Multilayer flat wire winding stator assembly and motor

Abstract

A multi-layer flat wire winding stator assembly includes a stator core, the starting end of the winding is set as the starting layer and the starting slot, and the winding is performed along the circumferential direction of the stator core according to the pitch y. After winding one circle along the circumferential direction of the stator core, the flat wire in the slot of another pole phase group of the same layer is connected to the flat wire in the same layer in the manner of the same layer cross-wire according to the span k, and then the winding is performed along the circumferential direction of the stator core according to the pitch y. Finally, the output end of the winding is located in the same layer as the starting end. The busbar of the present invention does not have the situation of multi-layer cross-wire, and the lead-out line is arranged very clearly, so as to achieve the purpose of reducing the busbar size, number of layers, circumferential angle, optimizing the busbar structure, reducing the busbar volume, or canceling the busbar. At the same time, the twist of every two layers of the welding end is completely consistent with the welding form, which realizes the simplification of the welding end twist, welding and insulation treatment processes, simplifies the motor manufacturing process, reduces costs and improves product flexibility.

Description

Technical Field

[0001] The invention relates to the field of electricity, in particular to a motor, and more particularly to a multi-layer flat wire winding stator component and a motor. Background Art

[0002] As the requirements for torque density and power density of new energy vehicle drive motors increase sharply, drive motors are also showing a trend of flattening. The motor stator winding adopts a flat wire method, which greatly increases the slot fill rate while also achieving good heat dissipation of the winding in the slot. The motor flat wire winding usually adopts the form of wave winding, and different pitches can be used at the same time to meet the arrangement and insulation of the winding. Common stator winding flat wire forms include Hairpin structure, I-pin structure and continuous wave winding structure, and the first two are more mature now. The number of common stator winding flat wire layers also exists according to the complexity of the manufacturing process, including 2 layers, 4 layers, 5 layers, 6 layers, 7 layers, 8 layers, 10 layers, 12 layers and more layers. In the existing commonly used flat wire solutions, one or both ends of the flat wire must be welded to achieve the connection of the wires, and in order to form a "Y"-shaped or "△"-shaped connection of the three-phase winding and a connection between branches, the winding ends usually adopt many cross-wire methods, and multiple groups of cross-wire structures constitute a common busbar. The main function of the busbar is to realize the cross-wire connection of the same branch, the series or parallel connection of different branches, the neutral point connection, and the three-phase output line connection. It plays a very critical role in the winding composed of the flat wire motor. In the prior art, the cross-wire structure of the busbar is relatively complex, so that the busbar envelope size at the end of the flat wire winding stator assembly is larger, the number of layers is larger, and the circumferential angle is larger, resulting in high difficulty in the processing technology, high copper consumption, high processing cost and material cost, low application flexibility, excessively high local temperature at the busbar end, and unstable winding performance. Summary of the invention

[0003] The object of the present invention is to provide a multi-layer flat wire winding stator assembly and a motor, which are intended to solve the technical problems in the prior art that the flat wire motor stator winding has a complex structure, a difficult processing technique, and unstable winding performance.

[0004] A multi-layer flat wire winding stator assembly of the present invention comprises a stator core, wherein the stator core comprises stator slots, wherein flat wire windings are embedded in the stator slots, wherein the flat wire windings adopt a wave winding structure, wherein the windings are provided with U phase, V phase and W phase, wherein any phase is provided with at least one branch, wherein any branch is composed of a coil, wherein the number of layers of any coil is an even number of more than two layers, wherein the position of the starting end of the winding is set as the starting slot of the starting layer, wherein the windings are wound along the circumferential direction of the stator core according to the pitch y, after winding one turn along the circumferential direction of the stator core, the flat wires are connected to the slots of another pole phase group of the same layer in the manner of a same-layer cross-wire according to the span k, and then the flat wires are wound along the circumferential direction of the stator core according to the pitch y, wherein the windings are wound one turn along the circumferential direction of the stator core, and finally the winding outlet end and the starting end are located at the same layer, wherein y and k are both positive integers.

[0005] Furthermore, any phase is provided with two or more branches, and the branches are connected in series or in parallel.

[0006] Furthermore, k=y+1 or k=y-1.

[0007] Furthermore, each phase of the wave winding includes 2 parallel branches, the number of layers of coils in any stator slot is 6, the lead wire ends in any layer of coils are connected to the three-phase lead wires, the three-phase lead ends in each phase branch are connected in parallel, and the tail ends of the three-phase branches are connected together to form a star point line end to form a star connection, or the three-phase branches are connected head to tail to form a triangle connection.

[0008] A motor of the present invention comprises the multi-layer flat wire winding stator assembly.

[0009] Compared with the prior art, the effect of the present invention is positive and obvious. The busbar of the present invention does not have multiple layers of cross-wires, and the lead-out wires are arranged very clearly, thereby achieving the purpose of reducing the busbar size, number of layers, circumferential angle, optimizing the busbar structure, reducing the busbar volume, or eliminating the busbar. At the same time, the twist of every two layers of the welding end is completely consistent with the welding form, which simplifies the processes such as welding end twist, welding and insulation treatment, simplifies the motor manufacturing process, reduces costs and improves product flexibility. The cross-wire structure of the present invention is simple, with fewer bends, fewer busbar welding points, fewer layers, and small radial dimensions, which improves the stability of the winding structure performance and simplifies the process. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Figure 1 The present invention is a schematic diagram of the winding expansion structure of a multi-layer flat wire winding stator assembly and a motor according to an embodiment of the present invention.

[0011] Figure 2 The present invention is a schematic structural diagram of a stator assembly of a multi-layer flat wire winding stator assembly and a motor according to an embodiment of the present invention.

[0012] Figure 3 The present invention is a schematic structural diagram of a U-shaped wire of a stator assembly of a multi-layer flat wire winding stator assembly and a motor in an embodiment of the present invention.

[0013] Figure 4 The present invention is a schematic structural diagram of a U-shaped wire of a same-layer cross-wire of a multi-layer flat wire winding stator assembly and a motor in an embodiment of the present invention.

[0014] Figure 5 The present invention is a schematic structural diagram of a stator assembly welding end of a multi-layer flat wire winding stator assembly and a motor according to an embodiment of the present invention.

[0015] Illustration: stator core 1, stator winding corolla (U-shaped) end 2, stator winding welding end 3, busbar or copper busbar 4, conventional U-shaped wire 5, U-shaped wire below the busbar (layer change) 6. DETAILED DESCRIPTION

[0016] The present invention is further described below in conjunction with the accompanying drawings and embodiments, but the present invention is not limited to the embodiments, and all similar structures and similar variations of the present invention should be included in the protection scope of the present invention. The use of directions such as up, down, front, back, left, and right in the present invention is only for the convenience of description and is not a limitation on the technical solution of the present invention.

[0017] like Figure 1-Figure 5 As shown, a multi-layer flat wire winding stator assembly of the present invention includes a stator core 1, wherein the stator core 1 includes stator slots, wherein the stator slots are embedded with flat wire windings, wherein the flat wire windings adopt a wave winding structure, wherein the windings are provided with U phase, V phase and W phase, wherein any phase is provided with two branches, wherein the two branches are connected in parallel, wherein any branch is composed of coils, wherein the number of layers of any coil is an even number of two layers or more, wherein in any branch, the position of the starting end of the winding is set to the starting slot of the starting layer, and the winding is wound along the circumferential direction of the stator core 1 according to the pitch y, and after winding one circle along the circumferential direction of the stator core 1, the winding is connected to the flat wire in the slot of another pole phase group of the same layer in the same layer in the manner of the same layer cross-wire according to the span k, and then the winding is also wound one circle along the circumferential direction of the stator core 1 according to the pitch y, and finally the outlet end of the winding is located at the same layer as the starting end, and both y and k are positive integers.

[0018] Furthermore, k=y+1 or k=y-1.

[0019] Furthermore, the wave winding includes two parallel branches, the number of layers of coils in any stator slot is 6, the lead wire ends in any layer of coils are connected to the three-phase lead wires, the three-phase lead ends in each phase branch are connected in parallel, the tail ends of the three-phase branches are connected together to form a star point line end to form a star connection, or the three-phase branches are connected head to tail to form a triangle connection.

[0020] A motor of the present invention comprises the multi-layer flat wire winding stator assembly.

[0021] Specifically, each phase winding with the same polarity is defined as a pole-phase group.

[0022] Specifically, the flat wire winding, wave winding, and the winding method of winding one circle along the circumferential direction of the stator core 1 in this embodiment all adopt well-known solutions in the prior art, which are well known to those skilled in the art and will not be described in detail here.

[0023] If there are multiple parallel branches, any other parallel branches of any one are also connected in the same way, and each branch has a same-layer crossover wire, and the same-layer crossover wires between different branches form concentric symmetrical crossover wires. In this way, during the winding process of the motor winding, whether the branches are connected in series or in parallel, there will be no multi-layer crossover wires, and the starting ends and outlet ends of different branches are arranged in the same layer, making the lead wire arrangement very clear.

[0024] To ensure balanced current distribution in each branch, the winding in each branch includes windings of each layer, which can effectively reduce the circulating current between winding branches. The present invention is based on a stator assembly based on this winding connection method and a motor having the stator assembly.

[0025] The busbar 4 of the present invention does not have multiple layers of cross-wires, and the lead-out wires are clearly arranged, thereby achieving the purpose of reducing the size, number of layers, and circumferential angle of the busbar 4, optimizing the structure of the busbar 4, reducing the volume of the busbar 4, or eliminating the busbar 4. At the same time, the twisting of every two layers of the welding end is completely consistent with the welding form, which realizes the simplification of the processes such as the twisting of the welding end, welding and insulation treatment, thereby simplifying the motor manufacturing process, reducing costs and improving product flexibility.

[0026] The cross-wire structure of the present invention is simple, with fewer bends, fewer busbar welding points, fewer layers, and smaller radial dimensions, thereby improving the stability of the winding structure performance and simplifying the process.

[0027] The stator assembly of the above winding connection structure and the motor having the stator assembly are not limited in the number of winding layers, the number of parallel branches, the number of stator slots, the set pitch, the span of the same layer cross-wires, and the winding direction (clockwise / counterclockwise), and are highly flexible.

[0028] Example 1

[0029] like Figure 1-Figure 5 As shown, taking an 8-pole 48-slot motor as an example, the winding is provided with a U phase, a V phase and a W phase, and any phase is provided with two branches, the two branches are connected in parallel, and any branch is composed of a coil.

[0030] Taking phase U as an example,

[0031] The starting end of the U1 branch starts from the first layer of the first slot, and the pitch y is set to 6. After connecting from the second layer of the seventh slot through the U-shaped line, it is wound along the circumferential direction of the stator to the sixth layer of the 43rd slot, and then connected to the sixth layer of the second slot through the same-layer crossover line according to the span k1, and the span k1 is set to 7. Then, it continues to be wound along the circumferential direction according to the pitch y, and finally the outlet end returns to the first layer of the eighth slot;

[0032] The U2 branch is also wound in the same way as U1, and the same-layer cross-line span k2 is set to 5. The starting end of the U2 branch is located at the first layer of the second slot, and the outlet end is located at the first layer of the seventh slot.

[0033] In this way, the starting end and the outgoing end of the U1 branch and the U2 branch are both on the first layer, and the same-layer cross-wires on the two branches are concentrically symmetrical.

[0034] The connection of V phase and W phase is the same as that of U phase.

[0035] Finally, the busbar 4 is connected by welding adjacent wires, or directly using a copper busbar instead of the busbar 4, and the cross-wires are formed by connecting on the same layer.

Claims

1. A multi-layer flat wire winding stator assembly, characterized in that: The invention comprises a stator core, wherein the stator core comprises stator slots, wherein flat wire windings are embedded in the stator slots, wherein the flat wire windings adopt a wave winding structure, wherein the windings are provided with U phase, V phase and W phase, wherein any phase is provided with at least one branch, wherein any branch is composed of a coil, wherein the number of layers of any coil is an even number of more than two layers, wherein the position of the starting end of the winding is set as the starting slot of the starting layer, wherein the windings are wound along the circumferential direction of the stator core according to the pitch y, and after winding one circle along the circumferential direction of the stator core, the flat wires in the slots of another pole phase group in the same layer are connected according to the span k in the same layer cross-wire manner, and then the flat wires are wound along the circumferential direction of the stator core according to the pitch y, and finally the winding outlet end and the starting end are located in the same layer, wherein y and k are both positive integers, and k=y+1 or k=y-1.

2. A multi-layer flat wire winding stator assembly according to claim 1, characterized in that: Any phase is provided with two or more branches, and the branches are connected in series or in parallel.

3. The multi-layer flat wire winding stator assembly according to claim 1, characterized in that: Each phase of the wave winding includes 2 parallel branches, the number of layers of coils in any stator slot is 6, the lead wire ends in any layer of coils are connected to the three-phase lead wires, the three-phase lead ends in each phase branch are connected in parallel, the tail ends of the three-phase branches are connected together to form a star point line end to form a star connection, or the three-phase branches are connected head to tail to form a triangle connection.

4. A motor, characterized in that: A multi-layer flat wire winding stator assembly comprising any one of claims 1-3.

Images