Flat wire winding, multiphase motor and three-phase motor

Abstract

A flat wire wave winding, a multiphase motor and a three-phase motor, the flat wire wave winding is used in a multiphase motor, wherein the multiphase motor has a pole pitch, the multiphase motor includes a stator, the stator has a plurality of stator slots, wherein each of the stator slots includes an open end, each of the stator slots respectively defines an even number of wire layer positions including a first layer wire layer position farthest from the open end and a last layer wire layer position closest to the open end, the flat wire wave winding includes a first coil including a first shaped wire and a third shaped wire, and a second coil including a second shaped wire and a fourth shaped wire.

Description

TECHNICAL FIELD

[0001] The present application relates to a flat wire wave winding, in particular to a flat wire wave winding for a motor, a multiphase motor and a three-phase motor. BACKGROUND

[0002] New energy vehicles use motors as the main power source. The motor has a stator and a rotor, and generates power through electromagnetic effects between the stator and the rotor. The flat wire winding of the existing stator is mainly divided into hairpin or i-pin, both of which require a large amount of bending and welding of the wire. If damage occurs during production, it will affect the conductivity of the winding and the overall performance of the motor. SUMMARY

[0003] The present application provides a flat wire wave winding and a forming method thereof to solve the above problems.

[0004] The present application discloses a flat wire wave winding for a multiphase motor, wherein the multiphase motor has a pole pitch, the multiphase motor includes a stator, the stator has a plurality of stator slots, each of the stator slots includes an open end, each of the stator slots defines an even number of wire layer positions including a first layer wire layer position farthest from the open end and a last layer wire layer position closest to the open end, the flat wire wave winding includes a first coil including a first formed wire and a third formed wire, and a second coil including a second formed wire and a fourth formed wire.

[0005] The present application further discloses a multiphase motor having a pole pitch, the multiphase motor includes a rotor located at the center of the multiphase motor, a plurality of phase pairs, a stator having a lead-out side and a non-lead-out side, the stator includes a plurality of stator slots each having a stator open end facing the rotor, each of the stator slots defines an even number of wire layer positions, wherein the wire layer position farthest from the stator open end is a first layer wire layer position, and the wire layer position closest to the stator open end is a last layer wire layer position, and a flat wire wave winding including a plurality of coils, each of the coils being composed of two formed wires, wherein the formed wire includes a plurality of straight wire portions and a plurality of bridge portions connecting two straight wire portions, the straight wire portion includes a lead-out segment wire, a connecting segment wire and a plurality of straight segment wires, and the flat wire wave winding is placed in the stator according to a winding rule.

[0006] A three-phase motor includes a rotor having four pole pairs, a stator including 48 stator slots sequentially numbered #1~#48, wherein each stator slot has an opening end facing the rotor, each stator slot defines eight wire layer positions sequentially numbered L1~L8 from the farthest to the closest to the opening end, and a flat wire wave winding including a first coil and a third coil each including a first shaped wire and a third shaped wire, and a second coil and a fourth coil each including a second shaped wire and a fourth shaped wire, wherein each of the first shaped wire, the second shaped wire, the third shaped wire and the fourth shaped wire includes 16 straight wire portions and 15 bridge portions connecting two adjacent straight wire portions. BRIEF DESCRIPTION OF DRAWINGS

[0007] Figure 1 A schematic diagram of a flat wire wave winding of an embodiment of the present application;

[0008] Figure 2A A schematic diagram of a flat wire wave winding of an embodiment of the present application;

[0009] Figure 2B A top view of a flat wire wave winding of an embodiment of the present application;

[0010] Figure 3 A schematic diagram of a first shaped wire of a flat wire wave winding of an embodiment of the present application;

[0011] Figure 4 A schematic diagram of a first shaped wire in a stator of an embodiment of the present application;

[0012] Figure 5 A top view of a first shaped wire in a stator of an embodiment of the present application;

[0013] Figure 6 A schematic diagram of a second shaped wire of a flat wire wave winding of an embodiment of the present application;

[0014] Figure 7 A schematic diagram of a second shaped wire in a stator of an embodiment of the present application;

[0015] Figure 8 A schematic diagram of a third shaped wire of a flat wire wave winding of an embodiment of the present application;

[0016] Figure 9 A schematic diagram of a third shaped wire in a stator of an embodiment of the present application;

[0017] Figure 10 A schematic diagram of a fourth shaped wire of a flat wire wave winding of an embodiment of the present application;

[0018] Figure 11A structure diagram of a fourth shaped conductor in a stator according to an embodiment of the present application;

[0019] Figure 12 An unfolding diagram of a first pair of shaped conductors according to an embodiment of the present application;

[0020] Figure 13 An unfolding diagram of a second pair of shaped conductors according to an embodiment of the present application;

[0021] Figure 14A A diagram of a first coil according to an embodiment of the present application;

[0022] Figure 14B A diagram of a first coil according to an embodiment of the present application;

[0023] Figure 15 A diagram of a second coil according to an embodiment of the present application;

[0024] Figure 16 A winding structure diagram of a flat wire wave winding in a stator according to an embodiment of the present application;

[0025] Figure 17 A winding structure diagram of a flat wire wave winding in a stator according to another embodiment of the present application;

[0026] Figure 18A A diagram of a stator and a stator slot according to an embodiment of the present application;

[0027] Figure 18B A diagram of a conductor layer position in a stator slot according to an embodiment of the present application;

[0028] Reference signs:

[0029] 1: stator

[0030] 10: flat wire wave winding

[0031] 12: stator slot

[0032] 20: leading side

[0033] 30, 60, 80, 100: first shaped conductor

[0034] 120: first pair of shaped conductors

[0035] 130: second pair of shaped conductors

[0036] 301, 601, 801, 1001: leading section conductor

[0037] 316, 616, 816, 1016: connecting section conductor

[0038] 302-315, 602-615, 802-815, 1002-1015: straight section conductor

[0039] 401-415, 701-715, 901-915, 1101-1115: bridge portions

[0040] 350, 650, 850, 1050: connection end

[0041] 360, 660, 860, 1060: lead-out end

[0042] L1-L8: wire layer position

[0043] U1, U2, U3, U4: coil DETAILED DESCRIPTION

[0044] FIG. 18A and FIG. 18B respectively show a schematic diagram of a stator, a stator slot, and a wire layer position of an embodiment of the present application. As shown in FIG. 18A, a stator 1 of an embodiment of the present application includes a plurality of stator slots 12, and the opening end of the stator slot 12 faces a rotor (not shown in the figure). As shown in FIG. 18B, each stator slot 12 respectively defines a plurality of wire layer positions so that the flat wire wave winding of the present application can be placed therein. Although FIG. 18B takes eight wire layers L1-L8 as an example, the present application can be applied to any even number of wire layer embodiments, and is not limited to eight layers.

[0045] Please refer to FIG. 1, FIG. 2A, and FIG. 2B. FIG. 1 is a schematic diagram of a flat wire wave winding 10 of an embodiment of the present application, FIG. 2A is a schematic diagram of an unfolded structure of the flat wire wave winding 10, and FIG. 2B is a top view of the flat wire wave winding 10 from one side of the stator 1. As shown in the figures, the flat wire wave winding 10 of the present application is composed of a plurality of integrally formed shaped wires, and each shaped wire includes a plurality of straight wire portions and a plurality of bridge portions. As also shown in the figures, the flat wire wave winding 10 of the present application can be first bent into the required shape on a tool and then pushed into the corresponding stator slot 12 and wire layer position from the opening end of the stator slot 1. In an embodiment, the lead-out wire of the flat wire wave winding 10 of the present application is concentrated on a lead-out side 20 of the stator. In addition, the flat wire wave winding 10 of the present application is not limited to the parallel number of branches of each phase current; the designer can design the coil of the flat wire wave winding 10 into a stator winding with one, two, or four parallel branches according to actual needs.

[0046] In one embodiment, the flat wire wave winding 10 of the present application can be applied to a multiphase motor. The number of stator slots of the multiphase motor is (2*n), each of the stator slots defines (2*k) wire layer positions, and the number of rotor poles is p, where (2*k) is an even number not less than 4. According to the above assumptions, the pole pitch D of the multiphase motor of the embodiment of the present application can be expressed as: D = (2*n) / (2*p); and the number of slots per pole per phase can be expressed as: (D / phase number). For example, assuming a three-phase motor includes 48 stator slots (n = 24), each of the stator slots defines 8 wire layer positions (k = 4), and the rotor includes 4 pole pairs (p = 4). According to this embodiment, the pole pitch D of the three-phase motor is 6, and the number of slots per pole per phase is 2. In order to clarify the spirit of the present application, the following description of the flat wire wave winding is exemplified by this 48 stator slot three-phase motor embodiment unless otherwise indicated by algebraic expressions.

[0047] As shown in FIG. 1 and FIG. 2A, the flat wire wave winding 10 of the embodiment of the present application includes a plurality of coils sequentially occupying the stator slots 12 and the wire layer positions. In one embodiment, each of the coils is composed of at least one shaped wire. The shaped wire includes a plurality of straight wire portions and a plurality of bridge portions. The straight wire portions include a lead segment wire, a connection segment wire, and a plurality of straight segment wires. In addition, the end of the lead segment wire includes a lead end, and the end of the connection segment wire includes a connection end; wherein the lead end and the connection end are located at the lead-out side 20 of the stator 1. The bridge portions are used to connect two adjacent straight wires. The bridge portions can be distinguished into lead-out side bridge portions at the lead-out side 20 of the stator and non-lead-out side bridge portions not at the lead-out side 20 of the stator.

[0048] In one embodiment, the number of straight wire portions (including the lead segment wire, the connection segment wire, and the straight segment wire) and the number of bridge portions of a shaped wire can be designed according to the number of stator slots and the number of motor phases. For example, a three-phase motor including 48 stator slots, each shaped wire can be designed to include 16 straight wire portions (i.e. 16 = 48 / 3) and 15 bridge portions (i.e. 15 = 16-1). Although the present application does not limit the number of straight wire portions and the number of bridge portions, in actual design, at least 4 or more straight wire portions and 3 or more bridge portions can achieve better results.

[0049] FIG. 16 and FIG. 17 are schematic diagrams of two possible winding structure configurations of the flat wire wave winding 10 in the stator. As shown in the figures, in one embodiment, the stator 1 can include 48 stator slots sequentially numbered as 1# ~ 48#, and each of the stator slots defines 8 wire layer positions L1 ~ L8. Among them, L1 is the outermost wire layer position, and L8 is the innermost wire layer position close to the opening end of the stator slot.

[0050] The flat wire wave winding 10 of the present application is composed of a plurality of coils. As shown in the figures, in one embodiment, the flat wire wave winding 10 of the present application comprises a plurality of first coils U1, a plurality of second coils U2, a plurality of third coils U3 and a plurality of fourth coils U4. Each coil comprises at least one shaped wire, which fills the stator slots and the wire layers according to the winding rules of the flat wire wave winding 10 of the present application (Fig. 16 or Fig. 17). In addition, at least one first coil U1, at least one second coil U2, at least one third coil U3 and at least one fourth coil U4 form a phase winding. The winding rules of the flat wire wave winding 10 will be discussed in the following paragraphs.

[0051] The flat wire wave winding 10 of the present application can comprise a plurality of shaped wires with different shapes. In one embodiment, the flat wire wave winding 10 of the present application is composed of four shaped wires with different shapes, as shown in Fig. 3, Fig. 6, Fig. 8 and Fig. 10. Taking the example of a three-phase motor with 48 stator slots, as shown in the figures, each shaped wire can comprise 16 straight wires (48 stator slots / 3 phases) and 15 bridge portions, but the present application is not limited thereto. The following description takes the example of a three-phase motor with 48 stator slots.

[0052] Please refer to Fig. 3, Fig. 4 and Fig. 5. Fig. 3 is a schematic diagram of the shape of the first shaped wire 30 of the present application, Fig. 4 is a schematic diagram of the structure of the first shaped wire 30 in the stator, and Fig. 5 is a schematic diagram of the structure of the first shaped wire 30 in the stator according to the winding rules of Fig. 16.

[0053] As shown in FIG. 3, the first shaped conductor 30 includes a plurality of straight conductor portions 301-316 and a plurality of bridge portions 401-415. The straight conductor portions include an outgoing segment conductor 301, a connecting segment conductor 316, and a plurality of straight segment conductors 302-315. As shown in FIG. 5, the straight conductor portions 301-316 of the first shaped conductor 30 each occupies a specific stator slot and a specific conductor layer position according to a winding rule of the present application. In addition, the outgoing segment conductor 301 includes an outgoing end 360, and the connecting segment conductor 316 includes a connecting end 350. The outgoing end 360 and the connecting end 350 are located at the outgoing side of the stator. The bridge portions 401-415 link adjacent straight conductors, respectively. For example, the bridge portion 401 connects the outgoing segment conductor 301 and the straight segment conductor 302, the bridge portion 402 connects the straight segment conductors 302 and 303, and the bridge portion 415 connects the straight segment conductor 315 and the connecting segment conductor 316, and so on. Among them, the bridge portions 401, 403, 405, 407, 409, 411, 413, and 415 are located at the non-outgoing side of the stator, and the bridge portions 402, 404, 406, 408, 410, 412, and 414 are located at the outgoing side of the stator. The distance between two adjacent straight segment portions of the first shaped conductor 30 can be one of a first span, a second span, or a third span; this will be further explained in the following paragraphs. According to an embodiment, with reference to FIG. 3, a first shaped conductor 30 can include 16 straight conductors (48 stator slots / 3 phases) and 15 bridge portions, but the present application is not limited thereto.

[0054] Referring to FIG. 6 and FIG. 7. FIG. 6 is a schematic diagram of the shape of the second shaped conductor 60, and FIG. 7 is a schematic diagram of the structure of the second shaped conductor 60 in the stator. As shown in FIG. 6, the second shaped conductor 60 includes a plurality of straight conductor portions 601-616 and a plurality of bridge portions 701-715. The straight conductor portions include an outgoing segment conductor 601, a connecting segment conductor 616, and a plurality of straight segment conductors 602-615; these straight conductor portions respectively occupy a specific stator slot and a specific conductor layer position according to a winding rule of the present application. In addition, the outgoing segment conductor 601 includes an outgoing end 660, and the connecting segment conductor 616 includes a connecting end 650; the outgoing end 660 and the connecting end 650 are located at an outgoing side of the stator. The bridge portions 701-715 respectively link adjacent straight conductors. For example, the bridge portion 701 connects the outgoing segment conductor 601 and the straight segment conductor 602, the bridge portion 702 connects the straight segment conductors 602 and 603, and the bridge portion 715 connects the straight segment conductor 615 and the connecting segment conductor 616. Among them, the bridge portions 701, 703, 705, 707, 709, 711, 713, and 715 are located at a non-outgoing side of the stator, and the bridge portions 702, 704, 706, 708, 710, 712, and 714 are located at an outgoing side of the stator. The distance between two adjacent straight segment portions of the second shaped conductor 60 can be one of a first span, a second span, or a fourth span; this will be further explained in the subsequent paragraphs. According to an embodiment, referring to FIG. 6, each second shaped conductor 60 can include 16 straight conductors (48 stator slots / 3 phases) and 15 bridge portions, but the present application is not limited thereto.

[0055] Referring to FIG. 8 and FIG. 9. FIG. 8 is a schematic diagram of the third shaped conductor 80, and FIG. 9 is a schematic diagram of the third shaped conductor 80 in the stator. The third shaped conductor 80 is similar to the first shaped conductor 30 shown in FIG. 3, but the connection end is bent in a different direction. As shown in FIG. 8, the third shaped conductor 80 includes a plurality of straight conductor portions 801-816 and a plurality of bridge portions 901-915. The straight conductor portions include an outgoing segment conductor 801, a connection segment conductor 816, and a plurality of straight segment conductors 802-815; these straight conductor portions respectively occupy a specific stator slot and a specific conductor layer position according to a winding rule of the present application. In addition, the outgoing segment conductor 801 includes an outgoing end 860, and the connection segment conductor 816 includes a connection end 850; the outgoing end 860 and the connection end 850 are located at an outgoing side of the stator. The bridge portions 901-915 respectively link adjacent straight conductors. For example, the bridge portion 901 connects the outgoing segment conductor 801 and the straight segment conductor 802, the bridge portion 902 connects the straight segment conductors 802 and 803, and the bridge portion 915 connects the straight segment conductor 815 and the connection segment conductor 816. Among them, the bridge portions 901, 903, 905, 907, 909, 911, 913, and 915 are located at a non-outgoing side of the stator, and the bridge portions 902, 904, 906, 908, 910, 912, and 914 are located at an outgoing side of the stator. The distance between two adjacent straight segment portions of the third shaped conductor 80 can be one of a first span, a second span, or a third span; this will be further explained in the subsequent paragraphs. According to an embodiment, referring to FIG. 8, each third shaped conductor 80 can include 16 straight conductors (48 stator slots / 3 phases) and 15 bridge portions, but the present application is not limited thereto.

[0056] Referring to FIG. 10 and FIG. 11. FIG. 10 is a schematic diagram of the fourth shaped conductor 100, and FIG. 11 is a schematic diagram of the fourth shaped conductor 100 in the stator. The fourth shaped conductor 100 is similar to the second shaped conductor 60 shown in FIG. 6, but the connection end is bent in the opposite direction. As shown in FIG. 10, the fourth shaped conductor 100 includes a plurality of straight conductor portions 1001-1016 and a plurality of bridge portions 1101-1115. The straight conductor portions include an outgoing segment conductor 1001, a connection segment conductor 1016, and a plurality of straight segment conductors 1002-1015. These straight conductor portions occupy a specific stator slot and a specific conductor layer position according to a winding rule of the present application. In addition, the outgoing segment conductor 1001 includes an outgoing end 1060, and the connection segment conductor 1016 includes a connection end 1050. The outgoing end 1060 and the connection end 1050 are located at an outgoing side of the stator. The bridge portions 1101-1115 link adjacent straight conductors, respectively. For example, the bridge portion 1101 connects the outgoing segment conductor 1001 and the straight segment conductor 1002, the bridge portion 1102 connects the straight segment conductors 1002 and 1003, and the bridge portion 1115 connects the straight segment conductor 1015 and the connection segment conductor 1016. Among them, the bridge portions 1101, 1103, 1105, 1107, 1109, 1111, 1113, and 1115 are located at a non-outgoing side of the stator, and the bridge portions 1102, 1104, 1106, 1108, 1110, 1112, and 1114 are located at an outgoing side of the stator. The distance between two adjacent straight segment portions of the fourth shaped conductor 100 can be one of a first span, a second span, or a fourth span. This will be further explained in the subsequent paragraphs. According to an embodiment, referring to FIG. 10, each fourth shaped conductor 100 can include 16 straight conductors (48 stator slots / 3 phases) and 15 bridge portions, but the present application is not limited thereto.

[0057] In an embodiment, the first shaped conductor 30 and the third shaped conductor 80 are substantially the same in shape but the connection end is bent in the opposite direction. As shown in FIG. 3 and FIG. 8, the connection end 350 of the first shaped conductor 30 is bent in the opposite direction of the outgoing end 360, and the connection end 850 of the third shaped conductor 80 is bent in the direction of the outgoing end 860. Similarly, the second shaped conductor 60 and the fourth shaped conductor 100 are substantially the same in shape but the connection ends 350 and 360 are bent in the opposite direction. As shown in FIG. 6 and FIG. 10, the connection end 650 of the second shaped conductor 60 is bent in the opposite direction of the outgoing end 660, and the connection end 1050 of the fourth shaped conductor 100 is bent in the direction of the outgoing end 1060.

[0058] As mentioned above, the bridge portion of the shaped conductor is used to connect two adjacent straight conductor portions; wherein the middle bend of the bridge portion is substantially maintained at the angle bisector position of the two adjacent straight conductor portions. In an embodiment, in order to make more efficient use of the space on both sides of the stator winding, the bend of the bridge portion of the shaped conductor can be further varied.

[0059] In particular, assume that a shaped conductor contains J bridge portions. Wherein, as mentioned above, J can be defined as: J = (number of stator slots / number of motor phases) - 1; and the number of stator slots is assumed to be 2*n. In an embodiment, the bend of the bridge portion of the first shaped conductor 30 and the second shaped conductor 60 can be varied as follows:

[0060] (1) On the outgoing side, the bend of the central bridge portion (i.e. the (J+1) / 2 bridge portion) can be adjusted to offset a first arc Q1 in the direction of the outgoing segment conductor, wherein the first arc Q1 is: pi / (2*n);

[0061] (2) On the non-outgoing side, the bend of the two consecutive non-outgoing end bridge portions (i.e. the [(J+1) / 2]-1 bridge portion and the [(J+1) / 2]-3 bridge portion) near the central bridge portion can be adjusted to offset a second arc Q2 in the direction of the connecting segment conductor, wherein the second arc Q2 is: Q2 = pi / n;

[0062] (3) In addition to the above changes, the bend of the remaining bridge portions is maintained at the angle bisector position of the two adjacent straight segments.

[0063] Take the first shaped conductor 30 as an example, please refer to Figure 3. The first shaped conductor 30 contains 15 bridge portions in total, wherein the bends of the bridge portions 401-406 and 409-415 are substantially maintained at the angle bisector position of the two adjacent straight segments. In addition, the bend of the central bridge portion 408 (i.e. the 8th bridge portion) on the outgoing side is adjusted to offset the first arc Q1 = pi / (2*n) in the direction of the outgoing segment conductor 301; and the bends of the two consecutive non-outgoing end bridge portions 407 and 405 (i.e. the 7th and 5th bridge portions) before the central bridge portion 408 are adjusted to offset the second arc Q2 = pi / n in the direction of the connecting segment conductor 316.

[0064] In addition, in an embodiment, the bend of the bridge portion of the third shaped conductor 80 and the fourth shaped conductor 100 can be varied as follows:

[0065] (1) On the outgoing side, the bend of the central bridge portion (i.e. the (J+1) / 2 bridge portion) can be adjusted to offset a first arc Q1 in the direction of the outgoing segment conductor, wherein the first arc Q1 is: Q1 = pi / (2*n);

[0066] (2) In the lead-out side, the bend of the next lead-out side bridge portion (i.e. the [(J+1) / 2]+2th bridge portion) of the central bridge portion can be adjusted to offset a second arc Q2 toward the lead-out segment conductor direction, wherein the second arc Q2 is: Q2 = pi / n;

[0067] (3) In the non-lead-out side, the bend of the previous non-lead-out side end bridge portion (i.e. the [(J+1) / 2]-1th bridge portion) close to the central bridge portion can be adjusted to offset a second arc Q2 toward the connection segment conductor direction, wherein the second arc Q2 is: Q2 = pi / n;

[0068] (4) Except for the above changes, the bends of the rest of the bridge portions are maintained at the angular bisector positions of two adjacent straight line segments.

[0069] Take the third shaped conductor 80 as an example, please refer to Figure 8. The third shaped conductor 80 includes 15 bridge portions, wherein the bends of the bridge portions 901-906, 909 and 911-915 are substantially maintained at the angular bisector positions of two adjacent straight line segments. In addition, the bend of the central bridge portion 908 (i.e. the 8th bridge portion) located in the lead-out side is adjusted to offset a first arc Q1 = pi / (2*n) toward the lead-out segment conductor 801 direction; the bend of the next lead-out side bridge portion 910 (i.e. the 10th bridge portion) of the central bridge portion 908 is adjusted to offset a second arc Q2 = pi / n toward the lead-out segment conductor 801 direction; and the bend of the bridge portion 907 (i.e. the 7th bridge portion) close to the previous non-lead-out side end of the central bridge portion 908 is adjusted to offset a second arc Q2 = pi / n toward the connection segment conductor 816 direction.

[0070] The flat wire wave winding 10 of the present application is composed of a plurality of shaped wires. In the process of manufacturing, the plurality of shaped wires are stacked in order and offset by a fixed slot pitch according to the winding rule, and then wound into a coil with a set number of slots in a tool, and finally pushed into the stator through the open end of the stator slot to form the winding coil. As shown in FIG. 12 and FIG. 13, in an embodiment, the flat wire wave winding 10 of the present application can be composed of a plurality of first shaped wires 30, a plurality of second shaped wires 60, a plurality of third shaped wires 80 and a plurality of fourth shaped wires 100. As shown in FIG. 12 and FIG. 13, the first shaped wires 30 and the second shaped wires 60 can be regarded as a first pair of shaped wires 120, and the third shaped wires 80 and the fourth shaped wires 100 can be regarded as a second pair of shaped wires 130. In the process of manufacturing, the plurality of first pairs of shaped wires 120 and the plurality of second pairs of shaped wires 130 are stacked in order and offset by a fixed slot pitch according to the winding rule, and then wound into a coil with a set number of slots in a tool, and finally pushed into the stator through the open end of the stator slot to form the winding coil. In the above-mentioned embodiment of a 48-stator-slot three-phase motor, the flat wire wave winding 10 is composed of 12 pairs of shaped wires (6 wires of each of the four types of shaped wires), and each wire is offset by one slot pitch after being stacked, and then pushed into the stator after being wound.

[0071] The flat wire wave winding 10 of the present application is suitable for multi-phase motors containing multi-phase currents. Taking a three-phase motor as an example, the winding structure of the flat wire wave winding 10 of the present application is composed of a plurality of coils to form U-phase, V-phase and W-phase windings, so that U-phase current, V-phase current and W-phase current can flow into them respectively. In the following, the U-phase winding will be taken as an example to illustrate the coil winding configuration of the flat wire wave winding 10 of the present application. As shown in FIG. 15 and FIG. 16, in an embodiment, the U-phase winding includes a first coil U1, a second coil U2, a third coil U3 and a fourth coil U4. These four coils can be connected in parallel or in series to form one, two or four branches of U-phase winding according to design needs. In the following, the configuration of each coil in the stator will be described in detail.

[0072] Referring to FIG. 14A and FIG. 14B. FIG. 14A is an unfolded schematic diagram of the first coil U1, and FIG. 14B is a structural schematic diagram of the first coil U1 in the stator. According to an embodiment of the present application, the first coil U1 can be composed of a first shaped wire 30 and a third shaped wire 80. The first shaped wire 30 is a coil from the outermost layer to the inner layer of the wire layer, and the third shaped wire 80 is a coil from the innermost layer to the outer layer of the wire layer. The structure of the first shaped wire 30 and the third shaped wire 80 has been described above and will not be repeated here. The first coil U1 can be formed by welding the two connecting ends 350 and 850 of the two shaped wires. In this embodiment, the first coil U1 occupies a total of 32 specific wire layer positions of specific stator slots, forming part of the structure of the flat wire wave winding 10 of the present application.

[0073] Fig. 15 is a schematic diagram of the second coil U2. According to an embodiment, the second coil U2 is formed by a second shaped wire 60 and a fourth shaped wire 100. The second shaped wire 60 is a coil from the outermost layer of the wire layer to the inner layer, and the fourth shaped wire 100 is a coil from the innermost layer of the wire layer to the outer layer. The structure of the second shaped wire 60 and the fourth shaped wire 100 has been described above, and will not be described again. The second coil U2 can be formed by welding the two connecting ends 650 and 1050 of the two shaped wires. In this embodiment, the second coil U2 occupies a total of 32 specific wire layer positions of the specific stator slots, forming a part of the flat wire wave winding 10 structure of the present application.

[0074] In addition, the structure of the third coil U3 is similar to that of the first coil Ul, and is also formed by a first shaped wire 30 and a third shaped wire 80, which will not be described again. The fourth coil U4 is similar to the second coil U2, and is also formed by a second shaped wire 60 and a fourth shaped wire 100, which will not be described again.

[0075] Please refer to Figs. 16 and 17. Fig. 16 is an embodiment of the winding structure of the flat wire wave winding 10 of the present application, and Fig. 17 is another embodiment of the winding structure of the flat wire wave winding 10 of the present application. In order to clearly show the positions of the flat wire wave winding 10 in the stator slots and the wire layers, the following will describe the U-phase winding of the three-phase motor with 48 stator slots in combination with the example of Fig. 16.

[0076] Please refer to Figs. 14A and 16. As described above, the first coil Ul of the present embodiment is formed by the first shaped wire 30 and the third shaped wire 80. The first shaped wire 30 is a coil from the outermost layer of the wire layer to the inner layer, and the third shaped wire 80 is a coil from the innermost layer of the wire layer to the outer layer. As shown in Fig. 16, the lead-out segment wire 301 of the first shaped wire 30 occupies the wire layer position (3#L1) of the outermost coil of the third stator slot, the connecting segment wire 316 occupies the wire layer position (47#L8) of the innermost coil of the stator slot opening of the forty-seventh stator slot, and the straight segment wires 302-315 in between sequentially occupy the specific stator slots and the wire layer positions. In addition, as shown in Fig. 16, the connecting segment wire 816 of the third shaped wire 80 occupies the wire layer position (5#L8) of the innermost coil of the stator slot opening of the fifth stator slot, and the lead-out segment wire 801 occupies the wire layer position (9#L1) of the outermost coil of the ninth stator slot; similarly, the straight segment wires 802-815 in between sequentially occupy the specific stator slots and the wire layer positions. Specifically, as shown in Fig. 16, the structure of the first coil Ul in the stator can be configured as follows:

[0077] 3 #L1-10 #L2-15 #L2-22 #L2-27 #L3-34 #L4-39 #L4-46 #L4-4 #L5-11 #L6-16 #L6-23 #L6-28 #L7-35 #L8-40 #L8-47 #L8-5 #L8-46 #L7-41 #L7-34 #L7-29 #L6-22 #L5-17 #L5-10 #L5-4 #L4-45 #L3-40 #L3-33 #L3-28 #L2-21 #L1-16 #L1-9 #L1.

[0078] Referring to FIG. 15 and FIG. 16, the second coil U2 of the present embodiment is composed of the second shaped wire 60 and the fourth shaped wire 100. The second shaped wire 60 is a coil from the outermost wire layer to the inner wire layer, and the fourth shaped wire 100 is a coil from the innermost wire layer to the outer wire layer. As shown in FIG. 16, the lead-out section wire 601 of the second shaped wire 60 occupies the wire layer position (4#L1) of the outermost coil of the fourth stator slot, the connecting section wire 616 occupies the wire layer position (46#L8) of the innermost coil of the forty-sixth stator slot near the stator slot opening, and the straight section wires 602-615 in the middle sequentially occupy certain stator slots and wire layer positions. In addition, as shown in FIG. 15, the connecting section wire 1016 of the fourth shaped wire 100 occupies the wire layer position (4#L8) of the innermost coil of the fourth stator slot near the stator slot opening, and the lead-out section wire 1001 occupies the wire layer position (10#L1) of the outermost coil of the tenth stator slot; similarly, the straight section wires 1002-1015 in the middle sequentially occupy certain stator slots and wire layer positions. Specifically, as shown in FIG. 16, the structure of the second coil U2 in the stator can be configured as follows:

[0079] 4 #L1-9 #L2-16 #L2-21 #L2-28 #L3-33 #L4-40 #L4-45 #L4-5 #L5-10 #L6-17 #L6-22 #L6-29 #L7-34 #L8-41 #L8-46 #L8-4 #L8-47 #-L7-40 #L7-35 #L7-28 #L6-23 #L5-16 #L5-11 #L5-3 #L4-46 #L3-39 #L3-34 #L3-27 #L2-22 #L1-15 #L1-10 #L1.

[0080] As the first coil U1, the third coil U3 of the present embodiment is also composed of the first shaped wire 30 and the third shaped wire 80 (schematic diagram omitted). The first shaped wire 30 is a coil from the outermost layer of the wire layer to the inner layer, and the third shaped wire 80 is a coil from the innermost layer of the wire layer to the outside. As shown in FIG. 16, the lead-out segment wire 301 of the first shaped wire 30 occupies the wire layer position of the outermost coil of the 27th stator slot (27#L1), the connection segment wire 316 occupies the wire layer position of the innermost coil of the 23rd stator slot near the stator slot opening (23#L8), and the straight segment wires 302-315 in the middle sequentially occupy certain stator slots and wire layer positions. In addition, as shown in FIG. 16, the connection segment wire 816 of the third shaped wire 80 occupies the wire layer position of the innermost coil of the 29th stator slot near the stator slot opening (29#L8), and the lead-out segment wire 801 occupies the wire layer position of the outermost coil of the 33rd stator slot (33#L1); similarly, the straight segment wires 802-815 in the middle sequentially occupy certain stator slots and wire layer positions. Specifically, as shown in FIG. 16, the structure of the third coil U3 in the stator can be configured as follows:

[0081] 27#L1-34#L2-39#L2-46#L2-3#L3-10#L4-15#L4-22#L4-28#L5-35#L6-40#L6-47#L6-4#L7-11#L8-16#L8-23#L8-29#L8-22#L7-17#L7-10#L7-5#L6-46#L5-41#L5-34#L5-28#L4-21#L3-16#L3-9#L3-4#L2-45#L1-40#L1-33#L1.

[0082] As the second coil U2, the fourth coil U4 of the present embodiment is also composed of the second shaped wire 60 and the fourth shaped wire 100 (schematic diagram omitted). The second shaped wire 60 is a coil from the outermost layer of the wire layer to the inner layer, and the fourth shaped wire 100 is a coil from the innermost layer of the wire layer to the outside. As shown in FIG. 16, the lead-out section wire 601 of the second shaped wire 60 occupies the wire layer position of the outermost circle of the 28th stator slot (28#L1), the connection section wire 616 occupies the wire layer position of the innermost circle of the 22nd stator slot near the stator slot opening (22#L8), and the intermediate straight section wires 602-615 sequentially occupy certain stator slots and wire layer positions. In addition, as shown in FIG. 16, the connection section wire 1016 of the fourth shaped wire 100 occupies the wire layer position of the innermost circle of the 28th stator slot near the stator slot opening (28#L8), and the lead-out section wire 1001 occupies the wire layer position of the outermost circle of the 34th stator slot (34#L1); likewise, the intermediate straight section wires 1002-1015 sequentially occupy certain stator slots and wire layer positions. Specifically, as shown in FIG. 16, the structure of the fourth coil U4 in the stator can be configured as follows:

[0083] 28#L1-33#L2-40#L2-45#L2-4#L3-9#L4-16#L4-21#L4-29#L5-34#L6-41#L6-46#L6-5#L7-10#L8-17#L8-22#L8-28#L8-23#L7-16#L7-11#L7-4#L6-47#L5-40#L5-35#L5-27#L4-22#L3-15#L3-10#L3-3#L2-46#L1-39#L1-34#L1.

[0084] Comparing the structure configuration of the first coil U1 and the third coil U3 in the stator, it can be found that the configuration of the third coil U3 is offset by 24 stator slots (i.e., the number of stator slots / 2) from the first coil U1. That is, the coil shape structure of the third coil U3 is basically the same as that of the first coil U1, except that the stator slot positions occupied by each straight wire section of the third coil U3 and the first coil U1 are 24 slot distances apart. Likewise, comparing the structure configuration of the second coil U2 and the fourth coil U4 in the stator, it can be found that the configuration of the fourth coil U4 is offset by 24 stator slots (i.e., the number of stator slots / 2) from the second coil U2. That is, the coil shape structure of the fourth coil U4 is basically the same as that of the second coil U2, except that the stator slot positions occupied by each straight wire section of the fourth coil U4 and the second coil U2 are 24 slot distances apart. Only a plurality of these two groups of coils need to be manufactured to complete the structure of the flat wire wave winding 10 of the present application.

[0085] According to FIG. 16, the coil span of the flat wire wave winding 10 of the present application substantially maintains three different variations as the pole pitch D changes:

[0086] (1) The two adjacent straight wire portions maintain a first span and a second span in turn;

[0087] (2) When a central bridge portion of a shaped wire is encountered, the span of the two connected straight wire portions is adjusted to a third span;

[0088] (3) When a shaped wire is connected to another shaped wire, the span of the two connecting wire segments is adjusted to a fourth span.

[0089] In an embodiment, for the first coil U1 and the third coil U3, the first span is equal to the pole pitch D+1, and the second span is equal to the pole pitch D-1. In addition, the third span and the fourth span are equal, both equal to the pole pitch D. In addition, in an embodiment, for the second coil U2 and the fourth coil U4, the first span is equal to the pole pitch D-1, the second span is equal to the pole pitch D+1, the third span is equal to the pole pitch D+2, and the fourth span is equal to the pole pitch D.

[0090] Specifically, taking the above 48 stator slots as an example, assuming that the pole pitch D is equal to 6. Referring to FIG. 14A and FIG. 16, the span of the first coil U1 and the adjacent straight wire portions substantially maintains an alternating variation of 7 slot pitches (i.e., the first span) and 5 slot pitches (i.e., the second span). For example, as shown in the figure, the span of the lead wire segment 301 and the straight wire segment 302 is 7 slot pitches, the span of the straight wire segment 302 and the straight wire segment 303 is 5 slot pitches, the span of the straight wire segment 303 and the straight wire segment 304 is 7 slot pitches, and so on. However, when a central bridge portion of a shaped wire is encountered, the span is adjusted to 6 slot pitches (i.e., the third span). For example, the span of the two adjacent straight wire portions 308 and 309 connected by the central bridge portion 408 of the first shaped wire 30 is adjusted to 6 slot pitches; that is, when the first coil U1 spans from the 46th slot of the fourth wire layer (46#L4) to the 4th slot of the fifth wire layer (4#L5), the span is adjusted to 6 slot pitches. Similarly, the span of the two straight wire segments 808 and 809 connected by the central bridge portion 908 of the third shaped wire 80 is also adjusted to 6 slot pitches; that is, when the first coil U1 spans from the 10th slot of the fifth wire layer (10#L5) to the 4th slot of the fourth wire layer (4#L4). In addition, when two shaped wires are connected, the span is adjusted to 6 slot pitches (i.e., the fourth span). For example, the span of the connecting wire segment 316 of the first shaped wire 30 and the connecting wire segment 816 of the third shaped wire 80 changes to 6 slot pitches; that is, when the first coil U1 spans from the 47th slot of the eighth wire layer (47#L8) to the 5th slot of the eighth wire layer (5#L8).

[0091] Similarly, referring to Figure 16, the span of the third coil U3 and the adjacent straight wire portions maintains the same alternating pattern of approximately 7 slots (i.e. first span) and 5 slots (i.e. second span) as the first coil U1. However, when the central bridge portion of the shaped wire is encountered, the span is adjusted to 6 slots (i.e. third span); and when the two shaped wires are connected, the span is also adjusted to 6 slots (i.e. fourth span). Specifically, when the central bridge portion of the shaped wire is encountered, i.e. when the third coil U3 spans from the 22nd slot of the fourth wire layer (22#L4) to the 28th slot of the fifth wire layer (28#L5), and when the third coil U3 spans from the 34th slot of the fifth wire layer (34#L5) to the 28th slot of the fourth wire layer (28#L4), the span is adjusted to 6 slots. Furthermore, when the two shaped wires are connected, i.e. when the third coil U3 spans from the 23rd slot of the eighth wire layer (23#L8) to the 29th slot of the eighth wire layer (29#L8), the span is adjusted to 6 slots.

[0092] As shown in Figure 14A and Figure 16, the configuration of the three different spans allows the two lead segments of the first coil U1 to maintain a distance of 6 slots, and the first shaped wire 30 and the third shaped wire 80 to be aligned in the middle of the coil, i.e. the central positions of the two shaped wires are in the same stator slot (note the 4th stator slot) but in adjacent wire layers (i.e. the 4th layer and the 5th layer), while the remaining positions maintain a shift of one stator slot.

[0093] Similarly, the same applies to the third coil U3.

[0094] In addition, referring to FIG. 15 and FIG. 16, the span of the second coil U2 and the adjacent straight wire portions is substantially maintained in an alternating variation of 5 slot pitches (i.e., the first span) and 7 slot pitches (i.e., the second span). For example, as shown in the figure, the span of the lead wire segment 601 and the straight wire segment 602 is 5 slot pitches, the span of the straight wire segment 602 and the straight wire segment 603 is 7 slot pitches, the span of the straight wire segment 603 and the straight wire segment 604 is 5 slot pitches, and so on. However, when the central bridge portion of the shaped wire is encountered, the span is adjusted to 8 slot pitches (i.e., the third span). For example, the span of the two adjacent straight wire portions 608 and 609 connected by the central bridge portion 708 of the second shaped wire 60 is adjusted to 8 slot pitches; that is, when the second coil U2 spans from the fourth wire layer of the 45th slot (45#L4) to the fifth wire layer of the 5th slot (5#L5). Similarly, the span of the two straight wire segments 1008 and 1009 connected by the central bridge portion 1108 of the fourth shaped wire 100 is also adjusted to 8 slot pitches; that is, when the second coil U2 spans from the fifth conductive layer of the 11th slot (11#L5) to the fourth conductive layer of the 3rd slot (3#L4). In addition, when two shaped wires are connected, the span is adjusted to 6 slot pitches (i.e., the fourth span). For example, the span of the connection wire segment 616 of the second shaped wire 60 and the connection wire segment 1016 of the fourth shaped wire 100 is adjusted to 6 slot pitches; that is, when the second coil U2 spans from the eighth wire layer of the 46th slot (46#L8) to the eighth wire layer of the 4th slot (4#L8).

[0095] Similarly, referring to FIG. 16, the span of the fourth coil U4 and the adjacent straight wire portions is substantially maintained in an alternating variation of 5 slot pitches (i.e., the first span) and 7 slot pitches (i.e., the second span), as with the second coil U2. However, when the central bridge portion of the shaped wire is encountered, the span is adjusted to 8 slot pitches (i.e., the third span); and when two shaped wires are connected, the span is also adjusted to 6 slot pitches (i.e., the fourth span). Specifically, when the central bridge portion of the shaped wire is encountered, that is, when the fourth coil U4 spans from the fourth wire layer of the 21st slot (21#L4) to the fifth wire layer of the 29th slot (29#L5), and when the fourth coil U4 spans from the fifth conductive layer of the 35th slot (35#L5) to the fourth conductive layer of the 27th slot (27#L4), the span is adjusted to 8 slot pitches. In addition, when two shaped wires are connected, that is, when the fourth coil U4 spans from the eighth wire layer of the 22nd slot (22#L8) to the eighth wire layer of the 28th slot (28#L8), the span is adjusted to 6 slot pitches.

[0096] As shown in FIG. 15 and FIG. 16, the four different span configurations maintain the two outgoing segments of the second coil U2 at a distance of six slots, and the second shaped conductor 60 and the fourth shaped conductor 100 are wound at a difference of two slots in the middle, i.e., the central straight segments of the two shaped conductors 609 and 1009 are located at the adjacent conductor layer positions of the fifth and third stator slots (i.e., the fifth and fourth layers), and the remaining positions are maintained at a shift of one stator slot. Similarly, the fourth coil U4 is also the same case.

[0097] According to another embodiment of the present application, referring to FIG. 17, the flat wave winding 10 of the present application can also not change any span, but only change in sequence a first span (i.e., pole pitch D+1) and a second span (i.e., pole pitch D-1) alternately. Specifically, as shown in FIG. 17, the spans of the two adjacent straight conductor portions of the first coil U1 and the third coil U3 maintain an alternating change of seven slots and five slots. The spans of the two adjacent straight conductor portions of the second coil U2 and the fourth coil U4 maintain an alternating change of five slots and seven slots.

[0098] In addition to the span rule, the present application also maintains the principle that the span of the adjacent two straight conductor portions of the flat wave winding 10 does not exceed one conductor layer. As described above, the flat wave winding 10 is composed of a plurality of coils, and each coil is composed of at least one shaped conductor. When the shaped conductor is a coil from the outer layer to the inner layer of the conductor layer (for example, the first shaped conductor 30 of the first coil U1), the straight conductor portion of the shaped conductor only stays at all odd conductive layers once, and the remaining straight conductor portions average occupy all even layers; in addition, when the shaped conductor is a coil from the inner layer to the outer layer of the conductor layer (for example, the third shaped conductor 80 of the first coil U1), the straight conductor portion of the shaped conductor only stays at all even conductive layers once, and the remaining straight conductor portions average occupy all odd layers.

[0099] Referring to FIG. 14A and FIG. 16, the first shaped wire 30 of the first coil U1 is a coil from the outer layer of the wire layer to the inner layer, so the straight wire portions 301-316 of the first shaped wire 30 only stay once when passing through the odd wire layers, and the rest are evenly distributed in all even wire layers. Specifically, the straight wire portions 301, 305, 309, and 313 sequentially occupy the odd wire layers L1, L3, L5, and L7, respectively, and the straight wire portions 302-304, 306-308, 310-312, and 314-316 sequentially occupy the even wire layers L2, L4, L6, and L8, respectively. Conversely, the third shaped wire 80 of the first coil U1 is a coil from the inner layer of the wire layer to the outer layer, so the straight wire portions 801-816 of the third shaped wire 80 only stay once when passing through the even wire layers, and the rest are evenly distributed in all odd wire layers. Specifically, the straight wire portions 816, 812, 808, and 804 sequentially occupy the even wire layers L8, L6, L4, and L2, respectively, and the straight wire portions 813-815, 809-811, 805-807, and 801-803 sequentially occupy the odd wire layers L7, L5, L3, and L1, respectively. The wire layer winding rules of the second coil U2, the third coil U3, and the fourth coil U4 are the same as those of the first coil U1, and are not described here.

[0100] The first coil U1, the second coil U2, the third coil U3, and the fourth coil U4 form the U-phase winding of the flat wave winding 10. The V-phase winding and the W-phase winding of the present application are similar to the U-phase winding, but each occupies a position offset by two stator slots. For example, in various span change embodiments, the U-phase winding sequentially occupies the stator slots 3#-5#, 9#-11#, 15#-17#, 21#-23#, 27#-29#, 33#-35#, 39#-41#, and 45#-47#, the V-phase winding sequentially occupies the stator slots 5#-7#, 11#-13#, 17#-19#, 23#-25#, 29#-31#, 35#-37#, 41#-43#, and 47#-1#, and the W-phase winding sequentially occupies the stator slots 7#-9#, 13#-15#, 19#-21#, 25#-27#, 31#-33#, 37#-39#, 43#-45#, and 1#-3#. Similarly, those skilled in the art can further deduce the stator slots occupied by the U-phase winding, the V-phase winding, and the W-phase winding when there are only two span changes. As shown in FIG. 16 and FIG. 17, regardless of the winding rule, for a 48-stator-slot three-phase motor, the flat wave winding 10 needs a total of 24 shaped wires (3 phases * 4 windings * 2 shaped wires) to fill all the stator slots.

[0101] The flat wire wave winding disclosed in the present application can be applied to an M-phase motor. The M-phase motor includes 2*n stator slots, each of which defines 2*k wire layer positions, the pole number of the rotor is p, and the pole pitch is D; wherein 2*k is an even number not less than 4, and M is a positive integer. The flat wire wave winding of the embodiment includes M phase windings, each of which includes a plurality of coils, each of which is composed of at least one shaped wire. The shaped wire includes a plurality of straight wire segment portions and a plurality of bridge portions connecting adjacent two straight wire segments. The total number of straight wire segments I of the shaped wire can be set as: I = stator slot number 2*n / motor phase number M; and the total number of bridge portions J is: J = I-1.

[0102] In an embodiment, the shaped wire includes at least a first shaped wire and a second shaped wire. The straight wire portions of the first shaped wire and the second shaped wire respectively include a lead-out segment wire, a connection segment wire, and a plurality of straight wire segments. In addition, the lead-out segment wire respectively includes a lead-out end, and the connection segment wire respectively includes a connection end.

[0103] The structure shape of the first shaped wire and the second shaped wire of the present application and the winding rule of the flat wire wave winding are as follows:

[0104] Rule one: the adjacent two straight wire portions of the first shaped wire maintain the first span and the second span in turn alternately;

[0105] Rule two: the adjacent two straight wire portions of the second shaped wire maintain the second span and the first span in turn alternately;

[0106] Rule three: regardless of the first shaped wire or the second shaped wire, when encountering the central bridge portion, the span of the two connected straight wire portions is adjusted to the third span;

[0107] Rule four: regardless of the first shaped wire or the second shaped wire, when two shaped wires are connected, the span of the two connection segment wires is adjusted to the fourth span.

[0108] Among them, the first span is equal to the pole pitch D+1 of the M-phase motor, the second span is equal to the pole pitch D-1 of the M-phase motor, and the fourth span is equal to the pole pitch D of the M-phase motor. In addition, for the first shaped wire, the third span is also equal to the pole pitch D of the M-phase motor; but for the second shaped wire, the third span is equal to the pole pitch D+2 of the M-phase motor.

[0109] In another embodiment, the winding rules three and four described above are optional rules.

[0110] In another embodiment, the flat wire wave winding of the present application further comprises a plurality of coils forming a phase winding, each coil is composed of at least two shaped wires. Wherein, the first shaped wire is a coil from the outermost wire layer position of the stator to the inner circle of the slot opening of the stator, and the second shaped wire is a coil from the innermost wire layer position of the stator to the outer circle of the stator, and the two shaped wires are bent and welded together at one end. The winding rule of the flat wire wave winding of the present application further comprises the following:

[0111] Rule five: the straight wire part of the first shaped wire stays in an odd number wire layer on average only once, and the remaining straight wire part is sequentially and evenly distributed in all even number wire layers; and

[0112] Rule six: the straight wire part of the second shaped wire stays in an even number wire layer on average only once, and the remaining straight wire part is sequentially and evenly distributed in all odd number wire layers.

[0113] In another embodiment, the plurality of coils of the flat wire wave winding of the present application can be classified into first coils and second coils; the flat wire wave winding of the present application is composed of a plurality of first coils and a plurality of second coils. Wherein, each first coil can be composed of two first shaped wires; the first first shaped wire is a coil from the outermost wire layer position of the stator to the inner circle of the slot opening of the stator, and the second first shaped wire is a coil from the innermost wire layer position of the stator to the outer circle of the stator, and the two first shaped wires are bent and welded together at one end. In addition, each second coil can be composed of two second shaped wires; the first second shaped wire is a coil from the outermost wire layer position of the stator to the inner circle of the slot opening of the stator, and the second second shaped wire is a coil from the innermost wire layer position of the stator to the outer circle of the stator, and the two second shaped wires are bent and welded together at one end. The first coil and the second coil form a phase winding in the stator according to the above-mentioned rules one to six.

[0114] In addition, the winding rule of the flat wire wave winding of the present application further comprises the following:

[0115] Rule seven: the straight wire part of one first coil and another first coil occupies a stator slot position that differs by half the total number of stator slots; and the straight wire part of one second coil and another second coil occupies a stator slot position that differs by half the total number of stator slots.

[0116] In another embodiment, to facilitate the manufacturing process, the conductive wires used to form the flat wire winding of the present application can be formed into the desired shape to reduce the number of bends required during the soldering process. Specifically, the shaped conductive wires used to form the flat wire winding of the present application can further include a first shaped wire, a second shaped wire, a third shaped wire and a fourth shaped wire. The third shaped wire is substantially identical to the first shaped wire, and the straight wire portions follow the span rules set forth in rules 1-4 above. However, the connection end of the third shaped wire is bent in the opposite direction of the connection end of the first shaped wire. For example, the connection end of the first shaped wire is bent in the direction opposite to the direction of the outgoing end, while the connection end of the third shaped wire is bent in the direction of the outgoing end. Similarly, the fourth shaped wire is substantially identical to the second shaped wire, and the straight wire portions follow the span rules set forth in rules 1-4 above. However, the connection end of the fourth shaped wire is bent in the opposite direction of the connection end of the second shaped wire. For example, the connection end of the second shaped wire is bent in the direction opposite to the direction of the outgoing end, while the connection end of the fourth shaped wire is bent in the direction of the outgoing end. Because the connection end portions of the shaped wires are already pre-formed into the desired bends during the manufacturing process, the first coil can be formed by directly soldering the connection ends of the first shaped wire and the third shaped wire, and the second coil can be formed by directly soldering the connection ends of the second shaped wire and the fourth shaped wire. This reduces the number of bending steps during the soldering process, and reduces the likelihood of damage.

[0117] In addition, the shapes of the first shaped wire, the second shaped wire, the third shaped wire and the fourth shaped wire can be further modified as follows:

[0118] (1) At the outgoing side, the bend of the central bridge portion (i.e., the (J+1) / 2 bridge portion) can be adjusted to offset by a first arc Ql in the direction of the outgoing end wire, where the first arc Ql is: Ql = pi / (2*n);

[0119] (2) At the non-outgoing side, the bends of the two consecutive non-outgoing side bridge portions (i.e., the [(J+1) / 2]-l bridge portion and the [(J+1) / 2]-3 bridge portion) closest to the central bridge portion can be adjusted to offset by a second arc Q2 in the direction of the connection end wire, where the second arc Q2 is: Q2 = pi / n;

[0120] (3) In addition to the above modifications, the bends of the remaining bridge portions remain at the angle bisector positions of the two adjacent straight wire segments.

[0121] The bridge portion bends of the third shaped wire and the fourth shaped wire are modified as follows:

[0122] (1) At the outgoing side, the bend of the central bridge portion (i.e., the (J+1) / 2 bridge portion) can be adjusted to offset by a first arc Ql in the direction of the outgoing end wire, where the first arc Ql is: Ql = pi / (2*n);

[0123] (2) In the lead-out side, the bend of the next lead-out side bridge portion (i.e. the [(J+1) / 2]+2th bridge portion) of the central bridge portion can be adjusted to deviate by a second radian Q2 in the direction of the lead-out segment conductor, wherein the second radian Q2 is: Q2=pi / n;

[0124] (3) In the non-lead-out side, the bend of the previous non-lead-out side end bridge portion (i.e. the [(J+1) / 2]-1th bridge portion) close to the central bridge portion can be adjusted to deviate by a second radian Q2 in the direction of the connection segment conductor, wherein the second radian Q2 is: Q2=pi / n;

[0125] (4) In addition to the above changes, the bends of the remaining bridge portions are kept at the position of the angle bisector of two adjacent straight line segments.

[0126] Wherein pi is the circular constant.

[0127] In this embodiment, each first coil can be composed of a first shaped conductor and a third shaped conductor, and each second coil can be composed of a second shaped conductor and a fourth shaped conductor. The plurality of first coils and the plurality of second coils form the phase winding in the stator according to the configuration mode of the above-mentioned rule five to rule seven.

[0128] In summary, the flat wire wave winding coil of the present application is formed by winding a simple shaped conductor, which is simpler in manufacturing and process than the existing wave winding coil. By the one-time shaping of the conductor, 90% of the winding welding points are saved, and the amount of motor conductor can be saved. In addition, the flat wire wave winding coil of the embodiment of the present application can be designed with long pitch to weaken the tooth harmonic to improve NVH (noise, vibration and comfort), and can also be designed with positionally equal pitch to improve torque. Therefore, the flat wire wave winding coil of the present application can greatly reduce the risk operations such as cutting, bending and welding of the existing flat wire winding coil.

[0129] The above only describes the preferred embodiments of the present application, and any equivalent changes and modifications made within the scope of the patent application of the present application shall be included in the scope of the present application.

Claims

1. A flat wire wave winding for a multiphase electric machine, wherein the multiphase electric machine has a pole pitch, the multiphase electric machine comprises a stator, the stator has a plurality of stator slots, wherein each of the stator slots comprises an open end, each of the stator slots defines an even number of wire layer positions including a first layer wire layer position farthest from the open end and a last layer wire layer position closest to the open end, the flat wire wave winding comprises: a first coil comprising a first shaped wire and a third shaped wire; and a second coil comprising a second shaped wire and a fourth shaped wire; wherein the first shaped wire, the second shaped wire, the third shaped wire and the fourth shaped wire each have a plurality of straight wire portions and a plurality of bridge portions connecting two adjacent straight wire portions, wherein the plurality of straight wire portions comprises a lead-in segment wire, a connection segment wire and a plurality of straight segment wires; two adjacent straight wire portions of the first shaped wire and the third shaped wire maintain a round-robin variation of the pole pitch plus one and the pole pitch minus one in a position distance of the stator slot in sequence; two adjacent straight wire portions of the second shaped wire and the fourth shaped wire maintain a round-robin variation of the pole pitch minus one and the pole pitch plus one in a position distance of the stator slot in sequence; the lead-in segment wire of the first shaped wire occupies the first layer wire layer position of a stator slot of the plurality of stator slots, the connection segment wire occupies the last layer wire layer position of a stator slot of the plurality of stator slots, the plurality of straight segment wires stay in odd-numbered wire layer positions once on average and are evenly distributed in all even-numbered wire layer positions; the lead-in segment wire of the second shaped wire occupies the first layer wire layer position of a stator slot of the plurality of stator slots, the connection segment wire occupies the last layer wire layer position of a stator slot of the plurality of stator slots, the plurality of straight segment wires stay in odd-numbered wire layer positions once on average and are evenly distributed in all even-numbered wire layer positions; the lead-in segment wire of the third shaped wire occupies the first layer wire layer position of a stator slot of the plurality of stator slots, the connection segment wire occupies the last layer wire layer position of a stator slot of the plurality of stator slots, and the plurality of straight segment wires stay in even-numbered wire layer positions once on average and are evenly distributed in all odd-numbered wire layer positions; and the lead-in segment wire of the fourth shaped wire occupies the first layer wire layer position of a stator slot of the plurality of stator slots, the connection segment wire occupies the last layer wire layer position of a stator slot of the plurality of stator slots, and the straight segment wire stays in even-numbered wire layer positions once on average and is evenly distributed in all odd-numbered wire layer positions.

2. The flat wire coil of claim 1, wherein, Two adjacent straight conductor portions connected by a central bridge portion of the plurality of bridge portions of each of the first and third shaped conductors are located at a distance of the pole pitch from each other in the stator slot.

3. The flat wire coil of claim 1, wherein, Two adjacent straight conductor portions connected by a central bridge portion of the plurality of bridge portions of each of the second and fourth shaped conductors are located at a distance of the pole pitch plus two from each other in the stator slot.

4. The flat wire coil of claim 1, wherein, The first and second shaped conductors are connected by the connection segment conductors to form the first coil or a third coil, wherein two adjacent connection segment conductors are located at a distance of the pole pitch from each other in the stator slot.

5. The flat wire coil of claim 1, wherein, The flat wave winding further comprises a third coil and a fourth coil, wherein a stator slot position of the third coil is shifted from the stator slot position of the first coil by half of the number of the stator slots, and a stator slot position of the fourth coil is shifted from the stator slot position of the second coil by half of the number of the stator slots.

6. The flat wire coil of claim 5, wherein, The first, second, third and fourth coils form a phase winding of the flat wave winding.

7. The flat wire coil of claim 1, wherein, The number of straight conductor portions of the first, second, third and fourth shaped conductors is equal to the number of stator slots divided by the number of phases of the multiphase motor.

8. A multiphase motor having a pole pitch, the multiphase motor comprising: a rotor located at the center of the multiphase motor, comprising a plurality of phase pairs; a stator having a lead side and a non-lead side, the stator comprising a plurality of stator slots each having a stator opening facing the rotor, each of the stator slots defining an even number of conductor layer positions, wherein the conductor layer position farthest from the stator opening is a first layer conductor layer position, and the conductor layer position closest to the stator opening is a last layer conductor layer position; and a flat wave winding comprising a plurality of coils, each of the coils being formed by two shaped conductors, wherein the shaped conductors comprise a plurality of straight conductor portions and a plurality of bridge portions connecting two adjacent straight conductor portions, the straight conductor portions comprising a lead segment conductor, a connection segment conductor and a plurality of straight segment conductors, wherein the flat wave winding is placed in the stator according to a winding rule, the winding rule comprising: the lead segment conductor of a first one of the two shaped conductors is located at the first layer conductor layer position of one of the stator slots, and the connection segment conductor of the first one of the two shaped conductors is located at the last layer conductor layer position of the one of the stator slots, wherein the straight conductor portions of the first one of the two shaped conductors are evenly located at an odd number of the conductor layer positions in sequence, and evenly distributed in all even number of the conductor layer positions; and the lead segment conductor of a second one of the two shaped conductors is located at the last layer conductor layer position of one of the stator slots, and the connection segment conductor of the second one of the two shaped conductors is located at the first layer conductor layer position of the one of the stator slots, wherein the straight conductor portions of the second one of the two shaped conductors are evenly located at an even number of the conductor layer positions in sequence, and evenly distributed in all odd number of the conductor layer positions. a second one of the two shaped wires has its outgoing segment wire located at the first layer wire position of one of the stator slots, and its connecting segment wire located at the last layer wire position of one of the stator slots, wherein the straight wire portions of the second shaped wire are evenly present once at the even-numbered wire layer positions and evenly distributed in sequence among all odd-numbered wire layer positions; wherein the first shaped wire and the second shaped wire form the coils by connecting the respective connecting segment wires.

9. The multiphase electric machine of claim 8, wherein, The shaped wires include a first shaped wire and a second shaped wire, wherein the winding rule further includes: two adjacent straight wire portions of the first shaped wire have a distance in one of the stator slots that changes in sequence by a first span and a second span; and two adjacent straight wire portions of the second shaped wire have a distance in one of the stator slots that changes in sequence by the second span and the first span; wherein the first span is the pole pitch plus one, and the second span is the pole pitch minus one.

10. The multiphase electric machine of claim 9, wherein, The winding rule further includes: two adjacent straight wire portions of the first shaped wire have a distance in one of the stator slots that changes in sequence by a first span and a second span; and two adjacent straight wire portions of the second shaped wire have a distance in one of the stator slots that changes in sequence by the second span and the first span; 11. The multiphase electric machine of claim 9, wherein, wherein the first span is the pole pitch plus one, and the second span is the pole pitch minus one. The winding rule further includes: two adjacent straight wire portions of the first shaped wire have a distance in one of the stator slots that changes in sequence by a first span and a second span; and 12. The multiphase electric machine of claim 8, wherein, two adjacent straight wire portions of the second shaped wire have a distance in one of the stator slots that changes in sequence by the second span and the first span; The number of the straight wire portions of the shaped wires is respectively the number of the stator slots divided by the number of phases of the multi-phase electric machine.

13. A three-phase electric machine, comprising: a rotor having 4 pole pairs; a stator including 48 stator slots sequentially numbered as #1~48#, wherein each stator slot has an open end facing the rotor, and each stator slot defines 8 wire layer positions sequentially numbered as LI~L8 from the farthest to the closest to the open end; and a flat wire wave winding, including: a first coil and a third coil respectively including a first shaped wire and a third shaped wire; and a second coil and a fourth coil respectively including a second shaped wire and a fourth shaped wire; wherein each of the first shaped wire, the second shaped wire, the third shaped wire and the fourth shaped wire respectively includes 16 straight wire portions and 15 bridge portions for connecting two adjacent straight wire portions, The straight wire portions of the first and third coils change in a round flow of 7 slot pitches and 5 slot pitches in a position distance in the stator slots, and the straight wire portions of the second and fourth coils change in a round flow of 5 slot pitches and 7 slot pitches in a position distance in the stator slots, The straight wire portions of the first and second shaped wires stay in the wire layer positions L1, L3, L5 and L7 once on average, and are sequentially distributed in all the wire layer positions L2, L4, L6 and L8 on average; the straight wire portions of the third and fourth shaped wires stay in the wire layer positions L2, L4, L6 and L8 once on average, and are sequentially distributed in all the wire layer positions L1, L3, L5 and L7 on average.

14. The three-phase electric machine of claim 13, wherein, The two adjacent straight wire portions connected by the eighth bridge portion of the first and third shaped wires are 6 slot pitches apart in a position in the stator slots, and the two adjacent straight wire portions connected by the eighth bridge portion of the second and fourth shaped wires are 8 slot pitches apart in a position in the stator slots.

15. The three-phase electric machine of claim 13, wherein, The two adjacent straight wire portions at the connection of the first and third shaped wires are 6 slot pitches apart in a position in the stator slots, and the two adjacent straight wire portions at the connection of the second and fourth shaped wires are 6 slot pitches apart in a position in the stator slots.

16. The three-phase electric machine of claim 13, wherein, The position of the third coil in the stator slots is a translation of the position of the first coil in the stator slots by 24 stator slot pitches, and the position of the fourth coil in the stator slots is a translation of the position of the second coil in the stator slots by 24 stator slot pitches.

17. The three-phase electric machine of claim 13, wherein, The first, second, third and fourth coils form a phase winding of the flat wire wave winding.

18. The three-phase motor of claim 13, wherein: The position of the first coil in the stator slots is: 3#L1-10#L2-15#L2-22#L2-27#L3-34#L4-39#L4-46#L4-4#L5-11#L6-16#L6-23#L6-28#L7-35#L8-40#L8-47#L8-5#L8-46#L7-41#L7-34#L7-29#L6-22#L5-17#L5-10#L5-4#L4-45#L3-40#L3-33#L3-28#L2-21#L1-16#L1-9#L1. The second coil is located at the positions of the stator slots as follows: 4#L1-9#L2-16#L2-21#L2-28#L3-33#L4-40#L4-45#L4-5#L5-10#L6-17#L6-22#L6-29#L7-34#L8-41#L8-46#L8-4#L8-47#-L7-40#L7-35#L7-28#L6-23#L5-16#L5-11#L5-3#L4-46#L3-39#L3-34#L3-27#L2-22#L1-15#L1-10#L1; The third coil is located at the positions of the stator slots as follows: 27#L1-34#L2-39#L2-46#L2-3#L3-10#L4-15#L4-22#L4-28#L5-35#L6-40#L6-47#L6-4#L7-11#L8-16#L8-23#L8-29#L8-22#L7-17#L7-10#L7-5#L6-46#L5-41#L5-34#L5-28#L4-21#L3-16#L3-9#L3-4#L2-45#L1-40#L1-33#L1; and The fourth coil is located at the positions of the stator slots as follows: 28#L1-33#L2-40#L2-45#L2-4#L3-9#L4-16#L4-21#L4-29#L5-34#L6-41#L6-46#L6-5#L7-10#L8-17#L8-22#L8-28#L8-23#L7-16#L7-11#L7-4#L6-47#L5-40#L5-35#L5-27#L4-22#L3-15#L3-10#L3-3#L2-46#L1-39#L1-34#L1.

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