Single-path flat wire hairpin stator winding structure and winding method

Abstract

A single flat wire hairpin stator winding structure and winding method, comprising a stator core, a plurality of wire slots, a flat wire hairpin winding, a plurality of wire layers are arranged in each wire slot, the flat wire hairpin winding includes U-phase, W-phase and V-phase flat wire windings, the three-phase flat wire windings each include a plurality of inner single-layer flat copper wires and a plurality of cross-layer flat copper wires, all the wire layers are sequentially sorted in ascending order along the direction away from the center of the stator core, and are sequentially first wire layer to eighth wire layer, the first wire layer is embedded with a plurality of inner single-layer flat copper wires, the second wire layer to the seventh wire layer are embedded with a plurality of cross-layer flat copper wires, and the eighth wire layer is embedded with a plurality of inner single-layer flat copper wires, and the flat copper wires are connected into one body by welding. The inner and outer single-layer flat copper wires and the cross-layer flat copper wires are inserted into the wire slots and connected into one body by welding to form a single flat wire motor winding, the wire distribution is simple, a large number of bus bars and bus bars are not needed to connect the branches and neutral points of each phase winding, the manufacturing process is simple, the production cost is low, the processing efficiency is high, the lead-out wires are concentrated, and the wiring is more convenient.

Description

TECHNICAL FIELD

[0001] The present application relates to a single-path flat wire hairpin stator winding structure and a winding method. BACKGROUND

[0002] With the development of electric vehicle technology, the performance requirements of vehicle motors are also getting higher and higher. In the pursuit of high slot fill factor, high power density and high torque density, round wire motors have been difficult to break through the bottleneck of new performance requirements of driving motors. The emergence of flat wire hairpin motors has achieved performance requirements that round wire motors cannot meet. Flat wire hairpin motors have high slot fill factor, high power density, and good heat dissipation performance and NVH performance, which can greatly reduce the motor winding end height, reduce the amount of copper and reduce the winding copper loss, thereby improving the efficiency of the vehicle driving motor.

[0003] However, the flat wire motor winding with multiple parallel branches used in the prior art has many types of lines, complex arrangement, concentrated lead-out wires, and inconvenient wiring, and a large number of busbars and busbars are required to connect the branches and neutral points of each phase winding, which has complex manufacturing process, high production cost and low processing efficiency. SUMMARY

[0004] The technical problem to be solved by the present application is to provide a single-path flat wire hairpin stator winding structure.

[0005] In order to solve the above technical problems, the technical scheme adopted by the present application is: a single-path flat wire hairpin stator winding structure, comprising a stator core, a plurality of wire slots opened on the tooth portion of the stator core, and a hairpin flat wire winding embedded in the plurality of wire slots, each wire slot is provided with a plurality of wire layers, the hairpin flat wire winding comprises a U-phase flat wire winding, a W-phase flat wire winding and a V-phase flat wire winding, the U-phase flat wire winding, the W-phase flat wire winding and the V-phase flat wire winding each comprise a plurality of single-layer flat copper wires and a plurality of cross-layer flat copper wires, all the wire layers are sequentially sorted in ascending order along the direction away from the center of the stator core, sequentially as the first wire layer to the eighth wire layer, the first wire layer is embedded with a plurality of single-layer flat copper wires, the second wire layer to the seventh wire layer is embedded with a plurality of cross-layer flat copper wires, and the eighth wire layer is embedded with a plurality of single-layer flat copper wires, the flat copper wires in the U-phase flat wire winding, the W-phase flat wire winding and the V-phase flat wire winding are connected into one body by welding. By inserting single-layer flat copper wires and cross-layer flat copper wires into the wire slot and connecting them into one body by welding, a single-path flat wire motor winding is formed, the wire distribution is simple, a large number of busbars and busbars are not required to connect the branches and neutral points of each phase winding, the manufacturing process is simple, the production cost is low, the processing efficiency is high, the lead-out wires are concentrated, and the wiring is more convenient.

[0006] Preferably, the wire slot has 48, the wire layer has 8, the inner single-layer flat copper wire can be arranged across 6 and 4 wire slots, the cross-layer flat copper wire can be arranged across 5 wire slots, and the outer single-layer flat copper wire can be arranged across 5 wire slots.

[0007] Preferably, the connecting wire set for connecting the N end of the U-phase flat wire winding, the N end of the W-phase flat wire winding and the N end of the V-phase flat wire winding is further included. The three-phase flat wire winding is connected as a whole to form a single-path flat wire motor winding, and the wire distribution is simpler and the manufacturing process is simple.

[0008] Preferably, the inner single-layer flat copper wire includes two inner single-layer vertical copper wires inserted into the wire slot, and an inner single-layer horizontal copper wire connected to the top ends of the two inner single-layer vertical copper wires, and the two halves of the inner single-layer horizontal copper wire can be arranged in parallel about the middle point. The parallel arrangement of the two halves of the inner single-layer horizontal copper wire about the middle point makes it more convenient to install the next inner single-layer flat copper wire, and the installation is more convenient, improving the processing efficiency.

[0009] Preferably, the cross-layer flat copper wire includes two cross-layer vertical copper wires inserted into the wire slot, and a cross-layer horizontal copper wire connected to the top ends of the two cross-layer vertical copper wires, and the cross-layer horizontal copper wire is arranged upwardly bent, and the two halves of the cross-layer horizontal copper wire can be arranged in parallel about the middle point.

[0010] Preferably, the outer single-layer flat copper wire is consistent in shape with the cross-layer flat copper wire, the outer single-layer flat copper wire includes two outer single-layer vertical copper wires inserted into the wire slot, and an outer single-layer horizontal copper wire connected to the top ends of the two outer single-layer vertical copper wires, and the outer single-layer horizontal copper wire is arranged upwardly bent, and the two halves of the outer single-layer horizontal copper wire can be arranged in parallel about the middle point, and the bottom ends of the inner single-layer vertical copper wire, the cross-layer vertical copper wire and the outer single-layer vertical copper wire can be arranged outwardly bent. The subsequent mold integrated bending is facilitated, the welding is facilitated, the installation is facilitated, and the efficiency is improved.

[0011] The technical problem to be solved by the present application is to provide a winding method of a single-path flat wire hairpin stator winding structure.

[0012] In order to solve the above technical problems, the technical scheme adopted by the present application is: S1, taking one of the 48 slot grooves on the stator core as sequence 1, and sequentially setting the 48 slot grooves as sequence numbers clockwise, with sequence 48 and sequence 1 being adjacent; S2, setting the slot layer closest to the center of the stator core as the first slot layer, and sequentially setting the slot layers radially outward, with the outermost layer being the eighth slot layer; S3, inserting one of the inner single-layer flat copper wires of the U-phase flat wire winding, the W-phase flat wire winding and the V-phase flat wire winding into the first slot layer of sequence 1, and inserting the other inner single-layer vertical copper wire into the first slot layer of sequence 8 by spanning 6 slot grooves, inserting one of the inner single-layer vertical copper wires of the same phase into the first slot layer of sequence 2, and inserting the other inner single-layer vertical copper wire into the first slot layer of sequence 7 by spanning 4 slot grooves, then sequentially inserting the inner single-layer flat copper wires of different phases to complete the winding of the first slot layer; S4, inserting one of the cross-layer vertical copper wires of the cross-layer flat copper wire of one of the U-phase flat wire winding, the W-phase flat wire winding and the V-phase flat wire winding into the second slot layer of any sequence, and inserting the other cross-layer vertical copper wire into the third slot layer of other sequence by spanning 5 slot grooves, sequentially completing the winding of the second slot layer to the seventh slot layer; S5, inserting one of the outer single-layer vertical copper wires of the outer single-layer flat copper wire of one of the U-phase flat wire winding, the W-phase flat wire winding and the V-phase flat wire winding into the eighth slot layer of sequence 1, and inserting the other outer single-layer vertical copper wire into the eighth slot layer of sequence 7 by spanning 5 slot grooves, inserting one of the outer single-layer vertical copper wires of the same phase into the eighth slot layer of sequence 2, and inserting the other outer single-layer vertical copper wire into the eighth slot layer of sequence 8 by spanning 5 slot grooves, then sequentially inserting the outer single-layer flat copper wires of different phases to complete the winding of the eighth slot layer; S6, twisting the end portions of the cross-layer vertical copper wire and the inner single-layer vertical copper wire and the outer single-layer vertical copper wire extending from the other end of the stator core clockwise or counterclockwise, and welding and connecting the adjacent end portions of the same phase.

[0013] Preferably, the end portions of the cross-layer vertical copper wire, the inner single-layer vertical copper wire and the outer single-layer vertical copper wire extending from the stator core are twisted in the same direction from inside to outside.

[0014] Due to the use of the above technical scheme, the present application has the following advantages compared with the prior art:

[0015] 1. The present application inserts inner and outer single-layer flat copper wires and cross-layer flat copper wires into slot grooves, and connects them into one by welding, forming a single-path flat wire motor winding, which has simple distribution of slot arrangement, does not need to use a large number of bus bars and bus bars to connect the branches and neutral points of each phase winding, has simple manufacturing process, low production cost, high processing efficiency, concentrated lead-out wires and convenient wiring.

[0016] 2. The three-phase flat wire windings are connected into one, forming a single-path flat wire motor winding, which has simpler distribution of slot arrangement and simpler manufacturing process. BRIEF DESCRIPTION OF DRAWINGS

[0017] Figure 1 Fig. 1 is a perspective view of a flat wire hairpin stator winding structure;

[0018] Figure 2 Fig. 2 is an enlarged view of the top of the flat wire hairpin stator winding structure;

[0019] Figure 3 Fig. 3 is a top view of a stator core;

[0020] Figure 4 Fig. 4 is an enlarged view of the top of the stator core;

[0021] Figure 5 Fig. 5 is a schematic view of an inner single layer flat copper wire structure;

[0022] Figure 6 Fig. 6 is a schematic view of a cross layer flat copper wire structure;

[0023] Figure 7 Fig. 7 is a schematic view of an outer single layer flat copper wire structure;

[0024] Figure 8 Fig. 8 is a schematic view of the first wire layer winding;

[0025] Figure 9 Fig. 9 is a schematic view of the second to seventh wire layer winding;

[0026] Figure 10 Fig. 10 is a schematic view of the eighth wire layer winding;

[0027] Wherein: 1, stator core; 2, wire slot; 21, wire layer; 3, hairpin flat wire winding; 4, inner single layer flat copper wire; 41, inner single layer vertical copper wire; 42, inner single layer horizontal copper wire; 5, cross layer flat copper wire; 51, cross layer vertical copper wire; 52, cross layer horizontal copper wire; 6, connection wire group; 7, outer single layer flat copper wire; 71, outer single layer vertical copper wire; 72, outer single layer horizontal copper wire. DETAILED DESCRIPTION

[0028] As shown in the figures, a single-path flat wire hairpin stator winding structure includes a stator core 1, multiple slots 2 formed on the teeth of the stator core 1, and hairpin flat wire windings 3 embedded in 48 slots 2. Each slot 2 has 8 wire layers 21. The hairpin flat wire windings 3 include U-phase flat wire windings, W-phase flat wire windings, and V-phase flat wire windings. Each of the U-phase, W-phase, and V-phase flat wire windings includes multiple inner single-layer flat copper wires 4 and multiple cross-layer flat copper wires 5. The U-phase flat wire windings... The connecting wire group 6 connects the N-end of the N-phase flat wire winding, the N-end of the W-phase flat wire winding, and the N-end of the V-phase flat wire winding. All wire layers 21 are arranged in ascending order along the direction away from the center of the stator core 1, from the first wire layer to the eighth wire layer. The first wire layer is embedded with multiple inner single-layer flat copper wires 4. The second to seventh wire layers are embedded with multiple cross-layer flat copper wires 5. The eighth wire layer is embedded with multiple outer single-layer flat copper wires 7. The flat copper wires in the U-phase flat wire winding, the W-phase flat wire winding, and the V-phase flat wire winding are all connected together by welding.

[0029] By inserting inner and outer single-layer flat copper wires and cross-layer flat copper wires into the online slot and welding them together, a single-circuit flat wire motor winding is formed. The wiring distribution is simple, and there is no need to use a large number of busbars and busbars to connect the branches and neutral points of each phase winding. The manufacturing process is simple, the production cost is low, the processing efficiency is high, the lead wires are concentrated, and the wiring is more convenient.

[0030] like Figure 5 As shown, the inner single-layer flat copper wire 4 can span 6 and 4 wire slots 2. The inner single-layer flat copper wire 4 includes two inner single-layer vertical copper wires 41 inserted into the wire slot 2 and an inner single-layer horizontal copper wire 42 connected to the top of the two inner single-layer vertical copper wires 41. The two halves of the inner single-layer horizontal copper wire 42 can be staggered and parallel about the midpoint to facilitate the insertion of other inner single-layer vertical copper wires 41.

[0031] like Figure 6 As shown, the cross-layer flat copper wire 5 can span 5 wire slots 2. The cross-layer flat copper wire 5 includes two cross-layer vertical copper wires 51 inserted in the wire slots 2 and a cross-layer horizontal copper wire 52 connected to the top of the two cross-layer vertical copper wires 51. The cross-layer horizontal copper wire 52 is bent upward and the two halves of the cross-layer horizontal copper wire 52 can be staggered about the midpoint.

[0032] like Figure 7 As shown, the outer single-layer flat copper wire 7 and the cross-layer flat copper wire 5 have the same shape. The outer single-layer flat copper wire 7 includes two outer single-layer vertical copper wires 71 inserted in the wire groove 2 and an outer single-layer horizontal copper wire 72 connected to the top of the two outer single-layer vertical copper wires 71. The outer single-layer horizontal copper wire 72 is bent upwards. The two halves of the outer single-layer horizontal copper wire 72 can be staggered about the midpoint. The bottom ends of the inner single-layer vertical copper wire 41, the cross-layer vertical copper wire 51 and the outer single-layer vertical copper wire 71 can be bent outwards.

[0033] likeFigures 5-7 As shown, the setting of the bottom end one side bending of the two inner single-layer vertical copper wires 41 of the inner single-layer flat copper wire 4, the setting of the bottom end two sides bending of the two cross-layer vertical copper wires 51 of the cross-layer flat copper wire 5, and the setting of the bottom end one side bending of the two outer single-layer vertical copper wires 71 of the outer single-layer flat copper wire 7, facilitates the subsequent bending of the bottom end of the inner single-layer vertical copper wire 41 and the bottom end of the cross-layer vertical copper wire 51 and the outer single-layer vertical copper wire 71 by the module, and facilitates welding.

[0034] The winding method of the single-path flat wire hairpin stator winding structure includes the following specific steps: S1, one of the 48 wire slots 2 on the stator core 1 is set as sequence 1, and the 48 wire slots 2 are sequentially set with sequence numbers in clockwise direction, and the sequence 48 and the sequence 1 are adjacent, as shown in S2, the wire layer closest to the center of the stator core 1 in the wire slot 2 is set as the first wire layer, and the wire layers are sequentially set in radial outward direction, and the outermost layer is the eighth wire layer; S3, one of the inner single-layer vertical copper wires 41 of the inner single-layer flat copper wire 4 of one phase of the U-phase flat wire winding, the W-phase flat wire winding and the V-phase flat wire winding is inserted into the first wire layer of the sequence 1, the other one is inserted into the first wire layer of the sequence 8 by spanning 6 wire slots 2, one of the inner single-layer vertical copper wires 41 of the inner single-layer flat copper wire 4 of the same phase is inserted into the first wire layer of the sequence 2, the other one is inserted into the first wire layer of the sequence 7 by spanning 4 wire slots 2, then the inner single-layer flat copper wires 4 of different phases are sequentially inserted, and the winding of the first wire layer is completed, as shown in S4, one of the cross-layer vertical copper wires 51 of the cross-layer horizontal copper wire 52 of one phase of the U-phase flat wire winding, the W-phase flat wire winding and the V-phase flat wire winding is inserted into the second wire layer of any sequence, the other one is inserted into the third wire layer of other sequence by spanning 5 wire slots 2, and the winding of the second wire layer to the seventh wire layer is sequentially completed, as shown in S5, one of the outer single-layer vertical copper wires 71 of the outer single-layer flat copper wire 7 of one phase of the U-phase flat wire winding, the W-phase flat wire winding and the V-phase flat wire winding is inserted into the eighth wire layer of the sequence 1, the other one is inserted into the eighth wire layer of the sequence 7 by spanning 5 wire slots 2, one of the outer single-layer vertical copper wires 71 of the outer single-layer flat copper wire 7 of the same phase is inserted into the eighth wire layer of the sequence 2, the other one is inserted into the eighth wire layer of the sequence 8 by spanning 5 wire slots 2, then the outer single-layer flat copper wires 7 of different phases are sequentially inserted, and the winding of the eighth wire layer is completed, as shown in S6, the end portions of the cross-layer vertical copper wires 51 and the inner single-layer vertical copper wires 41 extending from the other end of the stator core 1 are twisted clockwise or counterclockwise, and the end portions of the same phase adjacent to each other are welded and connected. Figure 3 Figure 8 Figure 9 Figure 10

[0035] The end portions of the cross-layer vertical copper wires 51 and the inner single-layer vertical copper wires 41 and the outer single-layer vertical copper wires 71 extending from the stator core 1 are twisted in the same direction from inside to outside. ​​​​

[0036] The above examples are only for illustrating the technical concept and characteristics of the present application, and the purpose is to enable those skilled in the art to understand the content of the present application and to implement it, and cannot limit the protection scope of the present application. Any equivalent changes or modifications made according to the spirit and essence of the present application shall be covered within the protection scope of the present application.

Claims

1. A single-path flat wire hairpin stator winding structure, characterized in that: The stator core (1) includes multiple slots (2) formed on the teeth of the stator core (1) and hairpin flat wire windings (3) embedded in the slots (2). Each slot (2) contains multiple wire layers (21). The hairpin flat wire windings (3) include U-phase flat wire windings, W-phase flat wire windings and V-phase flat wire windings. The U-phase flat wire windings, W-phase flat wire windings and V-phase flat wire windings each include multiple inner single-layer flat copper wires (4), multiple cross-layer flat copper wires (5), and multiple... The outer single-layer flat copper wire (7) is arranged in ascending order along the direction away from the center of the stator core (1), from the first layer to the eighth layer. The first layer is embedded with multiple inner single-layer flat copper wires (4), the second to seventh layers are embedded with multiple cross-layer flat copper wires (5), and the eighth layer is embedded with multiple outer single-layer flat copper wires (7). The wire slots (2) have 48 slots, the wire layers have 8 slots, and the inner single-layer flat copper wires (4) can cross 6 and 4 wire slots respectively. The slot (2) is set, and the cross-layer flat copper wire (5) can span 5 slots (2). The outer single-layer flat copper wire (7) can span 5 slots (2). The inner single-layer flat copper wire (4) includes two inner single-layer vertical copper wires (41) inserted into the slot (2) and an inner single-layer horizontal copper wire (42) connected to the top of the two inner single-layer vertical copper wires (41). The two halves of the inner single-layer horizontal copper wire (42) can be staggered and parallel about the midpoint. The cross-layer flat copper wire (5) includes Two cross-layer vertical copper wires (51) are inserted into the wire groove (2), and a cross-layer horizontal copper wire (52) is connected to the top of the two cross-layer vertical copper wires (51). The cross-layer horizontal copper wire (52) is bent upward. The two halves of the cross-layer horizontal copper wire (52) can be staggered about the midpoint. The outer single-layer flat copper wire (7) has the same shape as the cross-layer flat copper wire (5). The flat copper wires in the U-phase flat wire winding, the W-phase flat wire winding and the V-phase flat wire winding are all connected together by welding.

2. The single-path flat wire hairpin stator winding structure according to claim 1, characterized in that: It also includes a connecting wire group (6) that connects the N end of the U-phase flat wire winding, the N end of the W-phase flat wire winding and the N end of the V-phase flat wire winding.

3. The single-path flat wire hairpin stator winding structure according to claim 1, characterized in that: The outer single-layer flat copper wire (7) includes two outer single-layer vertical copper wires (71) inserted into the wire groove (2) and an outer single-layer horizontal copper wire (72) connected to the top of the two outer single-layer vertical copper wires (71). The outer single-layer horizontal copper wire (72) is bent upwards. The two halves of the outer single-layer horizontal copper wire (72) can be staggered about the midpoint. The bottom ends of the inner single-layer vertical copper wire (41), the cross-layer vertical copper wire (51) and the outer single-layer vertical copper wire (71) can be bent outwards.

4. A winding method for a single-path flat wire hairpin stator winding structure as described in any one of claims 1-3, characterized in that: The specific steps include: S1, taking one of the 48 slots (2) on the stator core (1) and setting it as sequence 1, and setting the sequence number of the 48 slots (2) clockwise, with sequence 48 and sequence 1 being adjacent; S2, setting the wire layer closest to the center of the stator core (1) in the slot (2) as the first wire layer, and setting the number of wire layers radially outward in sequence, with the outermost layer being the eighth wire layer; S3, taking the inner single layer of flat copper wire (U-phase flat wire winding, W-phase flat wire winding, V-phase flat wire winding) of one phase of the three phases (U-phase flat wire winding, W-phase flat wire winding, V-phase flat wire winding) 4) One inner single-layer vertical copper wire (41) is inserted into the first wire layer of sequence 1, and another inner single-layer vertical copper wire (41) is inserted into the first wire layer of sequence 8 across 6 wire slots (2). One inner single-layer vertical copper wire (41) of the same phase is inserted into the first wire layer of sequence 2, and another inner single-layer vertical copper wire (41) is inserted into the first wire layer of sequence 7 across 4 wire slots (2). Then, inner single-layer flat copper wires (4) of different phases are inserted in sequence to complete the winding of the first wire layer; S4, Insert one of the cross-layer vertical copper wires (51) of the cross-layer horizontal copper wire (52) of one of the three phases of the U-phase flat wire winding, W-phase flat wire winding, and V-phase flat wire winding into the second wire layer of any sequence. The other cross-layer vertical copper wire (51) crosses 5 wire slots (2) and is inserted into the third wire layer of other sequences. This process is repeated to complete the winding from the second wire layer to the seventh wire layer. S5, insert one of the outer single-layer vertical copper wires (71) of the outer single-layer flat copper wire (7) of one of the three phases of the U-phase flat wire winding, W-phase flat wire winding, and V-phase flat wire winding into the eighth wire layer of sequence 1. The other outer single-layer vertical copper wire (71) crosses 5 wire slots (2) and is inserted into the third wire layer of other sequences. Five slots (2) are inserted into the eighth layer of sequence 7. One outer single-layer vertical copper wire (71) of the same phase is inserted into the eighth layer of sequence 2. Another outer single-layer vertical copper wire (71) is inserted across five slots (2) into the eighth layer of sequence 8. Then, outer single-layer flat copper wires (7) of different phases are inserted in sequence to complete the winding of the eighth layer. S6, the ends of the cross-layer vertical copper wire (51), inner single-layer vertical copper wire (41), and outer single-layer vertical copper wire (71) extending from the other end of the stator core (1) are bent clockwise or counterclockwise, and the adjacent ends of the same phase are welded together.

5. The winding method for a single-path flat wire hairpin stator winding structure according to claim 4, characterized in that: The ends of the cross-layer vertical copper wire (51), the inner single-layer vertical copper wire (41) and the outer single-layer vertical copper wire (71) extending out of the stator core (1) are bent in opposite directions from the inside to the outside.

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