Balanced winding layout for electric motor

Abstract

The invention relates to a balanced winding layout for an electric motor. A winding arrangement for a stator of an electric motor is disclosed, including winding clips arranged to form one or more phases. The stator includes a plurality of motor teeth forming a plurality of slots, each configured to house a plurality of layers. A first set of winding clips spanning M slots are coupled in series and to a phase lead, and are sequentially arranged in a first azimuthal direction. A jumper is arranged in a layer and coupled in series with the first set of winding clips. A second set of winding clips configured to span M slots are coupled in series between the jumper and a neutral lead. The second set of winding clips are sequentially arranged in an opposite azimuthal direction, and together with the first set of winding clips and the jumper form a continuous electrical path between the phase lead and the neutral lead.

Description

[0001] introduction

[0002] This disclosure relates to a balanced winding layout for an electric motor, and more specifically, to a winding layout comprising a hairpin with a specific span that includes a reduced number of component differences. Summary of the Invention

[0003] In some embodiments, this disclosure relates to a stator of an electric motor. The stator includes a plurality of motor teeth, phase leads, a neutral lead, winding hairpins, and layer-specific jumpers. The plurality of motor teeth are configured to accommodate a plurality of slots in N layers, where N is an integer. The phase leads and the neutral lead are arranged in a first layer of the N layers. A first set of winding hairpins, each configured to achieve a span of M slots, is coupled together in series and also coupled to the phase lead. The first set of winding hairpins is arranged sequentially in a first azimuth direction. The jumpers are arranged between slots in a second layer and are coupled in series with the first set of winding hairpins. The second set of winding hairpins is each configured to achieve the span of M slots and is coupled in series between the jumpers and the neutral lead. The second set of winding hairpins is arranged sequentially in a second azimuth direction opposite to the first azimuth direction. The first winding hairpin, the jumper wire, and the second winding hairpin form a continuous electrical path between the phase lead and the neutral lead. In some embodiments, the first layer is the outermost radial layer, and the second layer is the innermost radial layer. In some embodiments, the first layer is the innermost radial layer, and the second layer is the outermost radial layer.

[0004] In some embodiments, the jumper is configured to achieve the span of M slots. In some embodiments, the jumper is configured to achieve a shorter span than the span of M slots. In some embodiments, M equals seven slots, such that seven stator teeth are arranged between the legs of each of the first set of winding hairpins and between the legs of each of the second set of winding hairpins. For illustration, the side of the stator on which the hairpin is laid is referred to as the crown end, and the other end of the stator on which the hairpin is welded to form a continuous circuit for current is referred to as the weld end. In some embodiments, the pitch of the winding on the crown side is seven, and the pitch on the weld side is five. In some embodiments, the pitch of five on the crown side and the pitch of seven on the weld side are used. In some embodiments, equal pitches are achieved on the crown side and the weld side (e.g., a pitch of six on either side).

[0005] In some embodiments, the plurality of slots includes 48 slots, and the phase lead, the neutral lead, the first set of winding hairpins, the jumper wire, and the second set of winding hairpins correspond to the first winding of the first phase. In some such embodiments, the stator includes additional windings corresponding to two additional phases.

[0006] In some embodiments, this disclosure relates to a stator having a plurality of slots and a plurality of phases arranged in the slots. Each phase includes: a first set of winding hairpins coupled in series and arranged sequentially in a first azimuth direction; a second set of winding hairpins coupled in series and arranged sequentially in a second azimuth direction opposite to the first azimuth direction; and a jumper wire. Each of the first set of winding hairpins and each of the second set of winding hairpins includes the span of M slots. The jumper wire is arranged in a single layer and coupled in series with the first set of winding hairpins and with the second set of winding hairpins.

[0007] In some embodiments, the first set of winding hairpins, the second set of winding hairpins, and the jumper wire correspond to a first continuous winding, and each phase includes a second continuous winding coupled in parallel with the first continuous winding. In some such embodiments, each second continuous winding includes: a third set of winding hairpins, which are coupled in series and arranged sequentially in the first azimuth direction; a fourth set of winding hairpins, which are coupled in series and arranged sequentially in the second azimuth direction; and another jumper wire. Each of the third set of winding hairpins and each of the fourth set of winding hairpins includes a span of M slots. The other jumper wire is arranged in a single layer and is coupled in series with the third set of winding hairpins and the fourth set of winding hairpins.

[0008] In some embodiments, the jumper is configured to achieve the span of M slots, and the additional jumper is configured to achieve a shorter span than M slots. In some embodiments, M equals seven slots, such that seven stator teeth are arranged between the legs of each first set of winding hairpins and between the legs of each second set of winding hairpins. In some embodiments, the single layer is the outermost radial layer. In some embodiments, the single layer is the innermost radial layer.

[0009] In some embodiments, the plurality of phases includes three phases, wherein each of the three phases includes at least two windings coupled in parallel. For example, the first set of winding hairpins, the second set of winding hairpins, and the jumper wire are included in the first winding of the at least two windings.

[0010] In some embodiments, this disclosure relates to a stator of an electric motor, the stator including a plurality of stator teeth, a plurality of winding hairpins, a plurality of jumper hairpins, and jumpers. The plurality of stator teeth form a plurality of slots, each configured to accommodate N layers, where N is an even integer. Each of the plurality of winding hairpins is configured to implement a span and includes N / 2 subsets of the winding hairpins, each subset including a corresponding length corresponding to the span. Each of the plurality of jumper hairpins is configured to implement the span. The plurality of jumper hairpins includes N / 2-1 subsets of the jumper hairpins, each subset including a corresponding length corresponding to the span. The jumper is arranged in a single layer of the N layers. The plurality of winding hairpins, the plurality of jumper hairpins, and the jumper are coupled in series to form a continuous electrical path of phase.

[0011] In some embodiments, the single layer is the outermost radial layer. In some embodiments, the single layer is the innermost radial layer. In some embodiments, the jumper is configured to achieve the span. In some embodiments, the jumper is configured to achieve a shorter span than the span.

[0012] In some embodiments, the plurality of winding hairpins, the plurality of jumper hairpins, and the jumper form a sequence, wherein the jumper is arranged at the center of the sequence, and wherein the jumper corresponds to a change in the azimuth winding direction of the plurality of winding hairpins and the plurality of jumper hairpins. Attached Figure Description

[0013] The present disclosure is described in detail with reference to the following accompanying drawings, which illustrate one or more various embodiments. The drawings are provided for illustrative purposes only and show only typical or exemplary embodiments. These drawings are provided to facilitate understanding of the concepts disclosed herein and should not be considered as limitations on the breadth, scope, or applicability of these concepts. It should be noted that these drawings are not necessarily drawn to scale for clarity and ease of illustration.

[0014] Figure 1 Two perspective views of a schematic motor stator comprising ten layers and having balanced windings, according to some embodiments of the present disclosure, are shown.

[0015] Figure 2 Some embodiments according to this disclosure are shown. Figure 1 Two perspective views of a schematic motor stator, showing only the windings of the two corresponding parallel phase windings installed;

[0016] Figure 3 Some embodiments according to this disclosure are shown. Figure 1Two perspective views of a schematic motor stator, in which only two additional corresponding parallel phase windings are installed;

[0017] Figure 4 Two perspective views of a schematic motor stator comprising six layers and having balanced windings, according to some embodiments of the present disclosure, are shown.

[0018] Figure 5 Some embodiments according to this disclosure are shown. Figure 4 Two perspective views of a schematic motor stator, showing only the windings of the two corresponding parallel phase windings installed;

[0019] Figure 6 Three end views are shown of schematic slot arrangements with different numbers of conductor layers according to some embodiments of the present disclosure;

[0020] Figure 7 Three end views are shown of additional schematic slot arrangements with different numbers of conductor layers according to some embodiments of the present disclosure;

[0021] Figures 8A to 8F A schematic wiring diagram of a parallel winding corresponding to one phase of an eight-layer stator according to some embodiments of the present disclosure is shown, wherein the winding pitch is six slots.

[0022] Figures 9A to 9F A schematic wiring diagram of a parallel winding corresponding to one phase of a ten-layer stator according to some embodiments of the present disclosure is shown, wherein the winding pitch is six slots.

[0023] Figures 10A to 10F A schematic wiring diagram of a parallel winding corresponding to one phase of a six-layer stator according to some embodiments of the present disclosure is shown, wherein the winding pitch is six slots;

[0024] Figures 11A to 11F A schematic wiring diagram of a parallel winding corresponding to one phase of a ten-layer stator according to some embodiments of the present disclosure is shown, wherein the winding pitch is seven slots;

[0025] Figures 12A to 12F A schematic wiring diagram of parallel windings corresponding to one phase of a six-layer stator according to some embodiments of the present disclosure is shown, wherein the winding pitch is seven slots; and

[0026] Figure 13 A flowchart illustrating a schematic process for manufacturing a motor stator with balancing windings according to some embodiments of the present disclosure is shown. Detailed Implementation

[0027] This disclosure relates to a balanced winding layout for an electric motor. For example, electric vehicles may require motors exhibiting high torque and power for rapid acceleration (e.g., especially for higher-end vehicles). In another example, when larger vehicles (such as trucks and SUVs) are electrified, the electric motor requires increased torque and power. High-power motors may require an increased number of parallel-connected windings (e.g., depending on the level of motor power). For illustration, more parallel winding connections typically require hairpins (e.g., in a bar winding machine), thereby creating multiple pitches per layer. The winding pitch (or “span”) refers to the number of slots between one leg of the hairpin and the other leg of the hairpin. For example, the hairpin may extend to “full pitch,” meaning the number of slots covered by the hairpin is equal to the number of slots divided by the number of poles (e.g., typically an integer for integrated slot machines). Conversely, the winding pitch may be “short,” in which case the number of slots covered by the hairpin is less than that of a full-pitch winding. Furthermore, the winding pitch can be "long," in which case the number of slots covered by the hairpins is greater than the full pitch. When windings are connected in parallel, many windings are arranged in each layer and hairpins are needed to achieve several pitches: standard pitch (full pitch); short pitch; and (sometimes) long pitch.

[0028] The number of layers in a winding layout is limited by the number of conductors (e.g., radially stacked) in each slot. In some arrangements, each conductor constitutes one layer. For example, a winding layout with 4 or 6 conductors per slot can have 4 or 6 layers of windings, respectively. In some arrangements, parallel connections require a large number of hairpin shapes (e.g., different pitches) to balance the windings connected in parallel. For example, several hairpin shapes may be needed to balance these parallel windings so that the same phase (angle) is maintained relative to each winding. To achieve the same phase angle, each winding should occupy the same position of the slot relative to the winding pole an equal number of times. Achieving this may require hairpins of several shapes for different layer pairs. As the number of hairpin shapes required increases, stator manufacturing can become more complex (e.g., requiring more tooling with associated tooling costs and longer cycle times), which can affect product costs and manufacturing time, and thus productivity. As used herein, a balancing winding refers to a sequence of hairpins oriented clockwise and counterclockwise for each winding of a phase.

[0029] In some embodiments, the winding arrangement of this disclosure allows for a large number of parallel-connected coils and a reduced number of hairpin-shaped balanced windings, thereby reducing unit and production costs. Each layer pair may include two sets of windings: a first set (referred to herein as the forward winding) is wound around the stator in a forward direction (e.g., azimuth) to complete the winding, and a second set (referred to herein as the reverse winding) is wound in a reverse direction (e.g., in the opposite azimuth direction of the forward winding). In some arrangements, the forward and reverse windings are balanced separately and then connected in parallel (e.g., for increased power). However, this approach may require many hairpin shapes (e.g., hairpins with different spans), thus increasing costs. In the winding arrangement of this disclosure, the forward and reverse windings are not connected in parallel, but rather in series. For example, the forward and reverse windings of this disclosure may occupy all or part of the slots in each layer (e.g., depending on the number of parallel connections). As illustrated in more detail with respect to the following examples, the forward winding can be connected (e.g., via a same-layer jumper) to the reverse winding, with the forward and reverse windings complementing each other to achieve complete winding balance. The method of this disclosure utilizes standard shapes in the layer pairs (e.g., full-pitch hairpins), thereby reducing the number of different shapes in the winding layout. For example, a identical winding layout can be applied to all forward windings, and after a same-layer jumper, connected to a reverse winding with the same or similar winding layout. The combination of forward and reverse windings achieves complete winding balance, thereby reducing the number of hairpin shapes.

[0030] exist Figures 1 to 3 The diagram shows a schematic 10-layer stator, and... Figures 4 to 5 A schematic six-layer stator is shown. For clarity, several windings of each stator are shown in an isolated arrangement, and therefore, Figures 2 to 3 and Figure 5 It can be considered a partial component.

[0031] Figure 1Two perspective views (e.g., panels 198 and 199) of a schematic motor stator 100 comprising ten layers and having balanced windings according to some embodiments of the present disclosure are shown. The views shown in panels 198 and 199 are taken from different sides of the stator (e.g., rotated approximately 120 degrees relative to each other). Terminals 111, 112, and 113 are configured to couple to corresponding phases (e.g., A, B, and C) of a motor (e.g., three-phase, four-pole, as shown). The stator body 110 includes a plurality of slots (e.g., 48 slots as shown, with slots 1, 4, and 6 indicated) arranged between a plurality of stator teeth. A plurality of hairpins 120 are arranged in the slots (e.g., intersecting each other at weld 130). For example, as shown, the hairpins 120 are configured to be axially inserted into the slots, wherein each hairpin includes one or two legs corresponding to a respective slot. For example, the hair clip in hair clip 120 may include two legs configured to (i) engage in two corresponding slots in a radial position (e.g., the two legs are configured to engage in a first layer and a second layer, respectively, thereby forming layer pairs such as 1-2, 3-4, 5-6, 7-8, 9-10) and (ii) engage in the two corresponding slots across a predetermined pitch (e.g., the number of slots in the hair clip). For clarity, Figures 2 to 3 The schematic windings B1, B2, B3, and B4 are shown isolated in the middle, and... Figures 11A to 11F The diagram shows a schematic wiring diagram of some phases of the motor stator 100 (e.g., for four parallel windings B1, B2, B3, and B4). In some embodiments, the hairpin 120 includes standard hairpins (e.g., hairpins with a common shape) extending across a certain span and layer pairs, as well as the same layer winding jumpers for connecting the forward windings to the reverse windings. Therefore, the stator 100 can reduce the number of wire (e.g., hairpin) shapes, which can reduce tooling costs and improve production cycle time.

[0032] Figure 2 Some embodiments according to this disclosure are shown. Figure 1 The diagram shows two perspective views of a schematic motor stator 100 (e.g., panels 298 and 299), with only two corresponding parallel windings installed (e.g., winding B1 in panel 298 and winding B2 in panel 299). The views shown in panels 298 and 299 are shown from the same side of the stator. For example, panel 298 shows winding 281 (e.g., winding B1), and panel 299 shows winding 282 (e.g., winding B2) connected in parallel with winding 281 shown in panel 298. Figure 3 Some embodiments according to this disclosure are shown. Figure 1The schematic motor stator 100 is shown in two perspective views (e.g., panels 398 and 399), with only two additional corresponding parallel windings 381 and 382 installed (e.g., winding B3 in panel 398 and winding B4 in panel 399). The views shown in panels 398 and 399 are shown from the same side of the stator (e.g., and from...). Figure 2 Those shown are rotated approximately 150 degrees. For example, panel 398 shows winding 381, and panel 399 shows winding 382 connected in parallel with windings 281 and 282. Figure 2 and Figure 3 In the example shown, windings 281, 282, 381, and 382 (e.g., windings B1, B2, B3, and B4 of phase B) are connected in parallel to each other to form the winding of phase B. Figure 2 As shown, slots 1, 13 and 20 are indicated by leads in panel 298, and slots 1, 14 and 19 are indicated by leads in panel 299.

[0033] Referring to the panel 298 showing winding 281, winding leads 291 enter slot 13 ("slot 13" out of 48 slots) at layer 10 (i.e., the outermost layer) from the lead side (e.g., axially, as shown at the top). Hairpins of winding 281 form a continuous path to neutral lead 292 (e.g., at slot 20, as shown). Figure 2 As shown in panel 298, the hair clip of winding 281 includes:

[0034] - Layer 10-phase lead wire (hair clip 291);

[0035] - Layer 10 neutral lead (hair clip 292);

[0036] - Layer 9-10 standard hair clips (hair clips 202 and 203);

[0037] - Layer 7-8 standard hair clips (hair clips 206 and 207);

[0038] - Layer 5-6 standard hair clips (hair clips 212 and 213);

[0039] - Layer 3-4 standard hair clips (hair clips 216 and 217);

[0040] - Layer 1-2 standard hair clips (hair clips 222 and 223);

[0041] - Layer 8-9 jumper wires (hair clips 204 and 205);

[0042] - Layer 6-7 jumper wires (hair clips 208 and 209);

[0043] - Layer 4-5 jumper wires (hair clips 215 and 214);

[0044] - Layer 2-3 jumper wires (hair clips 218 and 219); and

[0045] - Layer 1-1 jumper wire (hair clip 224, with the same span as other hair clips in phase B1).

[0046] The current path of phase B1 follows the hairpins 291 (lead), 202, 204, 206, 208, 212, 214, 216, 218, 222, 224 (e.g., where the winding direction changes from counterclockwise to clockwise), 223, 219, 217, 215, 213, 209, 207, 205, 203, and 292 (neutral) in sequence. As shown, each of the two hairpins of winding B1 has a span of 7.

[0047] Referring to the panel 299 showing winding 282, winding leads 293 enter slot 14 at layer 10 from the lead side (e.g., axially, as shown at the top), wherein the hairpin of winding 282 forms a continuous path to neutral lead 294 (e.g., as shown at slot 19). The hairpin of winding 282 includes:

[0048] - Layer 10-phase lead wire (hair clip 293);

[0049] - Layer 10 neutral lead (hair clip 294);

[0050] - Layer 9-10 standard hair clips (hair clips 232 and 233);

[0051] - Layer 7-8 standard hair clips (hair clips 236 and 237);

[0052] - Layer 5-6 standard hair clips (hair clips 242 and 243);

[0053] - Layer 3-4 standard hair clips (hair clips 246 and 247);

[0054] - Layer 1-2 standard hair clips (hair clips 252 and 253);

[0055] - Layer 8-9 jumper wires (hair clips 234 and 235);

[0056] - Layer 6-7 jumper wires (hair clips 238 and 239);

[0057] - Layer 4-5 jumper wires (hair clips 245 and 244);

[0058] - Layer 2-3 jumper wires (hair clips 248 and 249); and

[0059] - Layer 1-1 jumper wire (hair clip 254, with a shorter span than other hair clips in winding B2).

[0060] The current path of winding 282 follows the sequence of hairpins 293 (lead), 232, 234, 236, 238, 242, 244, 246, 248, 252, 254 (e.g., where the winding direction changes from counterclockwise to clockwise), 253, 249, 247, 245, 243, 239, 237, 235, 233, and 294 (neutral). All two-leg hairpins of phase B1 have a span of 7, except for hairpin 254 (e.g., 1-1 jumper wire) which has a span of 5, as shown in the figure.

[0061] Referring to the panel 398 showing winding 381 (i.e., winding 381), the winding lead 391 enters slot 13 at layer 1 from the lead side (e.g., axially, as shown at the top). A hairpin of winding 381 forms a continuous path to neutral lead 392 (e.g., as shown at slot 6). The hairpin of winding 381 includes:

[0062] - Layer 1 phase lead (hair clip 391);

[0063] - Layer 1 neutral lead (hair clip 392);

[0064] - Layer 9-10 standard hair clips (hair clips 322 and 323);

[0065] - Layer 7-8 standard hair clips (hair clips 316 and 317);

[0066] - Layer 5-6 standard hair clips (hair clips 312 and 313);

[0067] - Layer 3-4 standard hair clips (hair clips 306 and 307);

[0068] - Layer 1-2 standard hair clips (hair clips 302 and 303);

[0069] - Layer 8-9 jumper wires (hair clips 318 and 319);

[0070] - Layer 6-7 jumper wires (hair clips 314 and 315);

[0071] - Layer 4-5 jumper wires (hair clips 308 and 309);

[0072] - Layer 2-3 jumper wires (hair clips 304 and 305); and

[0073] - Layer 10-10 jumper wire (hair clip 324, with the same span as other hair clips in phase B3).

[0074] The current path of phase 381 follows the hairpins 391 (lead), 302, 304, 306, 308, 312, 314, 316, 318, 322, 324 (for example, where the winding direction changes from clockwise to counterclockwise), 323, 319, 317, 315, 313, 309, 307, 305, 303, and 392 (neutral) in sequence. All two legs of the hairpins in winding 381 have a span of 7, as shown in the figure.

[0075] Referring to panel 399 showing winding B4 (i.e., winding 382), winding leads 393 enter slot 12 at layer 1 from the lead side (e.g., axially, as shown at the top), wherein hairpins of winding 382 form a continuous path to neutral lead 394 (e.g., as shown at slot 7). The hairpins of winding B4 include:

[0076] - Layer 1 phase lead (hair clip 393);

[0077] - Layer 1 neutral lead (hair clip 394);

[0078] - Layer 9-10 standard hair clips (hair clips 352 and 353);

[0079] - Layer 7-8 standard hair clips (hair clips 346 and 347);

[0080] - Layer 5-6 standard hair clips (hair clips 342 and 343);

[0081] - Layer 3-4 standard hair clips (hair clips 336 and 337);

[0082] - Layer 1-2 standard hair clips (hair clips 332 and 333);

[0083] - Layer 8-9 jumper wires (hair clips 348 and 349);

[0084] - Layer 6-7 jumper wires (hair clips 344 and 345);

[0085] - Layer 4-5 jumper wires (hair clips 338 and 339);

[0086] - Layer 2-3 jumper wires (hair clips 334 and 335); and

[0087] - Layer 10-10 jumper wire (hair clip 354, with a shorter span than other hair clips of winding B4).

[0088] The current path of winding 382 follows the hairpins 393 (leads), 332, 334, 336, 338, 342, 344, 346, 348, 352, 354 (e.g., where the winding direction changes from clockwise to counterclockwise), 353, 349, 347, 345, 343, 339, 337, 335, 333, and 394 (neutral) in sequence. All two-legged hairpins of winding 382 have a span of 7, except for hairpin 354 (e.g., a 10-10 jumper) which has a span of 5, as shown in the figure.

[0089] Therefore, for windings 281, 282, 381, and 382 (i.e., windings B1-B4), we can conclude that:

[0090] - The first set of hair clips 202, 203, 232, 233, 322, 323, 352 and 353 are the same;

[0091] - The second set of hair clips 206, 207, 236, 237, 316, 317, 346 and 347 are the same;

[0092] - The third set of hair clips 212, 213, 242, 243, 312, 313, 342 and 343 are the same;

[0093] - The fourth set of hair clips 216, 217, 246, 247, 306, 307, 336 and 337 are the same;

[0094] - The fifth set of hair clips 222, 223, 252, 253, 302, 303, 332 and 333 are the same;

[0095] - Jumper wires 204, 205, 234, 235, 318, 319, 348, and 349 are the same;

[0096] - Jumper wires 208, 209, 238, 239, 314, 315, 344 and 345 are the same;

[0097] - Jumper wires 214, 215, 244, 245, 308, 309, 338 and 339 are the same;

[0098] - Jumper wires 218, 219, 248, 249, 304, 305, 334 and 335 are the same;

[0099] - Jumper wire 224 is unique;

[0100] - Jumper wire 254 is unique;

[0101] - Jumper wire 324 is unique;

[0102] - Jumper wire 354 is unique;

[0103] - Leads 291 and 293 are the same;

[0104] - Leads 292 and 294 are the same;

[0105] - Leads 391 and 393 are identical; and

[0106] Leads 392 and 394 are identical, as outlined in Table 1 below.

[0107] Table 1 - Required number of unique parts (10 layers).

[0108] Hair clip type quantity Notes conventional 5 (Five dimensions for radial positional differences) jumper wire 4 (Bridging of floors 9-8, 7-6, 5-4, and 3-2) jumper wire 4 (5-slot 1-1, 7-slot 1-1, 5-slot 10-10, 7-slot 10-10 bridging) Mutually 2 (Layer 1 phase lead, Layer 10 phase lead) neutral 2 (Neutral lead in layer 1, neutral lead in layer 10) total 17

[0109] As shown in this example, two of the four parallel paths of the winding of phase B (e.g., Figure 2 The windings B1 and B2 shown begin on the outside at layer 10 and are wound clockwise until they reach the inside at layer 1 where the winding direction changes. The other two parallel paths of phase B (e.g., Figure 3 The windings B3 and B4 shown start at layer 1 inside and are wound clockwise until they reach the outside at layer 10 where the winding direction changes.

[0110] Figure 4Two perspective views (e.g., panels 498 and 499) of a schematic motor stator 400 comprising six layers and having balanced windings according to some embodiments of the present disclosure are shown. The views shown in panels 498 and 499 are taken from opposite sides of the stator (e.g., rotated approximately 180 degrees relative to each other). As shown, the motor stator 400 corresponds to a 3-phase, 8-pole motor; however, it should be understood that the arrangement of the present disclosure can be applied to any suitable electric motor having any suitable number of slots, poles, phases, and layers. Terminals 411, 412, and 413 are configured to couple to the corresponding phases (e.g., A, B, and C) of the motor (e.g., a three-phase, eight-pole motor as shown). The stator body 410 includes a plurality of slots (e.g., 48 slots as shown, where line 421 indicates slot 1, line 431 indicates slot 47, line 441 indicates slot 3, and line 451 indicates slot 6) arranged between a plurality of stator teeth. Multiple hairpins 420 are arranged in slots (e.g., intersecting each other at weld 430). For example, as shown, hairpins 420 are configured to be axially inserted into slots (e.g., and welded to the axial side opposite to the insertion, as shown in weld 430), wherein each hairpin includes one or two legs corresponding to a respective slot. For example, a hairpin in hairpin 420 may include two legs configured to (i) engage in two respective slots in a radial position (e.g., the two legs are configured to engage in a first layer and a second layer, respectively, thereby forming layer pairs such as 1-2, 3-4, 5-6) and (ii) engage in two respective slots across a predetermined pitch (e.g., the number of slots of the hairpin).

[0111] Figure 5 Some embodiments according to this disclosure are shown. Figure 4 Figure 12 shows two perspective views of a schematic motor stator (e.g., panels 598 and 599), with only the windings of the two corresponding parallel windings of each phase installed (e.g., winding B1 in panel 598 and winding B2 in panel 599). Panel 598 shows winding 581 (e.g., winding B1 of phase B), while panel 599 shows winding 582 (e.g., winding B2 of phase B), where windings 581 and 582 are connected in parallel to form the winding of phase B. Figure 12 shows a schematic wiring diagram of some phases of the motor stator 400 (e.g., for windings 581 and 582). The views shown in panels 598 and 599 are taken from opposite sides of the stator (e.g., rotated approximately 180 degrees relative to each other). Figure 5 As shown, slots 14 and 19 are indicated by leads in panel 598, and slots 13 and 20 are indicated by leads in panel 599.

[0112] Referring to panel 598 showing winding 581 (i.e., winding B1), phase lead 591 enters slot 14 at layer 6 from the lead side (e.g., axially, as shown at the top). A first set of counter-clockwise hairpins 502, 503, and 504 and jumper 505 extend counter-clockwise in layers 5 and 6, continuing to a second set of counter-clockwise hairpins 512, 513, and 514 and jumper 515 extending counter-clockwise in layers 3 and 4, and continuing to a third set of counter-clockwise hairpins 522, 523, and 524 and jumper 525 extending counter-clockwise in layers 1 and 2. Although hairpins 502-504, 512-514, and 522-524 and jumpers 505 and 515 have the same span (e.g., 7 slots as shown), jumper 525 includes a different span (e.g., 5 slots as shown), as illustrated. Jumper 525 is referred to as a “1-1” jumper because it extends between the slots in layer 1 and marks the location of the winding where the azimuth winding direction changes (e.g., for winding 581, the counterclockwise winding direction changes to clockwise). A third set of clockwise hairpins 532, 533, and 534, along with jumper 535, extend clockwise in layers 1 and 2, continuing to another second set of clockwise hairpins 542, 543, and 544 extending clockwise in layers 3 and 4, and jumper 545, continuing to another first set of clockwise hairpins 552, 553, and 554 extending clockwise in layers 1 and 2, and continuing to the neutral lead 592 (e.g., at slot 19, as shown). Hairpins 532-534, 542-544, and 552-554, as well as jumpers 535 and 545, have the same span (e.g., 7 slots, as shown). Therefore, hairpins 502-504 and 552-554 are identical, hairpins 512-514 and 542-544 are identical, and hairpins 522-524 and 532-534 are identical, wherein each group differs in length (e.g., all have the same span, but the azimuth distance varies with the radius based on the layer pair).

[0113] Referring to panel 599 showing winding 582 (i.e., winding B2), phase lead 593 enters slot 13 at layer 6 from the lead side (e.g., axially, as shown at the top). A first set of hairpins 506, 507, and 508, along with jumper 509, extends counterclockwise in layers 5 and 6, continuing to a second set of hairpins 516, 517, and 518, along with jumper 519, which extends counterclockwise in layers 3 and 4, continuing to a third set of hairpins 526, 527, and 528, along with jumper 529, which extends counterclockwise in layers 1 and 2. Hairpins 506-508, 516-518, and 526-528, along with jumpers 509, 519, and 529, have the same span (e.g., 7 slots, as shown). Jumper 529 is also a "1-1" jumper because it extends between the slots in layer 1 and marks the winding location where the direction changes (e.g., counterclockwise to clockwise for winding 582), but includes the same span as the hairpins. Another third set of hairpins 536, 537, and 538, along with jumper 539, extends clockwise in layers 1 and 2, continuing to another second set of hairpins 546, 547, and 548 extending clockwise in layers 3 and 4, along with jumper 549, continuing to another first set of hairpins 556, 557, and 558 extending clockwise in layers 1 and 2, and continuing to the neutral lead 594 (e.g., at slot 20, as shown). Hairpins 536-538, 546-548, and 556-558, along with jumpers 539 and 549, have the same span (e.g., 7 slots, as shown). Therefore, for windings 581 and 582, we can conclude that:

[0114] -The first set of hair clips 502-504, 506-508, 552-554 and 556-558 are the same;

[0115] - The second set of hair clips 512-514, 516-518, 542-544 and 546-548 are the same;

[0116] and

[0117] -The third set of hair clips, 522-524, 526-528, 532-534, and 536-538, are identical.

[0118] - Each group differs only in length (e.g., all have the same span, but the azimuth distance changes with the radius based on the layer pair).

[0119] Table 2 below shows the total number of different shapes of the winding hair clip.

[0120] Table 2 - Required number of unique components (6 layers).

[0121] Hair clip type quantity Notes conventional 3 (Three dimensions for radial positional differences) jumper wire 2 (Bridging between layers 5-4 and 3-2) jumper wire 2 (5-slot 1-1 bridging, 7-slot 1-1 bridging) Mutually 1 All 6 phase leads are identical. neutral 1 All six neutral leads are identical. total 9

[0122] Figure 6 Three end views (e.g., panels 600, 630, and 650) of schematic slot arrangements with different numbers of conductor layers according to some embodiments of the present disclosure are shown. Panel 600 shows an arrangement of six conductors per slot. For reference, azimuth directions (e.g., the direction of the slot index) and radial directions (e.g., the direction of the layer index) are indicated in panel 600, and these directions are similarly oriented in panels 630 and 650. Panel 630 shows an arrangement of eight conductors per slot. Panel 650 shows an arrangement of ten conductors per slot. In each of panels 600, 630, and 650, several windings are shown for three phases (e.g., portions having repeating phase A but with opposite current orientations). As shown, each arrangement of panels 600, 630, and 650 includes slots 601-606 and stator teeth 611-615 arranged between adjacent slots. In each of panels 600, 630, and 650, several windings are shown for three phases (e.g., portions of phase A that repeat but have opposite current orientations). As shown in each of panels 600, 630, and 650, the windings for each phase are distributed among the three in the slots shown, wherein two of the three slots share a slot with the other phases. As shown, the windings for phase A of the first polarity (e.g., current entering or leaving the page, as shown) are included in slots 601 and 602, and the windings for phase A of the opposite polarity are included in slot 606. As shown, the windings for phase B of the first polarity are included in slots 602, 603, and 604. As shown, the windings for phase C of the first polarity are included in slots 604, 605, and 606. The interleaving of windings between the three slots in the layer (e.g., radial interleaving of phase A winding in panel 600 between slots 601, 602, and 606, and phases B and C) reduces fifth and seventh winding harmonics, resulting in lower torque ripple, which can be a source of motor noise. Figure 6 In some embodiments not shown, the windings of each phase may be distributed in two slots, wherein there will be no phase sharing within each of these slots. For illustration, the latter may be preferred for manufacturing reasons, but in some cases at the cost of higher space harmonics in the motor.

[0123] Figure 7 Three end views (e.g., panels 700, 730, and 750) of additional schematic slot arrangements with different numbers of conductor layers according to some embodiments of the present disclosure are shown. For illustration, Figure 6 and Figure 7Schematic arrangements of windings in slots according to some embodiments of this disclosure are provided. For reference, azimuth directions (e.g., slot index directions) and radial directions (e.g., layer index directions) are indicated in panel 700, and these directions are similarly oriented in panels 730 and 750. Panel 700 shows an arrangement of six conductors per slot. Panel 730 shows an arrangement of eight conductors per slot. Panel 750 shows an arrangement of ten conductors per slot. As shown, each arrangement of panels 700, 730, and 750 includes slots 701-706 and stator teeth 711-715 arranged between adjacent slots. In each of panels 700, 730, and 750, several windings are shown for three phases (e.g., portions having repeating phase A but with opposite current orientations). As shown in each of panels 700, 730, and 750, the windings for each phase are distributed among the three slots, wherein two of the three slots share slots with other phases. As shown, the windings of phase A of the first polarity (e.g., current entering or leaving the page, as shown) are included in slots 701 and 702, and the windings of phase A with the opposite polarity are included in slot 706. As shown, the windings of phase B of the first polarity are included in slots 702, 703, and 704. As shown, the windings of phase C of the first polarity are included in slots 704, 705, and 706. The interleaving of the windings between the three slots in the layer (e.g., the radial interleaving of the phase A windings in panel 700 between slots 701, 702, and 706, and phases B and C) reduces fifth and seventh winding harmonics, resulting in lower torque ripple, which can be a source of motor noise. In some embodiments, the windings of each phase may be distributed in two slots, where there will be no phase sharing within the slots. For illustration, the latter may be preferred for manufacturing reasons, but in some cases at the cost of higher space harmonics in the motor.

[0124] Figures 8A to 8F , Figures 9A to 9F , Figures 10A to 10F , Figures 11A to 11F and Figures 12A to 12F Schematic wiring diagrams are shown for slots of different sizes and / or different winding pitches. A forty-eight slot arrangement is shown. Figures 8A to 12F The wiring diagram shows the slot numbers. The solder side is shown as the top side of each layer (see, for example, solder side 820) and the lead side is shown as the bottom side of each layer (see, for example, lead side 821).

[0125] Figures 8A to 8F A schematic wiring diagram of a parallel winding corresponding to one phase (e.g., phase B) of an eight-layer stator is shown according to some embodiments of the present disclosure, wherein the winding pitch is six slots. Figures 8A to 8FArranged in a 2×3 array to form a composite table, wherein Figures 8A to 8C Arranged in a 1×3 array, from left to right, to form a table, and in which Figures 8D to 8F Arrange them in a 1×3 array below, from left to right, to form another table. Figures 8A to 8F The winding diagram is arranged with slots indexed along the horizontal axis and layers indexed along the vertical axis. Figures 8A to 8F The path of windings B1, B2, B3, and B4 is shown (e.g., as windings 801-804). As shown, the hairpin can be axially inserted from the bottom of each layer (e.g., the crown side or lead side 821), wherein the legs of the hairpin extend vertically in the corresponding slots. As shown, the weld 810 between the legs of the hairpin is shown on the top (e.g., the weld side 820), represented by a thick rectangular segment (exemplary weld 810 is shown in...). Figure 8A (as shown in the illustration). In the illustrative example (not shown), phases A1 and A2 are... Figures 8A to 8F Phases B1 and B2 are identical, but offset by 4 slots (e.g., phase A1 starts in slot 17 instead of slot 13 like phase B1). Phases A3 and A4 are similarly identical to B3 and B4, but offset by 4 slots (e.g., phase A3 starts in slot 28 instead of slot 24 like phase B2). Phases C1 and C2 are identical to B1 and B2, but offset by 8 slots (e.g., phase C1 starts in slot 21 instead of slot 13 like phase B1). Phases C3 and C4 are identical to B1 and B2, but offset by 8 slots (e.g., phase C3 starts in slot 32 instead of slot 24 like phase B2). Based on... Figures 8A to 8F The wiring paths are shown in Table 3, which shows the number of unique hair clips (e.g., the total number of each type and different shapes).

[0126] Table 3 - Corresponding to Figures 8A to 8F Unique hair clip

[0127] Hair clip type quantity Notes conventional 4 (Four dimensions for radial positional differences) jumper wire 3 (Bridging between layers 6 and 7, 5 and 4, and 3 and 2) jumper wire 4 (Two 1-1 jumpers, two 8-8 jumpers) Mutually 2 neutral 2 total 15

[0128] Figures 9A to 9F A schematic wiring diagram of a parallel winding corresponding to one phase of a ten-layer stator according to some embodiments of the present disclosure is shown, wherein the winding pitch is six slots. Figures 9A to 9F Arranged in a 2×3 array to form a composite table, wherein Figures 9A to 9C Arranged in a 1×3 array, from left to right, to form a table, and in which Figures 9D to 9F Arrange them in a 1×3 array below, from left to right, to form another table. Figures 9A to 9F The winding diagram is arranged with slots indexed along the horizontal axis and layers indexed along the vertical axis. Figures 9A to 9FThe path of windings B1, B2, B3, and B4 is shown (e.g., as windings 901-904). As shown, the hairpin is axially inserted from the bottom of each layer (e.g., crown side or lead side), with the legs of the hairpin extending vertically in corresponding slots. As shown, the weld 910 between the legs of the hairpin is shown on the top (e.g., weld side), indicated by the thick line segment. Based on... Figures 9A to 9F The wiring path is shown in Table 4, which shows the number of unique hair clips (e.g., the total number of each type and different shapes).

[0129] Table 4 - Corresponding to Figures 9A to 9F Unique hair clip

[0130] Hair clip type quantity Notes conventional 5 (Five dimensions for radial positional differences) jumper wire 4 (Bridging between layers 8-9, 6-7, 5-4, and 3-2) jumper wire 4 (Two 1-1 bridging connections, two 10-10 bridging connections) Mutually 2 neutral 2 total 17

[0131] Figures 10A to 10F A schematic wiring diagram of a parallel winding corresponding to one phase of a six-layer stator according to some embodiments of the present disclosure is shown, wherein the winding pitch is six slots. Figures 10A to 10F Arranged in a 2×3 array to form a composite table, wherein Figures 10A to 10C Arranged in a 1×3 array, from left to right, to form a table, and in which Figures 10D to 10F Arrange them in a 1×3 array below, from left to right, to form another table. Figures 10A to 10F The winding diagram is arranged with slots indexed along the horizontal axis and layers indexed along the vertical axis. Figures 10A to 10F The path of windings B1 and B2 is shown (e.g., as windings 1001-1002). As shown, the hairpin is inserted axially from the bottom of each layer (e.g., crown side or lead side), with the legs of the hairpin extending vertically in corresponding slots. As shown, the weld 1010 between the legs of the hairpin is shown on the top (e.g., weld side), indicated by the thick line segment. In the schematic example (not shown), phases A1 and A2 are the same as B1 and B2, but offset by 4 slots (e.g., the A1 phase lead starts in slot 17), and phases C1 and C2 are the same as B1 and B2, but offset by 8 slots (e.g., the C1 phase lead starts in slot 21). Based on Figures 10A to 10F The wiring paths are shown in Table 5, which shows the number of unique hair clips (e.g., the total number of each type and different shapes).

[0132] Table 5 - Corresponding to Figures 10A to 10F Unique hair clip

[0133] Hair clip type quantity Notes conventional 3 (Three dimensions for radial positional differences) jumper wire 2 (Bridging between layers 5-4 and 3-2) jumper wire 2 (Two 1-1 bridging connections) Mutually 1 neutral 1 total 9

[0134] Figures 11A to 11F A schematic wiring diagram of a parallel winding corresponding to one phase of a ten-layer stator according to some embodiments of the present disclosure is shown, wherein the winding pitch is seven slots. Figures 11A to 11F Arranged in a 2×3 array to form a composite table, wherein Figures 11A to 11C Arranged in a 1×3 array, from left to right, to form a table, and in which Figures 11D to 11F Arrange them in a 1×3 array below, from left to right, to form another table. Figures 11A to 11F The winding diagram is arranged with slots indexed along the horizontal axis and layers indexed along the vertical axis. Figures 11A to 11F The path of windings B1, B2, B3, and B4 is shown (e.g., as windings 1101-1104). As shown, the hairpin is axially inserted from the bottom of each layer (e.g., crown side or lead side), with the legs of the hairpin extending vertically in corresponding slots. As shown, the weld 1110 between the legs of the hairpin is shown on the top (e.g., weld side), indicated by a thick line segment. For example, in... Figures 1 to 3 The path of windings B1-B4 is shown. In a schematic example (not shown), phases A1 and A2 are the same as B1 and B2, but offset by 4 slots (e.g., the A1 phase lead starts in slot 17), phases A3 and A4 are the same as B3 and B4, but offset by 4 slots (e.g., the A3 phase lead starts in slot 17), phases C1 and C2 are the same as B1 and B2, but offset by 8 slots (e.g., the C1 phase lead starts in slot 21), and phases C3 and C4 are the same as B1 and B2, but offset by 8 slots (e.g., the C3 phase lead starts in slot 21). Based on Figures 11A to 11F The wiring paths are shown in Table 6, which shows the number of unique hair clips (e.g., the total number of each type and different shapes).

[0135] Table 6 - Corresponding to Figures 11A to 11F Unique hair clip

[0136] Hair clip type quantity Notes conventional 5 (Five dimensions for radial positional differences) jumper wire 4 (Bridging between layers 8-9, 6-7, 5-4 and 3-2) jumper wire 4 (Two 1-1 bridging connections, two 10-10 bridging connections) Mutually 2 neutral 2 total 17

[0137] Figures 12A to 12F A schematic wiring diagram of a parallel winding corresponding to one phase of a six-layer stator according to some embodiments of the present disclosure is shown, wherein the winding pitch is seven slots. Figures 12A to 12F Arranged in a 2×3 array to form a composite table, wherein Figures 12A to 12C Arranged in a 1×3 array, from left to right, to form a table, and in which Figures 12D to 12F Arrange them in a 1×3 array below, from left to right, to form another table. Figures 12A to 12F The winding diagram is arranged with slots indexed along the horizontal axis and layers indexed along the vertical axis. Figures 12A to 12F The diagram shows the winding path of each winding in windings B1 and B2 (e.g., as windings 1201-1202). As shown, the hairpin is inserted from the bottom of each layer (e.g., crown side or lead side), with the legs of the hairpin extending vertically in corresponding slots. As shown, the weld 1210 between the legs of the hairpin is shown on the top (e.g., weld side), indicated by a thick line segment. For example, in... Figures 4 to 5 The winding paths of windings B1 and B2 are shown. In a schematic example (not shown), windings A1 and A2 (of phase A) are the same as B1 and B2, but offset by 4 slots (e.g., the A1 phase lead starts in slot 18), and windings C1 and C2 (of phase C) are the same as B1 and B2, but offset by 8 slots (e.g., the C1 winding lead starts in slot 22). Based on Figures 12A to 12F The wiring paths are shown in Table 7, which shows the number of unique hair clips (e.g., the total number of each type and different shapes).

[0138] Table 7 - Corresponding to Figures 12A to 12F Unique hair clip

[0139] Hair clip type quantity Notes conventional 3 (Three dimensions for radial positional differences) jumper wire 2 (Bridging between layers 5-4 and 3-2) jumper wire 2 (Two 1-1 bridging connections) Mutually 1 neutral 1 total 9

[0140] Figures 1 to 12F The schematic winding arrangement illustrates some aspects of this disclosure. For example, the specific slot numbers are merely illustrative, and the windings shown can begin at any suitable slot location and layer. Furthermore, according to this disclosure, the number of slots, the number of poles, the number of phases, the number of parallel windings in each phase, the number of layers, the pole pitch, or any combination thereof can be any suitable value. Additionally, whether each winding begins at the highest or lowest index layer is merely illustrative. In some embodiments, for example, Figures 9A to 9F The winding paths of B1 and B2 can start at the innermost layer, rather than the outermost layer.

[0141] Figure 13 A flowchart illustrating an illustrative process 1300 for manufacturing a motor stator with balancing windings according to some embodiments of the present disclosure is shown. In the illustrative example, Figures 1 to 12F Any stator or winding arrangement, or any other suitable stator, can be wound using process 1300. According to this disclosure, the illustrative steps of process 1300 can be performed in any suitable order. For example, steps 1302 and 1308 can be performed simultaneously, sequentially in any suitable order, or a combination thereof. In another example, step 1310 can be performed incrementally (e.g., after each of steps 1302-1308 or at any suitable intermediate stage in the assembly). Process 1300 can be repeated for each phase, each winding of each phase (e.g., where multiple windings are coupled in parallel to form a phase), or a combination thereof. For illustration, Figures 1 to 3 Each of the windings B1-B4 can be wound using process 1300, and the windings B1-B4 can be electrically coupled in parallel to form the “B” phase of the motor (for example, process 1300 can be repeated for the “A” and “C” phases).

[0142] Step 1302 includes arranging the phase lead and neutral lead in corresponding slots in the stator. In some embodiments, the phase lead and neutral lead are axially inserted into the corresponding slots. In some embodiments, step 1302 includes bending the inserted lead after insertion (e.g., to position the ends of the lead for soldering). In some embodiments, each phase lead and neutral lead includes a leg that inserts into the corresponding slot.

[0143] Step 1304 includes sequentially arranging the first set of winding hairpins in corresponding slots of the stator along a first azimuth orientation. In some embodiments, each winding hairpin is axially inserted into the corresponding slot. In some embodiments, step 1304 includes bending the inserted lead after insertion (e.g., to position the ends of the lead for soldering). The first azimuth orientation may be clockwise or counterclockwise. In some embodiments, the first set of winding hairpins may include jumpers spanning one or more layers. In some embodiments, each of the first set of winding hairpins includes the same span (e.g., spanning the same number of slots).

[0144] Step 1306 includes arranging the same-layer jumper hairpins in corresponding slots of the stator. In some embodiments, the same-layer jumpers are arranged in the innermost radial layer. In some embodiments, the same-layer jumpers are arranged in the outermost radial layer. Compared to the first set of winding hairpins, the same-layer jumpers may include the same span, a shorter span, or a longer span.

[0145] Step 1308 includes sequentially arranging the second set of winding hairpins in corresponding slots of the stator along a second azimuth orientation. In some embodiments, each winding hairpin is axially inserted into the corresponding slot. In some embodiments, step 1308 includes bending the inserted leads after insertion (e.g., to position the ends of the leads for soldering). The second azimuth orientation may be clockwise or counterclockwise, either opposite to the direction of step 1304. In some embodiments, the second set of winding hairpins may include jumpers spanning one or more layers. In some embodiments, each of the second set of winding hairpins includes the same span (e.g., spanning the same number of slots). In some embodiments, each winding hairpin of the first and second sets includes the same span (e.g., as shown in the image). Figures 1 to 5 (The seven slots shown, or any other suitable number of slots).

[0146] Step 1310 includes welding the legs of the sequentially wound hairpin together. Step 1310 may include contact welding, laser welding, friction welding, soft soldering, hard soldering, crimping, using any other suitable technique to perform the joining, or any combination thereof.

[0147] In an illustrative example, each winding applied using process 1300 may follow a path from the outside to the inside (e.g., for a 10-layer winding, and vice versa), then be bridging the same layer, and then return to the outside or inside by changing the winding direction (e.g., azimuth direction), instead of starting at an outer or inner layer and ending on a relatively radial side (e.g., inside or outside, respectively). In other illustrative examples, for some ten-layer and eight-layer arrangements, each winding does not necessarily complete each layer before bridging to the next layer.

[0148] The foregoing description is merely illustrative of the principles of this disclosure, and various modifications can be made by those skilled in the art without departing from the scope of this disclosure. The above embodiments are presented for illustrative purposes and not for limitation. This disclosure may also take many forms other than those expressly described herein. Therefore, it should be emphasized that this disclosure is not limited to the methods, systems, and instruments expressly disclosed, but is intended to include variations and modifications thereof, which are within the spirit of the following claims.

Claims

1. A stator for an electric motor, the stator comprising: Multiple motor teeth form multiple slots, wherein each slot is configured to accommodate N layers, where N is an integer; Phase leads and neutral leads are arranged in the first layer; The first group of winding hairpins is configured to achieve the span of M slots, wherein the first group of winding hairpins is connected in series and coupled to the phase lead, and wherein the first group of winding hairpins is arranged sequentially in the first azimuth direction. A single hair clip jumper wire, wherein the first leg and the second leg of the single hair clip jumper wire are inserted into the slot of the second layer, wherein the first leg of the single hair clip jumper wire is coupled in series with the first group of winding hair clips. and The second set of winding hairpins, each configured to achieve the span of M slots, wherein the second set of winding hairpins is connected in series between the second leg of the single hairpin jumper and the neutral lead, wherein the second set of winding hairpins is arranged sequentially in a second azimuth direction opposite to the first azimuth direction, and wherein the first set of winding hairpins, the single hairpin jumper, and the second set of winding hairpins form a continuous electrical path between the phase lead and the neutral lead.

2. The stator of claim 1, wherein the single hairpin jumper is configured to achieve the span of the M slots.

3. The stator of claim 1, wherein the single hairpin jumper is configured to achieve a span smaller than that of the M slots.

4. The stator according to claim 1, wherein M equals seven slots, such that seven stator teeth are arranged between the legs of each of the first set of winding hairpins and between the legs of each of the second set of winding hairpins.

5. The stator according to claim 4, wherein: The plurality of slots includes 48 slots; The phase lead, the neutral lead, the first set of winding hairpins, the single hairpin jumper wire, and the second set of winding hairpins correspond to the first winding of the first phase, and the stator also includes windings corresponding to the two additional phases.

6. The stator according to claim 1, wherein the first layer is the outermost radial layer, and wherein the second layer is the innermost radial layer.

7. The stator according to claim 1, wherein the first layer is the innermost radial layer, and wherein the second layer is the outermost radial layer.

8. A stator for an electric motor, the stator comprising: Multiple slots; Multiple phases, said multiple phases arranged in said slot, each phase comprising: The first set of winding hairpins are connected in series and arranged sequentially in the first azimuth direction. The second set of winding hairpins, the second set of winding hairpins being connected in series and arranged sequentially in a second azimuth direction opposite to the first azimuth direction, wherein each of the first set of winding hairpins and each of the second set of winding hairpins includes the span of M slots; and A single hairpin jumper wire, wherein the first leg and the second leg of the single hairpin jumper wire are inserted into a slot in a single layer, wherein the first leg of the single hairpin jumper wire is coupled in series with the first group of winding hairpins and the second leg of the single hairpin jumper wire is coupled in series with the second group of winding hairpins.

9. The stator of claim 8, wherein the first set of winding hairpins, the second set of winding hairpins, and the single hairpin jumper correspond to a first continuous winding, and wherein each phase includes a second continuous winding coupled in parallel with the first continuous winding, each second continuous winding comprising: The third set of winding hair clips are connected in series and arranged sequentially in the first azimuth direction. The fourth group of winding hair clips are connected in series and arranged sequentially in the second azimuth direction, wherein each of the third group of winding hair clips and each of the fourth group of winding hair clips includes the span of M slots. and Another single hairpin jumper wire, the other single hairpin jumper wire being arranged in a single layer, wherein the first leg of the other single hairpin jumper wire is coupled in series with the third group of winding hairpins and the second leg of the other single hairpin jumper wire is coupled in series with the fourth group of winding hairpins.

10. The stator of claim 9, wherein the single hairpin jumper is configured to achieve the span of the M slots, and wherein the other single hairpin jumper is configured to achieve a span smaller than the M slots.

11. The stator according to claim 8, wherein M equals seven slots, such that seven stator teeth are arranged between the legs of each first set of winding hairpins and between the legs of each second set of winding hairpins.

12. The stator of claim 8, wherein the single layer is the outermost radial layer.

13. The stator according to claim 8, wherein the single layer is the innermost radial layer.

14. The stator of claim 8, wherein the plurality of phases comprises three phases, wherein each of the three phases comprises at least two windings coupled in parallel, and wherein the first set of winding hairpins, the second set of winding hairpins, and the single hairpin jumper are included in the first winding of the at least two windings.

15. A stator for an electric motor, the stator comprising: Multiple stator teeth form multiple slots, wherein each slot is configured to accommodate N layers, where N is an even integer; A plurality of winding hair clips, each of the plurality of winding hair clips being configured to achieve a span, wherein the plurality of winding hair clips comprises N / 2 subsets of winding hair clips, and wherein each subset of the N / 2 subsets comprises a corresponding length corresponding to the span; A plurality of jumper hair clips, each of the plurality of jumper hair clips being configured to achieve the span, wherein the plurality of jumper hair clips comprises N / 2-1 subsets of jumper hair clips, and wherein each subset of the N / 2-1 subsets comprises a corresponding length corresponding to the span; and A single hairpin jumper wire, wherein the first and second legs of the single hairpin jumper wire are inserted into slots in a single layer of the N layers, wherein the plurality of winding hairpins, the plurality of jumper hairpins and the single hairpin jumper wire are coupled in series to form a continuous electrical path of the phase.

16. The stator of claim 15, wherein the single layer is the outermost radial layer.

17. The stator of claim 15, wherein the single layer is the innermost radial layer.

18. The stator of claim 15, wherein the single hairpin jumper is configured to achieve the span.

19. The stator of claim 15, wherein the single hairpin jumper is configured to achieve a shorter span than the span.

20. The stator of claim 15, wherein the plurality of winding hairpins, the plurality of jumper hairpins, and the single hairpin jumper form a sequence, wherein the single hairpin jumper is arranged at the center of the sequence, and wherein the single hairpin jumper corresponds to a change in the azimuth winding direction of the plurality of winding hairpins and the plurality of jumper hairpins.

Images