Flat wire hairpin stator structure and motor

Abstract

The present invention relates to a flat wire hairpin stator structure and a motor. The flat wire hairpin stator structure includes a stator core, a stator winding, and a bus bar; the stator core includes a core body, and a plurality of stator slots evenly spaced and axially extending along the inner circumferential wall surface of the core body; the stator winding includes multiple layers of flat wire conductors inserted into each stator slot, one end of each layer of flat wire conductor is an insertion end and the other end is a welding end; the multiple layers of flat wire conductors are bent circumferentially along the core body to respectively form a U-phase winding, a V-phase winding, and a W-phase winding, and the conductor lead-out wire and the conductor neutral wire of each parallel branch of each phase winding are both arranged at the welding end of the flat wire conductor; the bus bar includes a U-phase lead-out wire bus bar, a V-phase lead-out wire bus bar, a W-phase lead-out wire bus bar, and a neutral wire bus bar arranged at the welding end of the flat wire conductor; the layout of the multiple layers of flat wire conductors of the stator winding is simplified, and the overall volume of the flat wire hairpin motor is reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of motors, and particularly to a flat wire hairpin stator structure and a motor. Background Art

[0002] With the development of electric vehicle technology, the performance requirements for vehicle motors are getting higher and higher. While continuously pursuing high slot fill factor, high power density, and high torque density of motors, it has become very difficult for round wire motors to break through the bottleneck of the new performance requirements of current drive motors. The emergence of flat wire hairpin motors has achieved performance requirements that cannot be met by round wire motors. Flat wire hairpin motors have a high slot fill factor, high power density, as well as good heat dissipation performance and NVH performance, which can greatly reduce the height of the motor winding end, reduce the copper consumption, and lower the copper loss of the winding, thereby improving the efficiency of the vehicle drive motor.

[0003] However, due to the particularity of the stator winding structure and the difference in winding connection methods in the current prior art, the star point connection and the three-phase lead-out wires are distributed on the insertion side of the stator winding, increasing the number of special-shaped wires. Moreover, these special-shaped wires have problems such as non-concentrated distribution, complex structural wiring, and poor manufacturing process, thus increasing the overall structural size of the flat wire hairpin motor, resulting in the production of flat wire hairpin motors not being able to adapt to large-scale fully automated production lines and unable to meet the supply demand of the current market. Summary of the Invention

[0004] The embodiments of the present invention provide a flat wire hairpin stator structure and a motor, which simplify the layout of multi-layer flat wire conductors of the stator winding, improve the mass production of the stator winding, and reduce the overall volume of the flat wire hairpin motor.

[0005] On the one hand, an embodiment of the present invention provides a flat wire hairpin stator structure, including a stator core, a stator winding, and a bus bar; the stator core includes a core body arranged in a cylindrical shape, and a plurality of stator slots evenly spaced and axially extending along the inner circumferential wall surface of the core body; the stator winding includes multiple layers of flat wire conductors inserted into each of the stator slots, one end of each layer of the flat wire conductor is an insertion end, and the other end is a welding end; the multiple layers of the flat wire conductors are bent along the circumference of the core body to respectively form a U-phase winding, a V-phase winding, and a W-phase winding, and the U-phase winding, the V-phase winding, and the W-phase winding each include four parallel branches, and the conductor lead-out wire and the conductor neutral wire of each parallel branch are both arranged at the welding end of the flat wire conductor; the bus bar includes a U-phase lead-out wire bus bar, a V-phase lead-out wire bus bar, a W-phase lead-out wire bus bar, and a neutral wire bus bar arranged at the welding end of the flat wire conductor, and the U-phase lead-out wire bus bar, the V-phase lead-out wire bus bar, and the W-phase lead-out wire bus bar are respectively connected corresponding to the conductor lead-out wires of the four parallel branches of the U-phase winding, the conductor lead-out wires of the four parallel branches of the V-phase winding, and the conductor lead-out wires of the four parallel branches of the W-phase winding, and the neutral wire bus bar is connected corresponding to the conductor neutral wire of each parallel branch.

[0006] In some embodiments, the U-phase winding, the V-phase winding, and the W-phase winding each include a plurality of hairpin units, and the plurality of hairpin units are connected to each other to form the parallel branches; the hairpin unit includes a first bending member protruding from the insertion end of the flat wire conductor, a connecting member connected to the end of the first bending member and respectively inserted into one of the two stator slots, and two second bending members respectively connected to the ends of the two connecting members in a one-to-one correspondence and protruding from the welding end of the flat wire conductor, the two second bending members are bent and extended along the outer side of the connecting member, and the first bending member is bent and extended along the inner side of the connecting member; wherein the ends of the plurality of second bending members are respectively the conductor lead-out wires of the four parallel branches of the U-phase winding, the conductor lead-out wires of the four parallel branches of the V-phase winding, the conductor lead-out wires of the four parallel branches of the W-phase winding, and the conductor neutral wire of each parallel branch; the ends of every two adjacent second bending members are mutually attached and connected.

[0007] In some embodiments, the conductor lead-out wires of the four parallel branches of the U-phase winding, the conductor lead-out wires of the four parallel branches of the V-phase winding, the conductor lead-out wires of the four parallel branches of the W-phase winding, and the conductor neutral wire of each parallel branch are all arranged inside or outside the stator slot.

[0008] In some embodiments, the conductor lead-out wires of the four parallel branches of the U-phase winding are respectively arranged on the inner and outer sides of the stator slots, and the conductor neutral wires corresponding to each parallel branch of the U-phase winding are correspondingly arranged on the outer and inner sides of the stator slots; the conductor lead-out wires of the four parallel branches of the V-phase winding are respectively arranged on the inner and outer sides of the stator slots, and the conductor neutral wires corresponding to each parallel branch of the V-phase winding are correspondingly arranged on the outer and inner sides of the stator slots; the conductor lead-out wires of the four parallel branches of the W-phase winding are respectively arranged on the inner and outer sides of the stator slots, and the conductor neutral wires corresponding to each parallel branch of the W-phase winding are correspondingly arranged on the outer and inner sides of the stator slots.

[0009] In some embodiments, the distance between the two connectors of the hairpin unit is Y1 or Y2 stator slots; the distance between two adjacent connectors of the hairpin unit where the ends of every two adjacent second bending pieces are mutually attached and connected is Y3 or Y4 stator slots.

[0010] In some embodiments, the flat wire conductors in the stator slots are 2n layers, where n is a positive integer greater than 1; the nth layer of flat wire conductors to the first layer of flat wire conductors are bent circumferentially along the core body in the order of Y2, Y4, Y1, and Y4 to enclose the first parallel branch of the U-phase winding, V-phase winding, and W-phase winding; the nth layer of flat wire conductors to the first layer of flat wire conductors are bent circumferentially along the core body in the order of Y1, Y4, Y2, and Y4 to enclose the second parallel branch of the U-phase winding, V-phase winding, and W-phase winding; the first layer of flat wire conductors to the nth layer of flat wire conductors are bent circumferentially along the core body in the order of Y1, Y4, Y2, and Y4 to enclose the third parallel branch of the U-phase winding, V-phase winding, and W-phase winding; the first layer of flat wire conductors to the nth layer of flat wire conductors are bent circumferentially along the core body in the order of Y1, Y4, Y2, and Y4 to enclose the fourth parallel branch of the U-phase winding, V-phase winding, and W-phase winding.

[0011] In some embodiments, when the flat wire conductors are 8 layers, Y1 is 5, Y2 is 7, Y3 is 5, and Y4 is 6; the distance between the first parallel branch and the second parallel branch of the U-phase winding, V-phase winding, and W-phase winding between the 5th layer of flat wire conductors and the 4th layer of flat wire conductors is changed from Y4 to Y3; the distance between the first parallel branch and the second parallel branch of the U-phase winding, V-phase winding, and W-phase winding between the 5th layer of flat wire conductors and the 6th layer of flat wire conductors is changed from Y4 to Y3.

[0012] In some embodiments, 8. When the flat wire conductor has 6 layers, Y1 is 5 or 4, Y2 is 7 or 6, Y3 is 7, and Y4 is 6; when the flat wire conductor has 4 layers, Y1 is 5 or 4, Y2 is 7 or 6, Y3 is 7, and Y4 is 6.

[0013] In some embodiments, the bus bar is bent along the circumferential direction of the iron core body.

[0014] On the other hand, an embodiment of the present invention provides a flat wire hairpin motor, including the flat wire hairpin stator structure described above.

[0015] The beneficial effects brought by the technical solution provided by the present invention include: for the flat wire hairpin stator structure provided by the embodiments of the present invention, the conductor lead-out wire and the conductor neutral wire of each parallel branch of the U-phase winding, V-phase winding and W-phase winding are all arranged at the welding end of the flat wire conductor. Therefore, the bridge connection wire at the insertion end of the flat wire conductor, the conductor lead-out wires and the conductor neutral wires of the three phases (U-phase winding, V-phase winding and W-phase winding) are cancelled; at the same time, no bridge connection wire is arranged at the welding end of the flat wire conductor, and only the conductor lead-out wires and the conductor neutral wires of the U-phase winding, V-phase winding and W-phase winding are retained, reducing the number of special-shaped wires, simplifying the layout of the multi-layer flat wire conductors of the stator winding, further reducing the height of the end part of the stator winding, improving the feasibility of the mass production manufacturing process of the stator winding, making it more convenient for automatic insertion, and reducing the overall volume of the flat wire hairpin motor. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the following will briefly introduce the drawings required for the description of the embodiments. Obviously, the following drawings are only some embodiments of the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can be obtained according to these drawings.

[0017] Figure 1 It is a schematic three-dimensional structure view from the insertion end perspective of an embodiment of the present invention;

[0018] Figure 2 It is a schematic three-dimensional structure view from the welding end perspective of an embodiment of the present invention;

[0019] Figure 3 It is a schematic plan view of the hairpin unit at the insertion end of an embodiment of the present invention;

[0020] Figure 4 It is a schematic plan view of the hairpin unit at the welding end of an embodiment of the present invention;

[0021] Figure 5 It is a schematic structure view of the bus bar of an embodiment of the present invention;

[0022] Figure 6 Schematic diagram of the principle of the conductor lead-out wire and conductor neutral wire of the U-phase winding, V-phase winding, and W-phase winding with 8 layers of flat wire conductors according to the embodiment of the present invention;

[0023] Figure 7 Schematic diagram of the principle of each parallel branch of the U-phase winding, V-phase winding, and W-phase winding with 8 layers of flat wire conductors according to the embodiment of the present invention;

[0024] Figure 8 Cross-sectional view of the connection of each parallel branch of the U-phase winding with 8 layers of flat wire conductors according to the embodiment of the present invention;

[0025] Figure 9 Schematic diagram of the principle of each parallel branch of the U-phase winding, V-phase winding, and W-phase winding with 6 layers of flat wire conductors according to the embodiment of the present invention;

[0026] Figure 10 Cross-sectional view of the connection of each parallel branch of the U-phase winding with 6 layers of flat wire conductors according to the embodiment of the present invention;

[0027] Figure 11 Cross-sectional view of the connection of each parallel branch of the U-phase winding with 4 layers of flat wire conductors according to the embodiment of the present invention.

[0028] In the figure: 1, stator core; 10, core body; 11, stator slot; 2, stator winding; 20, insertion end; 21, welding end; 22, hairpin unit; 220, first bending part; 221, connecting part; 222, second bending part; 3, bus bar; 30, U-phase lead-out bus bar; 31, V-phase lead-out bus bar; 32, W-phase lead-out bus bar; 33, neutral wire bus bar. Detailed implementation manners

[0029] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are some but not all of the embodiments of the present invention. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0030] See Figure 1 、 Figure 2As shown in the figure; an embodiment of the present invention provides a flat wire hairpin stator structure, including a stator core 1, a stator winding 2 and a bus bar 3; the stator core 1 includes a core body 10 arranged in a cylindrical shape, and a plurality of stator slots 11 evenly spaced and axially extending along the inner circumferential wall surface of the core body; the stator winding 2 includes multiple layers of flat wire conductors inserted into each stator slot 11, one end of each layer of flat wire conductor is an insertion end 20 and the other end is a welding end 21; the multiple layers of flat wire conductors are bent along the circumference of the core body 10 to respectively form a U-phase winding, a V-phase winding and a W-phase winding, and each of the U-phase winding, V-phase winding and W-phase winding includes four parallel branches, and the conductor lead-out wire and the conductor neutral wire of each parallel branch are both arranged at the welding end 21 of the flat wire conductor; the bus bar 3 includes a U-phase lead-out wire bus bar 30, a V-phase lead-out wire bus bar 31, a W-phase lead-out wire bus bar 32 and a neutral wire bus bar 33 arranged at the welding end of the flat wire conductor, and the U-phase lead-out wire bus bar 30, the V-phase lead-out wire bus bar 31 and the W-phase lead-out wire bus bar 32 are respectively connected corresponding to the conductor lead-out wires of the four parallel branches of the U-phase winding, the conductor lead-out wires of the four parallel branches of the V-phase winding and the conductor lead-out wires of the four parallel branches of the W-phase winding, and the neutral wire bus bar 33 is connected corresponding to the conductor neutral wire of each parallel branch.

[0031] In the flat wire hairpin stator structure provided by the embodiment of the present invention, the conductor lead-out wire and the conductor neutral wire of each parallel branch of the U-phase winding, V-phase winding and W-phase winding are both arranged at the welding end 21 of the flat wire conductor. Therefore, the bridge connection wire at the insertion end 20 of the flat wire conductor, the conductor lead-out wires and the conductor neutral wires of the three phases (U-phase winding, V-phase winding and W-phase winding) are cancelled; at the same time, no bridge connection wire is arranged at the welding end 21 of the flat wire conductor, and only the conductor lead-out wires and the conductor neutral wires of the U-phase winding, V-phase winding and W-phase winding are retained, reducing the number of special-shaped wires, simplifying the layout of the multiple layers of flat wire conductors of the stator winding 2, further reducing the height of the end part of the stator winding 2, improving the feasibility of the mass production manufacturing process of the stator winding 2, making it more convenient for automatic insertion, and reducing the overall volume of the flat wire hairpin motor.

[0032] See also Figure 3 、 Figure 4As shown, in the embodiment of the present invention, in order to illustrate the specific structural forms of each parallel branch of the U-phase winding, V-phase winding, and W-phase winding, and at the same time to ensure that the connection methods of each parallel branch of the U-phase winding, V-phase winding, and W-phase winding are overall unified and regular, which is convenient for automatic insertion and the manufacturing process is more feasible; the U-phase winding, V-phase winding, and W-phase winding all include a plurality of hairpin units 22, and the plurality of hairpin units 22 are connected to each other to form the parallel branches; the hairpin unit 22 includes a first bending member 220 protruding from the insertion end 20 of the flat wire conductor, a connecting member 221 connected to the end of the first bending member 220 and respectively inserted into one of the two stator slots 11, and two second bending members 222 respectively connected to the ends of the two connecting members 221 in one-to-one correspondence and protruding from the welding end 21 of the flat wire conductor. The two second bending members 222 are bent and extended along the outer side of the connecting member 221, and the first bending member 220 is bent and extended along the inner side of the connecting member 221; wherein the end parts of the plurality of second bending members 222 are respectively the conductor lead-out wires of the four parallel branches of the U-phase winding, the conductor lead-out wires of the four parallel branches of the V-phase winding, the conductor lead-out wires of the four parallel branches of the W-phase winding, and the conductor neutral lines of each parallel branch; the end parts of every two adjacent second bending members 222 are mutually attached and connected.

[0033] Optionally, the conductor lead-out wires of the four parallel branches of the U-phase winding, the conductor lead-out wires of the four parallel branches of the V-phase winding, the conductor lead-out wires of the four parallel branches of the W-phase winding, and the conductor neutral lines of each parallel branch are all arranged inside or outside the stator slot 11; the layout method of the conductor lead-out wires and conductor neutral lines of each parallel branch can make the structure of the welding end 21 of the stator winding 2 more firm and stable, and improve the structural rigidity of the entire flat wire hairpin stator structure.

[0034] See also Figure 5 、 Figure 6 As shown, in the embodiment of the present invention, the conductor lead-out wires of the four parallel branches of the U-phase winding are respectively arranged inside and outside the stator slot 11, and the conductor neutral lines corresponding to each parallel branch of the U-phase winding are correspondingly arranged outside and inside the stator slot 11; specifically, the ports of the U-phase lead-out busbar 30 corresponding to the conductor lead-out wires of the four parallel branches of the U-phase winding are U1, U2, u3, and u4 respectively. U1 and U2 are correspondingly arranged outside the stator slot 11, and u3 and u4 are correspondingly arranged inside the stator slot 11. Therefore, the ports u1 and u2 of the conductor neutral lines corresponding to U1 and U2 on the neutral busbar 33 are arranged inside the stator slot 11, and the ports U3 and U4 of the conductor neutral lines corresponding to u3 and u4 on the neutral busbar 33 are correspondingly arranged outside the stator slot 11.

[0035] Similarly, the conductor lead-out wires of the four parallel branches of the V-phase winding are respectively arranged on the inner and outer sides of the stator slot 11, and the conductor neutral lines corresponding to each parallel branch of the V-phase winding are correspondingly arranged on the outer and inner sides of the stator slot 11; specifically, the ports of the V-phase lead-out busbar 31 corresponding to the conductor lead-out wires of the four parallel branches of the V-phase winding are V1, V2, v3, and v4 respectively. V1 and V2 are arranged on the outer side of the stator slot 11, and v3 and v4 are arranged on the inner side of the stator slot 11. Therefore, the ports v1 and v2 of the conductor neutral lines corresponding to V1 and V2 on the neutral busbar 33 are arranged on the inner side of the stator slot 11, and the ports V3 and V4 of the conductor neutral lines corresponding to v3 and v4 on the neutral busbar 33 are arranged on the outer side of the stator slot 11.

[0036] Similarly, the conductor lead-out wires of the four parallel branches of the W-phase winding are respectively arranged on the inner and outer sides of the stator slot 11, and the conductor neutral lines corresponding to each parallel branch of the W-phase winding are correspondingly arranged on the outer and inner sides of the stator slot 11; specifically, the ports of the W-phase lead-out busbar 32 corresponding to the conductor lead-out wires of the four parallel branches of the W-phase winding are W1, W2, w3, and w4 respectively. W1 and W2 are arranged on the outer side of the stator slot 11, and w3 and w4 are arranged on the inner side of the stator slot 11. Therefore, the ports w1 and w2 of the conductor neutral lines corresponding to W1 and W2 on the neutral busbar 33 are arranged on the inner side of the stator slot 11, and the ports W3 and W4 of the conductor neutral lines corresponding to w3 and w4 on the neutral busbar 33 are arranged on the outer side of the stator slot 11.

[0037] To illustrate in detail the connection mode of each parallel branch of the U-phase winding, V-phase winding, and W-phase winding; optionally, the distance between the two connecting members 221 of the hairpin unit 22 is Y1 or Y2 stator slots; the distance between the two adjacent connecting members 221 of the hairpin unit 22 where the ends of every two adjacent second bending members 222 are mutually attached and connected is Y3 or Y4 stator slots.

[0038] Optionally, the rectangular wire conductors in the stator slots 11 are 2n layers, where n is a positive integer greater than 1; the nth layer to the first layer of rectangular wire conductors are bent circumferentially along the core body 10 in the order of Y2, Y4, Y1, and Y4 to form the first parallel branch of the U-phase winding, V-phase winding, and W-phase winding; the nth layer to the first layer of rectangular wire conductors are bent circumferentially along the core body 10 in the order of Y1, Y4, Y2, and Y4 to form the second parallel branch of the U-phase winding, V-phase winding, and W-phase winding; the first layer to the nth layer of rectangular wire conductors are bent circumferentially along the core body 10 in the order of Y1, Y4, Y2, and Y4 to form the third parallel branch of the U-phase winding, V-phase winding, and W-phase winding; the first layer to the nth layer of rectangular wire conductors are bent circumferentially along the core body 10 in the order of Y1, Y4, Y2, and Y4 to form the fourth parallel branch of the U-phase winding, V-phase winding, and W-phase winding.

[0039] See also Figure 7 、 Figure 8 As shown in, in the embodiment of the present invention, it is set that the number of stator slots 11 is 48 slots. When the rectangular wire conductors are 8 layers, Y1 is 5, Y2 is 7, Y3 is 5, and Y4 is 6. Among them, the distance between the connecting member 221 and the second bending member 222 is 2.5 or 3.5 stator slots, and the distance between the connecting member 221 and the first bending member 220 is 2.5 or 3.5 stator slots; the distance between the first parallel branch and the second parallel branch of the U-phase winding, V-phase winding, and W-phase winding between the 5th layer of the rectangular wire conductors and the 4th layer of the rectangular wire conductors is changed from Y4 to Y3; the distance between the first parallel branch and the second parallel branch of the U-phase winding, V-phase winding, and W-phase winding between the 5th layer of the rectangular wire conductors and the 6th layer of the rectangular wire conductors is changed from Y4 to Y3.

[0040] Since the V-phase, W-phase, and U-phase windings have the same law, the parallel branches of the U-phase winding are taken as an example for illustration;

[0041] The first parallel branch: U1 enters from the 8th layer of slot 8, then enters the 7th layer of slot 15 with Y2 = 7, then enters the 8th layer of slot 21 with Y4 = 6, then enters the 7th layer of slot 26 with Y1 = 5, and then enters the 8th layer of slot 32 with Y4 = 6; thus, it enters slots 39, 45, 2, and 8 in sequence according to the sequence rule of Y2, Y4, Y1, and Y4, just making a full turn in the 7th and 8th layers. Then, it enters the 5th layer of slot 15 from the 6th layer of slot 8 with Y2 = 7 in the same rule, then enters the 6th layer of slot 21 with Y4 = 6, then enters the 5th layer of slot 26 with Y1 = 5, and then enters slots 32, 39, 45, 2, and 7 in sequence in the same rule. The winding just makes a full turn in the 5th and 6th layers; to ensure that the stator winding 2 of the flat wire stator structure is distributed in a double-layer (upper 4 layers + lower 4 layers) short pitch, without changing the Y value of the welding end 21, one slot is retreated at the welding end 21 (Y3 = 5), so it directly enters the 4th layer of slot 7 from the 5th layer of slot 2, and then makes a full turn in the 3rd and 4th layers and the 1st and 2nd layers respectively according to the sequence rule of passing through Y2, Y4, Y1, and Y4, and finally exits from u1 of the 1st layer of slot 1 and connects to the conductor neutral line.

[0042] The second parallel branch: Similar to the first parallel branch, U2 enters from the 8th layer of slot 9, exits from the 7th layer of slot 3 according to the sequence rule of Y1, Y4, Y2, and Y4, then enters from the 6th layer of slot 9, exits from the 5th layer of slot 3, then enters from the 4th layer of slot 8, exits from the 3rd layer of slot 2, enters from the 2nd layer of slot 8, and finally exits from u2 of the 1st layer of slot 2 and connects to the conductor neutral line.

[0043] The third parallel branch: u3 enters from the 1st layer of slot 7, then enters the 2nd layer of slot 2 with Y1 = 5, then enters the 1st layer of slot 44 with Y4 = 6, then enters the 2nd layer of slot 37 with Y3 = 7, then enters the 1st layer of slot 31 with Y4 = 6, thus enters slots 26, 20, 13, and 7 in sequence according to the sequence rule of Y1, Y4, Y2, and Y4, just making a full turn in the 1st and 2nd layers. Then, it enters the 4th layer of slot 2 from the 3rd layer of slot 7 with Y1 = 5 in the same rule, then enters the 3rd layer of slot 44 with Y4 = 6, then enters the 4th layer of slot 37 with Y2 = 7, and then enters slots 31, 26, 20, and 13 in sequence in the same rule. The winding just makes a full turn in the 3rd and 4th layers; to ensure that the stator winding 2 of the flat wire stator structure is distributed in a double-layer (upper 4 layers + lower 4 layers) short pitch, without changing the Y value of the welding end 21, one slot is retreated at the welding end 21 (Y3 = 5), so it directly enters the 5th layer of slot 8 from the 4th layer of slot 13, and then makes a full turn in the 5th and 6th layers and the 7th and 8th layers respectively according to the sequence rule of Y1, Y4, Y2, and Y4, and finally exits from U3 of the 8th layer of slot 14 and connects to the conductor neutral line.

[0044] The fourth parallel branch, similar to the third parallel branch, u4 enters from the first layer of slot No. 8, and exits from the second layer of slot No. 14 in the order of Y1, Y4, Y2, and Y4. Then it enters from the third layer of slot No. 8, exits from the fourth layer of slot No. 3, then enters from the fifth layer of slot No. 9, exits from the sixth layer of slot No. 4, enters from the seventh layer of slot No. 9, and finally exits from the eighth layer of slot No. 15 as u2 and connects to the conductor neutral line.

[0045] See also Figure 9 、 Figure 10 As shown, in the embodiment of the present invention, the number of stator slots 11 is set to 48. When the flat wire conductor is 6 layers, Y1 is 5 or 4, Y2 is 7 or 6, Y3 is 7, and Y4 is 6. Among them, when Y1 is 4, the distance between the connecting piece 221 and the second bending piece 222 is 3.5 stator slots; when Y1 is 5, the distance between the connecting piece 221 and the second bending piece 222 is 2.5 or 3.5 stator slots; when Y2 is 6, the distance between the connecting piece 221 and the second bending piece 222 is 3.5 stator slots; when Y2 is 7, the distance between the connecting piece 221 and the second bending piece 222 is 2.5 or 3.5 stator slots; the distance between the connecting piece 221 and the first bending piece 220 is 2.5 or 3.5 stator slots; the first parallel branch U1 of the U-phase winding enters from the sixth layer of slot No. 16, and then exactly winds around one week at the sixth and fifth layers in the order of Y2 being 7, Y4, Y1 being 5, and Y4. Then, it winds around one week at the fourth and third layers in the order of Y2 being 6, Y4, Y1 being 4, Y4, and Y2 being 6, Y3, Y1 being 4, Y4. Then, it winds around one week at the second and first layers in the order of Y2 being 7, Y4, Y1 being 5, and Y4. Finally, it exits from the first layer of slot No. 9 as u1 and connects to the neutral line. Therefore, through Figure 7 The connection method of each parallel branch of the U-phase winding, V-phase winding, and W-phase winding can be obtained in detail, and will not be repeated here.

[0046] See also Figure 11 As shown, in the embodiment of the present invention, the number of stator slots 11 is set to 48. When the flat wire conductor is 4 layers, Y1 is 5, Y2 is 7, Y3 is 5, and Y4 is 6. Among them, the distance between the connecting piece 221 and the second bending piece 222 is 2.5 or 3.5 stator slots, and the distance between the connecting piece 221 and the first bending piece 220 is 2.5 or 3.5 stator slots; the first parallel branch U1 of the U-phase winding enters from the fourth layer of slot No. 16, winds around one week at the fourth and third layers in the order of Y2, Y4, Y1, and Y4. When directly entering from the third layer of slot No. 10 to the second layer of slot No. 15, Y4 changes to Y3. Then, it winds around one week at the second and first layers in the order of Y2, Y4, Y1. Finally, it exits from the first layer of slot No. 9 as u1 and connects to the conductor neutral line. Therefore, throughFigure 8 The connection mode of each parallel branch of the U-phase winding, V-phase winding, and W-phase winding can be obtained in detail and will not be described repeatedly here.

[0047] Optionally, in order to make the structure of the bus bar 3 better unified and stable with the internal structure of the flat wire hairpin stator structure, the bus bar 3 is bent along the circumferential direction of the iron core body 10.

[0048] The embodiment of the present invention also provides a flat wire hairpin motor, including the flat wire hairpin stator structure described above.

[0049] In the description of the present invention, it should be noted that the orientation or positional relationship indicated by terms such as "inner side" and "outer side" is based on the orientation or positional relationship shown in the drawings. It is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation of the present invention. Unless otherwise clearly specified and defined, the terms "set", "connected", and "connected" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be directly connected or indirectly connected through an intermediate medium, and it can be the communication inside two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific situations.

[0050] It should be noted that in this application, relational terms such as "first" and "second" are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the term "including" or any other variant thereof is intended to cover non-exclusive inclusion, so that a process, method, article, or device including a series of elements not only includes those elements, but also includes other elements not expressly listed, or also includes elements inherent to such process, method, article, or device.

[0051] The above are only specific embodiments of the present invention, enabling those skilled in the art to understand or implement the present invention. Various modifications to these embodiments will be obvious to those skilled in the art, and the general principles defined herein can be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention will not be limited to these embodiments shown herein, but will conform to the broadest scope consistent with the principles and novel features invented herein.

Claims

1. A flat wire hairpin stator structure, characterized in that, Comprising: A stator core (1), including a core body (10) arranged in a cylindrical shape, and a plurality of stator slots (11) evenly spaced and axially extending along the inner circumferential wall surface of the core body and opening in the core body (10); A stator winding (2), including multi-layer flat wire conductors inserted into each of the stator slots (11), with one end of each layer of the flat wire conductor being an insertion end (20) and the other end being a welding end (21); the multi-layer flat wire conductors are bent circumferentially along the core body (10) to respectively form a U-phase winding, a V-phase winding, and a W-phase winding, and the U-phase winding, V-phase winding, and W-phase winding each include four parallel branches, and the conductor lead-out wire and the conductor neutral wire of each parallel branch are both arranged at the welding end (21) of the flat wire conductor; and, A bus bar (3), including a U-phase lead-out wire bus bar (30), a V-phase lead-out wire bus bar (31), a W-phase lead-out wire bus bar (32), and a neutral wire bus bar (33) arranged at the welding end of the flat wire conductor, the U-phase lead-out wire bus bar (30), V-phase lead-out wire bus bar (31), and W-phase lead-out wire bus bar (32) are respectively connected corresponding to the conductor lead-out wires of the four parallel branches of the U-phase winding, the conductor lead-out wires of the four parallel branches of the V-phase winding, and the conductor lead-out wires of the four parallel branches of the W-phase winding, and the neutral wire bus bar (33) is connected corresponding to the conductor neutral wire of each parallel branch; The U-phase winding, V-phase winding, and W-phase winding each include a plurality of hairpin units (22), and the plurality of hairpin units (22) are connected to each other to form the parallel branches; The hairpin unit (22) includes a first bending member (220) protruding from the insertion end (20) of the flat wire conductor, a connecting member (221) connected to the end of the first bending member (220) and respectively inserted into one of two stator slots (11), and two second bending members (222) respectively connected to the ends of the two connecting members (221) in a one-to-one correspondence and protruding from the welding end (21) of the flat wire conductor, the two second bending members (222) are bent and extend along the outside of the connecting member (221), and the first bending member (220) is bent and extends along the inside of the connecting member (221); The distance between the two connecting members (221) of the hairpin unit (22) is Y1 or Y2 stator slots; the distance between the two adjacent connecting members (221) of the hairpin unit (22) where the ends of the two adjacent second bending members (222) are mutually attached and connected is Y3 or Y4 stator slots; The flat wire conductor in the stator slot (11) is 2n layers, where n is a positive integer greater than 1; the nth layer to the first layer of the flat wire conductor are bent circumferentially along the core body (10) in the order of Y2, Y4, Y1, and Y4 to form the first parallel branch of the U-phase winding, V-phase winding, and W-phase winding; The flat wire conductors from the nth layer to the first layer are bent circumferentially along the core body (10) in the order of Y1, Y4, Y2, and Y4 to form the second parallel branches of the U-phase winding, V-phase winding, and W-phase winding; The flat wire conductors from the first layer to the nth layer are bent circumferentially along the core body (10) in the order of Y1, Y4, Y2, and Y4 to form the third parallel branches of the U-phase winding, V-phase winding, and W-phase winding; The flat wire conductors from the first layer to the nth layer are bent circumferentially along the core body (10) in the order of Y1, Y4, Y2, and Y4 to form the fourth parallel branches of the U-phase winding, V-phase winding, and W-phase winding; The bus bar (3) is bent circumferentially along the core body (10).

2. The flat wire hairpin stator structure according to claim 1, wherein The end parts of the plurality of second bending members (222) are respectively the conductor lead-out wires of the four parallel branches of the U-phase winding, the conductor lead-out wires of the four parallel branches of the V-phase winding, the conductor lead-out wires of the four parallel branches of the W-phase winding, and the conductor neutral lines of each parallel branch; the end parts of the remaining adjacent second bending members (222) are mutually attached and connected.

3. The flat wire hairpin stator structure according to claim 1, characterized in that, The conductor lead-out wires of the four parallel branches of the U-phase winding, the conductor lead-out wires of the four parallel branches of the V-phase winding, the conductor lead-out wires of the four parallel branches of the W-phase winding, and the conductor neutral lines of each parallel branch are all arranged inside or outside the stator slot (11).

4. The flat wire hairpin stator structure according to claim 3, characterized in that, The conductor lead-out wires of the four parallel branches of the U-phase winding are respectively arranged inside and outside the stator slot (11), and the conductor neutral lines corresponding to each parallel branch of the U-phase winding are correspondingly arranged outside and inside the stator slot (11); The conductor lead-out wires of the four parallel branches of the V-phase winding are respectively arranged inside and outside the stator slot (11), and the conductor neutral lines corresponding to each parallel branch of the V-phase winding are correspondingly arranged outside and inside the stator slot (11); The conductor lead-out wires of the four parallel branches of the W-phase winding are respectively arranged inside and outside the stator slot (11), and the conductor neutral lines corresponding to each parallel branch of the W-phase winding are correspondingly arranged outside and inside the stator slot (11).

5. The flat wire hairpin stator structure according to claim 1, characterized in that, When the flat wire conductor is 8 layers, Y1 is 5, Y2 is 7, Y3 is 5, and Y4 is 6; The distance between the first parallel branch and the second parallel branch of the U-phase winding, V-phase winding, and W-phase winding is changed from Y4 to Y3 between the 5th layer of flat wire conductors and the 4th layer of flat wire conductors; The distance between the first parallel branch and the second parallel branch of the U-phase winding, V-phase winding, and W-phase winding is changed from Y4 to Y3 between the 5th layer of flat wire conductors and the 6th layer of flat wire conductors.

6. The flat wire hairpin stator structure according to claim 1, characterized in that, When the flat wire conductor is 6 layers, Y1 is 5 or 4, Y2 is 7 or 6, Y3 is 7, and Y4 is 6; When the flat wire conductor is 4 layers, Y1 is 5 or 4, Y2 is 7 or 6, Y3 is 7, and Y4 is 6.

7. A flat wire hairpin motor, characterized in that, It includes the flat wire hairpin stator structure according to any one of claims 1 to 6.

Images