 503 for receiving a signal from the temperature sensor 503 to determine whether the motor is operating within an acceptable temperature range. Furthermore, each control device 300 comprises an interface arrangement to allow communication between the control devices 300 via the communication bus 330, wherein one of the control devices 300 is arranged to communicate with a vehicle controller mounted externally to the motor.

[0049] The processor 320 is arranged to control the operation of the inverter switches mounted within each control device 300 to allow each motor coil set 60 to be supplied with a three-phase voltage supply to allow each coil sub-set to generate a rotating magnetic field. As mentioned above, although the present embodiment describes each coil set 60 as having three coil sub-sets, the present application is not limited as such and it will be appreciated that each coil set 60 can have one or more coil sub-sets.

[0050] Each three-phase bridge inverter 310 is arranged to provide pulse width modulated voltage control in the respective coil sub-sets under the control of the processor to generate a current in the respective coil sub-sets to provide the required torque for the respective sub-machines. PWM control works by exploiting the motor inductance to average the applied pulse voltage to drive the required current into the motor coil. With pulse width modulated control, the applied voltage is switched between the motor windings. During the voltage switching through the motor coil, the current in the motor coil rises at a rate determined by its inductance and the applied voltage. The pulse width modulated voltage control is switched off before the current rises above the required value, thereby allowing precise control of the current. For a given coil set, the three-phase bridge inverter 310 switches are arranged to apply a single voltage phase on each coil sub-set. Using PWM switching, multiple switches are arranged to apply an alternating voltage on each coil sub-set. The voltage envelope and phase angle of the electrical signal is determined by the modulated voltage pulses.

[0051] The inverter formed on one control device is coupled to three coil windings forming a first set of three sub-machines, and the inverter formed on the other control device is coupled to the other coil winding sets forming a second set of three sub-machines.

[0052] Two inverters 310 are coupled to their respective coil groups via lead frames 255, with each leg of each inverter 310 coupled to the lead frame 255 via its respective phase winding bus. For this embodiment, the different voltage phases generated by the three branches of the inverters are designated as W, V, and U. The coil windings are coupled to the lead frame 255 to allow current to flow from the DC power supply to the coil windings through the respective inverters 310 in the control unit, thereby allowing the motor to generate drive torque.

[0053] Figure 4 The diagram illustrates the electrical connection provided by lead frame 255 between the phase winding busbar of one of the control devices and the coil windings mounted on the stator, wherein lead frame 255 is arranged in a Y-configuration for coupling the phase windings of corresponding coil subgroups. However, lead frame 255 can be configured to couple the phase windings of corresponding coil subsets in different configurations. As described above, each coil winding comprises three coil subgroups (i.e., phase windings) to form a three-phase sub-motor. In this embodiment, the first, second, and third coil windings of the first group of coil windings correspond one-to-one with the first, second, and third sub-motors described below.

[0054] In this embodiment, each coil group forming the coil subgroup is formed by three separate coils coupled through the circuit board layer of the lead frame 255.

[0055] refer to 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 corresponds to a coil on a single stator tooth 800, wherein the end of each coil is arranged to couple with the lead frame 255 to achieve coil alignment. Figure 4 The configuration shown is coupled.

[0056] The lead frame 255 is used to connect the W-phase inverter bus 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 bus 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.

[0057] like Figure 4 As 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 coil 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 coil 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 coil 400 of the second phase winding 408 and the third phase winding 409 of the third sub-motor 413. These connections serve as star points for each sub-motor.

[0058] Furthermore, the lead frame 255 is arranged to electrically connect the individual coils 400 of each phase winding to form a series connection between the individual coils 400 of each phase winding. Accordingly, the lead frame 255 provides electrical connections between the W, V, and U phase inverter buses and their respective coils 400 to form a three-sub-motor driven by a single inverter 310, wherein the coil windings of the respective sub-motors are coupled in a Y-configuration.

[0059] Similarly, the lead frame 255 connects the phase winding bus of the inverter 310 of the other control device 300 and the coil 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.

[0060] The structure of the lead frame 255 will now be described, wherein in the first embodiment, as shown... Figure 5 As shown, a substantially circular lead frame 255 is used to supply current from two control devices to the corresponding coil groups.

[0061] The lead frame 255 includes a first set of three holes 660 for receiving corresponding bus lead frame pins for coupling the lead frame 255 to the inverter 310 in the first control device 300, and a second set of three holes 660 for receiving corresponding bus lead frame pins for coupling the lead frame 255 to the inverter 310 in the second set.

[0062] The lead frame 255 has fixing holes at predetermined positions, and hot posts 630 are inserted into the fixing holes. In this embodiment, the hot posts 630 are arranged at the ends of the teeth of the stator winding unit 550, close to the lead frame 255. The hot posts 630 are designed on the inner and outer sides of the stator winding unit 550 and are arranged to extend through the holes formed in the lead frame 255. Once the lead frame 255 is mounted on the stator core 600 and the respective hot posts 630 pass through the corresponding fixing holes formed in the lead frame 255, the hot posts 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.

[0063] like Figure 6 As 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 coil wound on the stator teeth 800 and for coupling the coil 400 to the lead frame 255, as described below, wherein for each coil wound on the stator teeth 800, a portion is installed in the groove 640 formed on the inner radial edge of the lead frame 255 and another portion is installed in the groove 640 formed on the outer radial edge of the lead frame 255.

[0064] A single circumferential lead frame 255 serves as a current path from each inverter 310 within the control device 300 to each coil winding, wherein the lead frame 255 is a basic circumferential printed circuit board having multiple circuit board layers. Each layer has a conductive layer printed on it. Each circuit board layer includes an insulating substrate on which the conductive layer is formed. In this embodiment, there are two inverters; in other words, half a circumference of the lead frame printed circuit board is allocated for coupling the first control device 300 to a set of coil windings to form a three-sub-motor formed by the first set of coil windings, and the other half a circumference of the lead frame printed circuit board is allocated for coupling the second control device 300 to a three-sub-motor formed by the second set of coil windings. The multiple circuit board layers are separated by their respective insulating substrates.

[0065] To allow large currents to flow from the inverters 310 to the coil windings, allowing the electric motor to produce sufficient torque to drive the vehicle, the conductive layers on each circuit board layer are arranged to extend across a substantial portion of each circuit board, with each conductive layer arranged to correspond to a particular circuit path between each inverter 310 and coil winding, and between different subsets of coils making up each sub-motor, so that each circuit board layer optimizes current flow.

[0066] To achieve Figure 4 The configuration of the printed circuit board layers and the conductive layers printed on the circuit board layers will now be described, with reference to the circuit configuration shown. Each circuit board layer includes two sets of electrical connections for coupling a first set of three coil windings to one inverter, and a second set of three coil windings to another inverter, although 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 of the coil windings mounted on the stator, the conductive layers printed on each circuit board layer would be arranged to form a particular circuit path between the inverter and the coil windings, and between different subsets of coils making up each respective sub-motor.

[0067] The lead frame 255 in this embodiment 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, forming a substantially circumferential lead frame 255 when mounted on the stator 252. As shown, Figure 8 Each lead frame 255 is mounted on an axial mounting surface of the stator core 600, which forms part of the stator 252, with the coil windings being wound around stator teeth 800 formed on the stator core 600.

[0068] Both the first lead frame 701 and the second lead frame 702 include a set of three holes 660 for receiving respective busbar 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.

[0069] The first lead frame 701 and the second lead frame 702 are mounted to the stator core 600 by connecting to hot posts 630 at predetermined positions. The hot posts 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 the respective hot posts 630 pass through their respective holes formed in the first lead frame 701 and the second lead frame 702, the hot posts 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.

[0070] like Figure 8 As 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 end portions of coils 400 wound on stator teeth 800 for coupling, the coils 400 being connected to the first lead frame 701 and the second lead frame 702 respectively. For each coil wound on 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.

[0071] The circuit board layer of the first printed circuit board on the first lead frame 701 is a mirror image of the circuit board layer of the second printed circuit board on the second lead frame 702. The first printed circuit board is responsible for the three sub-motors formed by the first group of coil windings (named first sub-motor, second sub-motor, and third sub-motor, or sub-motor 1 / 2 / 3), and the second printed circuit board is responsible for the three sub-motors formed by the second coil windings (named fourth sub-motor, fifth sub-motor, and sixth sub-motor, or sub-motor 4 / 5 / 6).

[0072] The following description uses the circuit board layer and circuit connection of the first lead frame as an example.

[0073] The first printed circuit board includes a first circuit board layer, the first circuit board layer having, as shown in the figure Figure 9The first conductive layer is shown extending substantially to a first half circumferential portion of the circumferential circuit board, the first half circumferential portion being arranged to be electrically coupled to the W-phase inverter 310 bus bar and to first coils of first phase windings 401 of first sub-machines 411, first coils of first phase windings 404 of second sub-machines 412 and first coils of first phase windings 407 of third sub-machines 413. As mentioned above, the printed circuit board on the second lead frame 702 has circuit board layers corresponding to the first circuit board layers, on which the conductive layers are arranged to be electrically coupled to the W-phase inverter bus bar of the second inverter and to corresponding coil windings of the second set of coil windings mounted on the stator.

[0074] As Figure 10 shown, the W-phase inverter 310 bus bar is coupled to the first circuit board layer by bus bar lead frame pins 1010, which are cylindrical conductive elements coupled to the W-phase inverter 310 bus bar, the bus bar lead frame pins 1010 extending through associated lead frame pin holes 660 formed in the printed circuit board. The W bus bar lead frame pins 1010 are electrically coupled to the first conductive layer 900 at positions 910. In order for the first coils of the first phase windings 401 of the first sub-machines 411, the first coils of the first phase windings 404 of the second sub-machines 412 and the first coils of the first phase windings 405 of the third sub-machines 413 to be coupled to the first conductive layer 900 at positions 920, 930, 940, the ends of the associated coil windings are mounted in grooves 640 formed in the inner and outer radial edges of the lead frame 255 as described above, wherein the ends of the coil windings are mounted in grooves 640 formed in the inner radial edge of the lead frame 255 at positions 920, 930, 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-machines and the ends of the remaining coil windings are mounted in respective grooves formed in the inner and outer radial edges of the lead frame 255 and are electrically isolated from the first conductive layer 900.

[0075] The first printed circuit board comprises a second circuit board layer having a second conductive layer as Figure 11The second conductive layer 1100 shown extends substantially into the first half-circumferential portion of the circumferential circuit board, which is arranged to be electrically coupled to the busbar of the U-phase inverter 310 and 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. The printed circuit board on the second lead frame 702 has a circuit board layer corresponding to the second circuit board layer, on which conductive layers are arranged to be electrically coupled to the U-phase inverter busbar of the second inverter and to the corresponding coil windings of the second set of coil windings mounted on the stator.

[0076] like Figure 10 As shown, the U-phase inverter 310 busbar is coupled to the second circuit board layer via busbar lead frame pins 1010. These busbar lead frame pins 1010 are cylindrical conductive elements coupled to the U-phase inverter 310 busbar, extending through the corresponding lead frame 255 pinholes 660 formed in the printed circuit board. The U-shaped busbar lead frame pins 1010 are electrically coupled to the second conductive layer 1100 at position 1110. 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 grooves 640 formed within the inner and outer radial edges of the lead frame 255. The ends of the coil windings installed in the grooves formed within the inner radial edge of the lead frame 255 are electrically coupled to the second conductive layer at positions 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, are installed in their respective grooves formed within the inner and outer radial edges of the lead frame 255, electrically isolated from the second conductive layer.

[0077] The printed circuit board includes a third circuit board layer 1200, the third circuit board layer having, as shown in... Figure 12 The third conductive layer shown extends substantially to a first half-circumferential portion of the circumferential circuit board, which is arranged to be electrically coupled to the V-phase inverter 310 bus and the first coil of the first 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. 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, on which the conductive layer is arranged to be electrically coupled to the V-phase inverter bus of the second inverter and to the corresponding coil windings of the second set of coil windings mounted on the stator.Figure 10 As shown, the V-phase inverter 310 bus is coupled to the third circuit board layer by bus lead frame pins 1010, which are cylindrical conductive elements coupled to the V-phase inverter 310 bus that extend through the associated lead frame 255 pin holes 660 formed in the printed circuit board. The V-bus lead frame pins 1010 are arranged to electrically couple to the third conductive layer 1200 of the printed circuit board at locations 1210. To couple the first coils of the third phase windings 403 of the first sub-motor 411, the first coils of the third phase windings 406 of the second sub-motor 412, and the first coils of the third phase windings 409 of the third sub-motor 413 to the third conductive layer, the ends of the associated coils are arranged as described above in the grooves 640 formed in the inner and outer radial edges of the lead frame 255, the ends of the coil windings mounted in the grooves formed in the lead frame 255 at 1220, 1230, 1240 are electrically coupled to the third conductive layer. The other ends of the first coils of the first, second, and third sub-motor third phase windings, as well as the ends of the remaining coil windings, are mounted in the respective grooves formed in the inner and outer radial edges of the lead frame 255 are electrically isolated from the third conductive layer.

[0078] 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 shown in Figure 13 wherein the fourth conductive layer 1310, the fifth conductive layer 1320, and the sixth conductive layer 1330 together extend over the first semicircumferential portion of the annular printed circuit board. The fourth conductive layer 1310, the fifth conductive layer 1320, and the sixth conductive layer 1330 are electrically isolated from one another.

[0079] The fourth conductive layer 1310 is arranged to electrically couple the last coil of the first phase winding 401, the last coil of the second phase winding 402 and the last coil of the third phase winding 403 of the first sub-motor 411. The first coil winding 401, the second coil winding 402 and the third coil winding 403 of the first sub-motor 411 form a neutral point (i.e. star point) therebetween. In order to electrically couple the last coil of the first phase winding 401, the last coil of the second phase winding 402 and the last coil of the third phase winding 403 of the first sub-motor 411, the ends of the relevant coils are mounted at the inner and outer radial edges of the leadframe 255 as described above, wherein the ends of the coil windings mounted within the grooves formed in the outer radial edge of the leadframe 255 are electrically coupled to the fourth conductive layer 1310 at 1311, 1312, 1313. The other ends of the last coil of the first phase winding 401, the last coil of the second phase winding 402 and the last coil of the third phase winding 403 of the first sub-motor 411 and the ends of the remaining coil windings are mounted in the respective grooves formed therein. The inner and outer radial edges of the leadframe 255 are electrically isolated from the fourth conductive layer 1310.

[0080] The fifth conductive layer 1320 is arranged to electrically 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 first coil winding 404 of the second sub-motor 412, the second coil winding 405 of the second sub-motor 412 and the third coil winding 405 of the second sub-motor 412 form a neutral point (i.e. star point) between them. In order to electrically 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 coil are arranged to be mounted in the inner and outer radial edges of the lead frame 255 as described above, wherein the ends of the coil winding mounted in the grooves formed in the outer radial edge of the lead frame 255 are electrically coupled to the fifth conductive layer 1320 at 1321, 1322, 1323. The other ends 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 and the last coil of the third phase winding 406 of the second sub-motor 412 and the ends of the remaining coil windings, which are mounted in the respective grooves 640 formed in the inner radial edge and the outer radial edge of the lead frame 255, are electrically isolated from the fifth conductive layer 1320. The sixth conductive layer 1330 is arranged to electrically couple 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. The first coil winding 407 of the third sub-motor 413, the second coil winding 408 of the third sub-motor 413 and the third coil winding 409 of the third sub-motor 413 form a neutral point (i.e. star point) between them.

[0081] The printed circuit board of the second lead frame 702 has the same circuit board layers as the fifth circuit board layer structure for connecting the respective coils of the second set of coil windings, thereby forming the second set of sub-motors.

[0082] 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 end portions of the relevant coils are mounted at the inner and outer radial edges of the leadframe 255 as described above, specifically the end portions of the coil windings mounted within the grooves formed in the outer radial edge of the leadframe 255 are electrically coupled with the fourth conductive layer 1310 at 1311, 1312, 1313. The other end portions 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 and the last coil of the third phase winding 409 of the third sub-motor 413 and the end portions of the remaining coil windings are mounted in the corresponding grooves 640 formed in the inner and outer radial edges of the leadframe 255 which are electrically isolated from the sixth conductive layer 1330.

[0083] The printed circuit board comprises a fifth circuit board layer having Figure 14 The plurality of conductive layers shown are arranged for electrically coupling the coils 400 forming the first phase winding 401 of the first sub-motor 411, the coils 400 forming the second phase winding 402 of the first sub-motor 411 and the coils 400 forming the third phase winding 402 of the first sub-motor 411. With respect to the second sub-motor, the plurality of conductive layers are arranged for electrically coupling the coils 400 forming the first phase winding 404 of the second sub-motor 412, the coils 400 forming the second phase winding 405 of the second sub-motor 412 and the coils 400 forming the third phase winding 406 of the second sub-motor 412. With respect to the third sub-motor, the plurality of conductive layers are arranged for electrically coupling the coils 400 forming the first phase winding 407 of the third sub-motor 413, the coils 400 forming the second phase winding 408 of the third sub-motor 413 and the coils 400 forming the third phase winding 409 of the third sub-motor 413.

[0084] The plurality of conductive layers on the fifth circuit board layer are arranged to allow the plurality of coils of each respective coil subgroup to be coupled such that each coil within a coil winding generates a magnetic field which is anti-parallel to its adjacent coils in a given current direction while having a common phase.

[0085] The second printed circuit board includes a circuit board layer corresponding to the fifth circuit board layer having a plurality of conductive layers arranged to electrically couple a first coil winding, a second coil winding, a first phase winding, a second phase winding, and a third phase winding of a third coil winding of the second set of coil windings; the first phase winding, the second phase winding, and the third phase winding each include a plurality of coils, the plurality of conductive layers arranged to allow the plurality of coils of each respective phase winding to couple relative to one another so that each coil sub-group of coils produces a magnetic field that is anti-parallel to an adjacent coil in a given current direction while having a common phase. The connection of the second printed circuit board to the circuit board layer corresponding to the fifth circuit board layer to the second set of coil windings is a mirror image of the connection of the fifth circuit board to the first coil winding.

[0086] Among the plurality of conductive layers formed on the fifth printed circuit board layer, two conductive layers 1501, 1502 are used to form coupled coils 400 of a first phase winding 401 of a first sub-motor 411, two conductive layers 1503, 1504 are used to form coupled coils 400 of a second phase winding 402 of the first sub-motor 411, and two conductive layers 1505, 1506 are used to couple coils 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 coupled coils 400 of a first phase winding 404 of a second sub-motor 412, two conductive layers 1509, 1510 are used to couple coils 400 forming a second phase winding 405 of the second sub-motor 412, and two conductive layers 1511, 1512 are used to couple coils 400 forming 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 coupled coils 400 of a first phase winding 407 of a third sub-motor 413, two conductive layers 1515, 1516 are used to couple coils 400 forming a second phase winding 408 of the third sub-motor 413, and two conductive layers 1517, 1518 are used to couple coils 400 forming a third phase winding 409 of the third sub-motor 413. As described above, one end of a first coil forming a coil group of the first phase winding 401 of the first sub-motor 411 is mounted in a groove 640 formed at a location 920 on an inner radial edge of the leadframe 255. The first coil is electrically coupled to a first conductive layer 900 formed on the first circuit board layer while being electrically isolated from any other conductive layer on other circuit board layers. The other end of the first coil is mounted in an opposing groove formed at a location 950 on an outer radial edge of the leadframe 255 and is electrically coupled to a conductive layer 1502 on the fifth circuit board layer.

[0087] One end of a second coil of the coil set forming the first phase winding 401 of the first sub-motor 411 is mounted in a recess formed at a location 951 at the outer radial edge of the leadframe 255 and is electrically coupled to a layer 1502 on the fifth conductive circuit board layer, thereby electrically connecting the second coil to the W-phase bus leg pin through the first coil. The other end of the second coil is mounted in an opposing recess formed at a location 952 on the inner radial edge of the leadframe 255 and is electrically coupled to a conductive layer 1501 on the fifth circuit board layer, which is electrically isolated from the conductive layer 1502. One end of a third coil of the coil set forming the first phase winding 401 of the first sub-motor 411 is mounted in a recess formed at a location 953 at the inner radial edge of the leadframe 255 and is electrically coupled to a layer 1501 on the fifth conductive circuit board layer, thereby electrically connecting the third coil to the W-phase bus leg pin through the first and second coils. The other end of the third coil is mounted in an opposing recess formed at a location 954 on the outer radial edge of the leadframe 255 and is electrically connected to a fourth conductive layer 1310 on the fourth circuit board layer for coupling the third coil to the respective coils forming the second phase winding 402 and the third phase winding 403 of the first sub-motor 411.

[0088] The next set 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 leg pin, and the next set 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 leg pin. The next set of two conductive 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 next set of two conductive layers 1509 of the W-phase bus leg pin, 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 leg pin, and the next set of two conductive layers 1511, 1512 on the fifth circuit board layer are coupled to be used to couple the coils 400 forming the third phase winding 406 of the second sub-motor 412 to the U-phase bus leg pin. The next set 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 next set of two conductive layers 1515 of the W-phase bus leg pin, 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 leg pin, and the next set of two conductive layers 1517, 1518 on the fifth circuit board layer are coupled to be used to couple the coils 400 forming the third phase winding 409 of the third sub-motor 413 to the U-phase bus leg pin.

[0089] The electrical connections for coupling the W, U, V phase bus pins and corresponding coils to the lead frame 255 will now be described. For the electrical connections for coupling the phase bus pins 1010 to the corresponding conductive layers printed on the circuit board layers of the lead frame 255, conductive sleeves 1600 are inserted into corresponding holes formed in the lead frame 255 for the W, U, V phase bus pins 1010 as shown in Figure 15 When the W, U, V phase bus pins are inserted into the corresponding conductive sleeves 1600, the phase bus 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 material can be used.

[0090] For any conductive layers formed on the corresponding circuit board layers that need to be electrically connected to the phase bus pins 1010, the corresponding conductive layers are arranged to extend and be in electrical contact with the conductive sleeves 1600. For any conductive layers formed on the various circuit board layers that are electrically isolated from the phase bus pins 1010, the various conductive layers are arranged to be electrically isolated from the conductive sleeves 1600. For example, referring to Figure 15 , the lead frame 255 includes ten circuit board layers of which the first two circuit board layers 1611, 1612 correspond to the first circuit board layers described above for coupling the W bus lead frame pins to the lead frame 255, the next two circuit board layers 1613, 1614 correspond to the second circuit board layers for coupling the U bus lead frame pins to the lead frame 255, the next two circuit board layers 1615, 1616 or alternatively correspond to the third circuit board layers for coupling the V bus lead frame pins to the lead frame 255, the next two circuit board layers 1617, 1618 correspond to the fourth circuit board layers for coupling the first phase windings, the second phase windings and the third phase windings of the various sub-motors, the next two circuit board layers 1619, 1620 correspond to the fifth circuit board layers for coupling the coils of the various phase windings. As shown in Figure 15 , the first conductive layers on the first two circuit board layers 1611, 1612 are in contact with the conductive sleeves for coupling the W bus 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 sleeves.

[0091] Although the present embodiment uses the conductive sleeve 1600 to electrically couple the busbar lead frame pin 1010 to the lead frame 255, any mechanism can be used to couple the corresponding inverter leg to the lead frame 255. With respect to the corresponding end portions of the coils, a similar arrangement as used for electrically coupling the busbar pin 1010 can be used to electrically couple the corresponding end portions of the coils 400 to the desired conductive layer printed on one or more layers of the circuit board, where a semi-circular conductive sleeve is placed within the corresponding groove formed in the inner and outer radial edges of the lead frame 255. Alternatively, the ends of the individual coils 400 can be placed directly within the grooves 640 formed in the inner and outer radial edges of the lead frame 255, with a conductive material placed between the ends of the coils and the associated conductive layer for improving the electrical conductivity between the ends of the individual coils and the conductive layer, which are electrically connected to the conductive layer. The preferred process for mounting the ends of the coils 400 in the inner and outer radial grooves 640 of the lead frame 255 will now be described.

[0092] Prior to 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 in the same plane as the axial mounting face 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 in the radial direction away from the center of the stator core 600. The inner radial edge of the stator core 600 is arranged to extend in the radial direction toward the center of the stator core 600. Preferably, the grooves formed in the inner and outer radial edges of the lead frame 255 are arranged to align with the ends of the coils by using the thermal stakes 310, such that the corresponding grooves 640 formed in the inner and outer radial edges are positioned over the corresponding end sections of the coils of the lead frame 255.

[0093] The present embodiment provides a configuration for cooling the lead frame and the coils, as Figure 18 As shown in FIG. 18, the lead frame 255 is mounted on the stator core 600 and the ends of the coils have been connected to the lead frame 255, the stator core 600 is arranged to be mounted to the stator heat sink 253. Preferably, the stator core 600 is mounted on the stator heat sink 253 via thermal drop mechanisms. To cool the stator core 600, the coils 400 and the lead frame 255, the lead frame has a cooling channel having a first section 1810 that extends along the stator teeth 800 and the inner axial edge of the stator core 600, and a second section 1820 that is arranged to extend in a radially outward direction that is parallel to the axial mounting face of the stator core 600 on which the lead frame is mounted.

[0094] As shown in FIG. 18, the lead frame 255 is mounted on the stator core 600 and the ends of the coils have been connected to the lead frame 255, the stator core 600 is arranged to be mounted to the stator heat sink 253. Preferably, the stator core 600 is mounted on the stator heat sink 253 via thermal drop mechanisms. To cool the stator core 600, the coils 400 and the lead frame 255, the lead frame has a cooling channel having a first section 1810 that extends along the stator teeth 800 and the inner axial edge of the stator core 600, and a second section 1820 that is arranged to extend in a radially outward direction that is parallel to the axial mounting face of the stator core 600 on which the lead frame is mounted. Figure 18The stator cross-sectional view is shown. In order to improve the thermal conductivity between the stator heat sink 253 and the lead frame 255, a potting material 1830 is placed between the heat sink 253 and the lead frame 255 and between the lead frame 255 and the stator coil 400. A commonly used potting material 1830 is one that is arranged to provide good thermal conductivity. One example of a suitable potting material is a ceramic filled epoxy; however, other types of potting materials can be used.

[0095] For this embodiment, since each lead frame 255 portion forms only a semi-circular portion, this has the advantage of reducing the manufacturing cost of the overall lead frame 255 arrangement compared to the manufacturing cost of a single circumferential lead frame 255.

[0096] Embodiment 2

[0097] This embodiment provides a generator or motor having the stator described in embodiment 1.

[0098] Embodiment 3

[0099] This embodiment provides a vehicle having the generator or motor described in embodiment 2.

[0100] In conclusion, the above description is only the preferred embodiment of the present application, any equivalent changes and modifications made according to the scope of the patent application of the present application shall belong to the scope of the patent of the present application.

Claims

1. A connection structure of a lead frame and a winding coil, comprising a lead frame on which a printed circuit board having a plurality of circuit board layers is placed, characterized by: Each circuit board layer includes an insulating substrate and a conductive layer formed on the insulating substrate, the circuit board layers include 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 arranged to electrically couple to a first coil winding of the first set of coil windings and a first leg of the first inverter; the second circuit board layer includes a second conductive layer arranged to electrically couple to a second coil winding of the first set of coil windings and a second leg of the first inverter; the third circuit board layer includes a third conductive layer arranged to electrically couple to a third coil winding of the first set of coil windings and a third leg of the first inverter; the fourth circuit board layer includes a fourth conductive layer arranged to couple 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; further comprising a circumferential support perpendicular to an axis of rotation of the generator or motor, the neutral point is located on a surface of the circumferential support, the circumferential support has stator teeth evenly distributed on a circumferential side of the circumferential support, the first coil winding, the second coil winding, and the third coil winding are mounted on the stator teeth, the coil ends of the first coil winding, the second coil winding, and the third coil winding extend radially outward from the circumferential support and eventually rotate from a radial direction to an axial direction to form the coil ends of the first coil winding, the second coil winding, and the third coil winding in grooves formed in a lead frame; the coil ends of the first coil winding, the second coil winding, and the third coil winding are coupled to the lead frame; the ends of the first coil winding are mounted in the grooves of the lead frame so that the first coil winding is electrically connected to the first conductive layer; the ends of the second coil winding are mounted in the grooves of the lead frame so that the second coil winding is electrically connected to the second conductive layer; the ends of the third coil winding are mounted in the grooves of the lead frame so that the third coil winding is electrically connected to the third conductive layer; the lead frame is a whole circumferential shape, or two half circumferential lead frames are spliced into a whole circumferential lead frame; wherein each coil winding includes a coil end that extends radially, and then the ends of each coil are rotated 90 degrees to extend into the printed circuit board grooves and lead frame grooves located above each end of the coil, thereby causing the coil ends to extend axially; any device can be used to rotate the ends into the corresponding grooves formed on the inner and outer radial edges of the lead frame; The circumferential support includes a device that positions the lead frame at a predetermined position on the circumferential support, the ends of the first coil winding, the second coil winding, and the third coil winding are adjacent to the grooves in the lead frame to allow the lead frame to couple the individual coil windings into a multi-phase coil winding; Also included are control devices, connections between each coil set and the control devices, wherein three coil sets are connected to respective three-phase inverters on the control devices, each control device is in communication with the control devices of the other coil sets through a communication bus, the control devices include a processor for controlling the operation of the inverter switches in the two control devices, the control devices are also electrically connected to temperature sensors.

2. The connection structure of a lead frame and a winding coil according to claim 1, characterized in that: The apparatus for positioning the leadframe on the circumferential support includes a heat stake, wherein the method further includes melting the heat stake when the leadframe has been mounted on the circumferential support to secure the leadframe to the circumferential support.

3. The lead frame and winding coil connection structure according to claim 1, characterized in that: Also included are electrically conductive sleeves, and placing the electrically conductive sleeves in respective grooves on the leadframe, the respective end portions of the coil windings are arranged to be mounted within the electrically conductive sleeves.

4. The lead frame and winding coil connection structure according to claim 1, characterized in that: Welding the end portions of the coil windings to the leadframe when the end portions of the coil windings have been placed in respective grooves formed in the leadframe.

5. The lead frame and winding coil connection structure according to claim 1, wherein: The grooves are formed in an inner edge and an outer edge of the printed circuit board, each groove is arranged to receive a respective coil winding for electrically coupling the coil winding to the printed circuit board. The grooves are formed in an inner edge and an outer edge of the printed circuit board, 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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