Hairpin winding for slotless motor

Abstract

The application relates to a hairpin winding for a slotless motor. The hairpin winding for the slotless motor comprises a plurality of hairpin coils. The hairpin coils are uniformly arranged in a circumferential direction according to a winding phase mode and a winding arrangement rule of motor design, and are fixed and encapsulated by using a non-magnetic tool to form the hairpin winding for the slotless motor. The hairpin winding with the structure can ensure uniform winding distribution, improve space utilization, improve the power density of the motor, effectively reduce the size of the motor, and reduce the processing difficulty.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of electrical equipment, in particular to a hairpin winding suitable for a cog-free motor. BACKGROUND

[0002] With the expansion of the application field of the motor, higher requirements are put forward for the torque fluctuation, power density, volume quality and the like of the motor, and the cog-free motor emerges as the times require. The cog-free motor has no tooth slot, the output torque is very stable, and the power density is high, so it gradually becomes an important branch in the field of motors. In the cog-free motor, the armature winding is generally wound by using a mold and then rolled into a cylindrical shape. However, in actual processing, it is difficult to ensure that the winding arrangement is uniform, which affects the performance of the motor, reduces the production efficiency of the motor, and it is difficult to realize mass production. Therefore, a new type of winding is needed, which can not only ensure that the processing technology is not complicated, but also ensure that the winding arrangement is uniform, and can also meet the design arrangement index to a high degree. SUMMARY

[0003] The purpose of the present application is to provide a hairpin winding suitable for a cog-free motor, which can meet the design arrangement index to a high degree, so as to ensure that the winding arrangement is uniform while ensuring that the processing technology is not complicated.

[0004] To achieve the above-mentioned purpose, the present application provides the following scheme:

[0005] A hairpin winding for a cog-free motor, characterized in that the hairpin winding comprises: a plurality of hairpin coils.

[0006] The plurality of hairpin coils are uniformly arranged in the circumferential direction according to a winding phase distribution mode, and the plurality of hairpin windings are fixed and encapsulated by using a non-magnetic tool.

[0007] Optionally, the hairpin coil has multiple layers, and the positions of the hairpin coils in each layer in the circumferential direction are aligned.

[0008] Optionally, the winding phase distribution mode is a distribution mode of each phase of the motor in the circumferential direction, the number of phases of the motor is greater than or equal to 1, and each phase winding is symmetrically distributed in the circumferential direction. For example, for a three-phase motor, A, B and C are its respective phases, and their distribution in the circumferential direction is in the form of ACBACB.

[0009] Optionally, the hairpin coil comprises: a head portion, a straight line portion and an open end portion.

[0010] The head portion, the straight line portion and the open end portion are connected in sequence.

[0011] Optionally, the head portion is in the shape of "V" or "U".

[0012] Optionally, the straight part comprises a first straight subpart and a second straight subpart; the open circuit end part comprises a first open circuit subend part and a second open circuit subend part;

[0013] One end of the head opening is connected with the first straight subpart; the first straight subpart is connected with the first open circuit subend part; the other end of the head opening is connected with the second straight subpart; the second straight subpart is connected with the second open circuit subend part.

[0014] Optionally, two hairpin coils belonging to the same phase and contacting with each other at the open circuit end part are connected in series or in parallel by welding the open circuit end parts;

[0015] Hairpin coils belonging to the same phase, at the same position on the circumference but in different layers are connected in series or in parallel by welding the open circuit end parts.

[0016] Optionally, the hairpin winding further comprises an arc-shaped connecting device; the arc-shaped connecting device is used for connecting hairpin coils belonging to the same phase but not contacting with each other;

[0017] The arc-shaped connecting device comprises a plurality of welding holes; when the hairpin coil is used in cooperation with the arc-shaped connecting device, the hairpin coil further comprises a needle-shaped lead-out end; the needle-shaped lead-out end of the hairpin coil is inserted into the welding hole to form a physical connection; the welding hole and the needle-shaped lead-out end are welded and reinforced to form an electrical connection; the arc-shaped connecting device is made of a conductive metal material, and an insulating layer is arranged on the surface except the position of the welding hole.

[0018] Optionally, the hairpin winding further comprises a PCB connecting device;

[0019] The PCB connecting device is an integral printed circuit board, and a plurality of wirings, a plurality of soldering pads and a plurality of plug-in slots are arranged on the board.

[0020] When the hairpin coil is used in cooperation with the PCB connecting device, the hairpin coil further comprises a needle-shaped lead-out end; the needle-shaped lead-out end of the hairpin coil is inserted into the soldering pad of the PCB connecting device for welding, or is directly inserted into the plug-in slot of the PCB connecting device; the wirings are used for connecting the soldering pads or the plug-in slots belonging to the same phase.

[0021] Optionally, the arc-shaped connecting device and the PCB connecting device are used in cooperation or are used separately.

[0022] According to the specific embodiments of the present application, the following technical effects are provided.

[0023] The application provides a hairpin winding, which comprises a plurality of hairpin coils.

[0024] The hairpin winding with the structure can ensure uniform winding distribution, improve space utilization, improve power density of the motor, effectively reduce the size of the motor, and reduce processing difficulty.

[0025] In the application, the plurality of layers of hairpin coils are arranged in alignment in the circumferential direction, so that the torque can be increased, the heat dissipation capacity is better, and the copper loss is reduced. BRIEF DESCRIPTION OF DRAWINGS

[0026] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the drawings needed in the embodiments will be briefly introduced. Obviously, the drawings in the following description are only some embodiments of the present application, and other drawings can be obtained by those skilled in the art without creative labor.

[0027] Figure 1 The structure diagram of the hairpin winding provided by the application is shown in the figure.

[0028] Figure 2 The structure diagram of the hairpin winding provided by the application is shown in the figure.

[0029] Figure 3 The connection diagram of the hairpin winding with two open end portions in contact is shown in the figure.

[0030] Figure 4 The structure diagram of the hairpin winding with a needle-shaped lead-out end is shown in the figure.

[0031] Figure 5 The structure diagram of the arc-shaped connection device is shown in the figure.

[0032] Figure 6 The structure diagram of the PCB connection device is shown in the figure.

[0033] Symbol explanation:

[0034] Arc-shaped connection device 1, hairpin coil 2, PCB connection device 3, head portion 4, straight line portion 5, open end portion 6, needle-shaped lead-out end 7, first solder hole 801, second solder hole 802, third solder hole 803, fourth solder hole 804, first solder pad 901, second solder pad 902, first insertion slot 1001, second insertion slot 1002, wiring 11. DETAILED DESCRIPTION

[0035] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0036] The purpose of the present invention is to provide a hairpin winding suitable for a slotless motor that can highly meet the design arrangement indicators, so as to solve the problems of difficult processing and uneven position arrangement of traditional cylindrical windings.

[0037] In order to make the above-mentioned objects, features and advantages of the present invention more clearly understood, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. Figure 1 As shown, the hairpin winding provided by the present invention includes:

[0038] A plurality of hairpin coils 2.

[0039] There are multiple hairpin coils 2, which are evenly arranged in the circumferential direction according to the winding phases, and the multiple hairpin windings are fixed and sealed using non-magnetic tooling.

[0040] The hairpin coil 2 is multi-layered. By arranging the multi-layer hairpin coil 2 and aligning the positions of the hairpin coils 2 of each layer on the circumference, the torque can be increased, the heat dissipation capacity is better, and the copper loss is also reduced.

[0041] The winding phasing pattern is the distribution of the motor phases around the circumference. If the number of phases in a motor is greater than or equal to 1, the windings of each phase are symmetrically distributed around the circumference. For example, in a three-phase motor, A, B, and C are the phases, and their distribution around the circumference is ACBACB.

[0042] The hairpin coils 2 belonging to the same branch can be connected in series by welding, and the hairpin coils of different branches can be connected in parallel by welding.

[0043] like Figure 2 As shown, the hairpin coil provided by the present invention includes: a head 4, a straight portion 5 and an open end 6, and the head 4, the straight portion 5 and the open end 6 are connected in sequence.

[0044] In the present invention, the head portion may be a "V"-shaped structure or a convex structure such as a "U"-shaped structure.

[0045] The straight portion 5 includes a first straight sub-portion and a second straight sub-portion; the open end portion 6 includes a first open sub-end portion and a second open sub-end portion;

[0046] The head 4 opening one end is connected with the first straight line sub-department; the first straight line sub-department is connected with the first open circuit sub-end; the head 4 opening other end is connected with the second straight line sub-department; the second straight line sub-department is connected with the second open circuit sub-end.

[0047] The first straight line sub-department and the second straight line are defined as the inside, and the outside of the first straight line sub-department and the second straight line sub-department, and the open circuit end 6 can be located in the inside or the outside.

[0048] In the specific use process, the open circuit end 6 of the hairpin coil belonging to the same phase is connected (welded), such as Figure 3 When the open circuit end of the hairpin coil belonging to the same phase does not contact each other, in order to facilitate the series or parallel connection of the hairpin coils in each phase, or the star connection of each phase, the hairpin winding provided by the application further comprises an arc-shaped connecting device 1 and a PCB connecting device 3. The arc-shaped connecting device 1 and the PCB connecting device 3 are located at the open circuit end of the hairpin winding, and are used to connect the hairpin coils belonging to the same phase and needing to be connected in series or parallel, but the open circuit end 6 does not contact.

[0049] When the winding end is not wrapped by the stator core, the arc-shaped connecting device 1 is used.

[0050] When the winding end is wrapped by the stator core, but there is still space in the axial direction of the motor, the PCB connecting device 3 is used.

[0051] As shown in Figure 4 The hairpin coil further comprises a needle-shaped lead-out end 7, which is used in cooperation with the arc-shaped connecting device or the PCB connecting device. The needle-shaped lead-out end is in an elongated structure and is located on the side or end of the open circuit end of the hairpin coil.

[0052] The needle-shaped lead-out end 7 of the hairpin coil 2 is inserted into the welding hole to form a physical connection, and the welding hole and the needle-shaped lead-out end 7 are welded and reinforced to form an electrical connection; the arc-shaped connecting device 1 is made of conductive metal material, and an insulating layer is provided on the surface except the position of the welding hole.

[0053] The needle-shaped lead-out end 7 of the hairpin coil 2 is inserted into the solder pad of the PCB connecting device 3 for welding, or directly inserted into the slot of the PCB connecting device 3; the wiring is used to connect the solder pads or slots belonging to the same phase

[0054] The arc-shaped connecting device 1 is in an arc shape, and the arc length of the arc-shaped connecting device 1 is approximately equal to the length of the different hairpin coils connected along the circular arc direction.

[0055] Specifically, the arc-shaped connecting device has a plurality of welding holes, which are a first welding hole 801, a second welding hole 802, a third welding hole 803, and a fourth welding hole 804. The specific setting positions of the welding holes are as shown inFigure 5 shown.

[0056] like Figure 1 As shown, the needle-shaped lead ends of two hairpin coils are inserted into two welding holes on the arc-shaped connecting device 1, the first welding hole 801 and the second welding hole 802, and welded together to form a branch circuit in parallel. The two needle-shaped lead ends are inserted into two welding holes on the arc-shaped connecting device 1, the third welding hole 803 and the fourth welding hole 804, and welded together to form a branch circuit in parallel. The arc-shaped connecting device 1 also connects these two branches in series.

[0057] Specifically, the PCB connection device 3 is in the shape of a fan ring, and has pads and slots on its surface. The specific arrangement positions of the first pad 901, the second pad 902, the first slot 1001, the second slot 1002, and the wiring 11 on the PCB device 3 are as follows: Figure 6 shown.

[0058] like Figure 6 As shown, the needle-shaped lead ends 7 of a portion of the hairpin coils 2 are inserted into the first and second solder pads 901, 902 on the PCB connector 3 and soldered. The wiring 11 on the PCB connector 3 connects the first solder pad 901 and the second solder pad 6-2, forming a parallel branch. The needle-shaped lead ends 7 of a portion of the hairpin coils 2 are inserted into the first and second slots 1001, 1002 on the PCB connector 3. The wiring 11 on the PCB connector 3 connects the first and second slots 1001, 1002, forming a parallel branch. The wiring 11 on the PCB connector 3 connects these two branches in series.

[0059] The arc-shaped connecting device 1 and the PCB connecting device 3 replace the traditional connecting wires, making the structure of the motor winding more compact and regular, and improving the space utilization.

[0060] The various embodiments in this specification are described in a progressive manner, and each embodiment focuses on the differences from other embodiments. The same or similar parts between the various embodiments can be referenced to each other.

[0061] This document uses specific examples to illustrate the principles and implementation methods of the present invention. The above examples are only intended to help understand the method and core concept of the present invention. At the same time, those skilled in the art will find that the specific implementation methods and application scopes may vary based on the concept of the present invention. In summary, the contents of this specification should not be construed as limiting the present invention.

Claims

1. A toothless motor with hairpin winding, characterized by, The hairpin winding comprises a plurality of hairpin coils; The hairpin coil comprises a head, a straight section and an open end section, which are sequentially connected; The hairpin coil further comprises an arc-shaped connecting device and a PCB connecting device, both of which are located at the open end section of the hairpin winding and used for connecting hairpin coils belonging to the same phase; when the open end sections of the two hairpin coils belonging to the same phase do not contact each other, the arc-shaped connecting device and the PCB connecting device are selected to be located at the open end section of the hairpin coil winding in order to facilitate the series or parallel connection of the hairpin coils in each phase; The arc-shaped connecting device is in the shape of an arc, and the arc length of the arc-shaped connecting device is approximately equal to the length of the different hairpin coils connected by the arc-shaped connecting device in the arc direction; the PCB connecting device is in the shape of a fan ring; The plurality of hairpin coils are uniformly arranged in the circumferential direction according to the winding phase distribution mode, and the plurality of hairpin windings are fixed and encapsulated by using a non-magnetic tool.

2. The toothless motor with a hairpin winding according to claim 1, characterized in that, The hairpin coil has multiple layers, and the positions of the hairpin coils in each layer are aligned in the circumferential direction.

3. The toothless motor with a hairpin winding according to claim 1, characterized in that, The winding phase distribution mode is the distribution mode of the phases of the motor in the circumferential direction, the number of phases of the motor is greater than or equal to 1, and the windings of each phase are symmetrically distributed in the circumferential direction.

4. The toothless motor with a hairpin winding according to claim 1, characterized in that, The head is in the shape of "V" or "U".

5. The toothless motor with a hairpin winding according to claim 1, characterized in that, The straight section comprises a first straight subsection and a second straight subsection; the open end section comprises a first open subsection and a second open subsection; One end of the opening of the head is connected with the first straight subsection; the first straight subsection is connected with the first open subsection; the other end of the opening of the head is connected with the second straight subsection; and the second straight subsection is connected with the second open subsection.

6. The hairpin winding for toothless motor according to claim 1, wherein, The two hairpin coils belonging to the same phase and having the open end sections in contact are connected in series or in parallel by welding the open end sections; The hairpin coils belonging to the same phase, being at the same position in the circumferential direction and being in different layers are connected in series or in parallel by welding the open end sections.

7. The toothless motor with a hairpin winding according to claim 1, characterized in that, The hairpin winding further comprises an arc-shaped connecting device; the arc-shaped connecting device is used for connecting hairpin coils belonging to the same phase but not contacting each other; The arc-shaped connecting device comprises a plurality of welding holes; when the hairpin coil is used in cooperation with the arc-shaped connecting device, the hairpin coil further comprises a needle-shaped lead-out end; the needle-shaped lead-out end of the hairpin coil is inserted into the welding hole to form a physical connection; the welding hole and the needle-shaped lead-out end are welded and reinforced to form an electrical connection; the arc-shaped connecting device is made of conductive metal material, and an insulating layer is provided on the surface except the position of the welding hole.

8. The toothless motor with a hairpin winding according to claim 7, characterized in that, The hairpin winding further comprises a PCB connecting device; The PCB connecting device is an integral printed circuit board, and a plurality of wirings, a plurality of soldering pads and a plurality of plug-in slots are provided on the board; When the hairpin coil is used in cooperation with the PCB connecting device, the hairpin coil further comprises a needle-shaped lead-out end; the needle-shaped lead-out end of the hairpin coil is inserted into the soldering pad of the PCB connecting device for welding, or is directly inserted into the plug-in slot of the PCB connecting device; the wirings are used for connecting the soldering pads or the plug-in slots belonging to the same phase.

9. The toothless machine with a hairpin winding according to claim 7 or 8, characterized in that, The arc-shaped connecting device and the PCB connecting device are used in combination or separately.

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