Method for winding a stator assembly of a flat wire motor and flat wire motor

Abstract

This invention provides a method for winding a stator assembly of a flat wire winding motor and a flat wire winding motor. The stator assembly includes a stator core and multi-phase flat wire windings. The stator core has multiple stator slots, and stator teeth are formed between each pair of adjacent stator slots. Each stator slot is wound with n layers of flat copper wire, where n is greater than or equal to 3 and is an odd number. This invention provides an odd-layer flat copper wire winding scheme, freeing the motor from being limited to an even-layer winding structure. It adopts a "first forward winding, then reverse winding" method. Furthermore, the provided stator assembly includes three-phase flat wire windings, where one phase is in the opposite direction to the other two phases. This achieves flexibility in the number of winding layers and connection design, and features fewer wire types, simple end connections, small end space occupation, and simple busbar structure. This reduces manufacturing difficulty and insulation failure risk, and improves motor reliability.

Description

Technical Field

[0001] This invention relates to the field of electric motors, and more particularly to multilayer flat wire winding motors, especially a method for winding a stator assembly of a flat wire winding motor and the flat wire winding motor itself. Background Technology

[0002] With the widespread application of flat copper wire winding technology in drive motors of new energy vehicles, multi-layer flat wire winding schemes are emerging in large numbers. Common stator windings typically have an even number of flat wire layers, and the number of layers can range from 2 to more than 10, depending on the slot size and manufacturing complexity. In some applications, to match product performance, an odd number of flat wire layers must be used. However, the end connection design of odd-layer flat wire windings is more complex, with a significantly greater variety of wire types compared to even-layer flat wire windings. This increases the difficulty of twisting and welding processes and may result in occupying a large amount of radial and axial space at the ends. Summary of the Invention

[0003] The purpose of this invention is to provide a method for winding a stator assembly of a flat wire winding motor and a flat wire winding motor, which solves the problems of complex end connection structure, complex processing and manufacturing process, and large end space occupation of existing odd-layer flat wire windings.

[0004] To achieve the above and other related objectives, the present invention provides a method for winding a stator assembly of a flat wire winding motor. The stator assembly includes: a stator core and a multi-phase flat wire winding; wherein the stator core has multiple stator slots, and stator teeth are formed between each pair of adjacent stator slots; the flat wire winding includes at least one winding unit; each stator slot is wound with n layers of flat copper wire; n is greater than or equal to 3, and n is an odd number; the method includes the following steps: Step 1, the lead wire of a winding unit of the flat wire winding, from the first layer of the first stator slot along a first direction, crosses into the second layer of the second stator slot with a pitch y, and continues to be wound layer by layer between the first stator slot and the second stator slot; Step 2, when the first stator slot is wound... After the nth layer of the stator slot, the wire is wound along the second direction at a pitch y into the nth layer of the third stator slot, and the winding continues to decrease layer by layer between the first and third stator slots until the first layer of the third stator slot is reached; the second direction is opposite to the first direction; Step 3: From the first layer of the third stator slot, the wire is wound along the second direction at a pitch k into the first layer of the first stator slot of the next target winding unit, thus completing the winding of one winding unit; Step 4: The target winding unit is wound according to the method of Step 1 to Step 3 until the flat copper wire on all stator slots is wound; the value of the pitch k corresponding to each winding is the same as or different from the value of the pitch k corresponding to the previous winding.

[0005] In one embodiment of the present invention, the formula for calculating the pitch y is:

[0006] y = z / 2p;

[0007] Where z represents the total number of stator slots; p represents the number of pole pairs of the motor; the relationship between k and y includes any of the following: k = y, k = y + 1, and k = y - 1.

[0008] In one embodiment of the present invention, the multiphase is three-phase.

[0009] In one embodiment of the present invention, the three-phase flat wire windings are wound in the stator slots, and two of the three-phase flat wire windings are wound in the same direction, while the remaining one-phase flat wire winding is wound in the opposite direction to the two-phase flat wire windings, so that the stator slots where the output ends of all branches of the three-phase flat wire windings are located are adjacent.

[0010] In one embodiment of the present invention, the lead-out ends of the three-phase flat wire windings are all located in the same layer, and are all located in the layer where the slot opening of the stator slot is located, or in the layer where the bottom of the stator slot is located.

[0011] In one embodiment of the present invention, the number of winding units included in each phase of the flat wire winding is equal to the number of pole pairs of the motor, or the number of winding units included in each phase of the flat wire winding is an integer multiple of the number of pole pairs of the motor.

[0012] In one embodiment of the present invention, the target winding unit is another winding unit of the flat wire winding, or the target winding unit is another winding unit of the flat wire winding.

[0013] In one embodiment of the present invention, the winding layers from the opening to the bottom of the stator slot are sequentially numbered from layer 1 to layer n; or the winding layers from the bottom to the opening of the stator slot are sequentially numbered from layer 1 to layer n.

[0014] In one embodiment of the present invention, each of the winding units includes a plurality of flat wire units; wherein the flat wire units are bent at both ends to form a hairpin shape, and the two ends of the flat wire units are inserted into different stator slots.

[0015] In one embodiment of the present invention, a plurality of stator slots are uniformly arranged.

[0016] The present invention also provides a flat wire winding motor, comprising: a stator assembly; the stator assembly is wound using the above-described winding method for a flat wire winding motor stator assembly.

[0017] As described above, the method for winding the stator assembly of the flat wire winding motor and the flat wire winding motor of the present invention have the following advantages:

[0018] Beneficial effects:

[0019] (1) Compared with the prior art, the present invention provides an odd-numbered layer flat copper wire winding scheme, which makes the motor no longer limited to an even-numbered layer winding structure. The number of winding layers and connection design that match the motor performance are more flexible. It also has the characteristics of fewer wire types, simple end connection, small end space occupation, and simple busbar structure. The output position is concentrated and the space is free, which reduces the manufacturing process difficulty and insulation failure risk, and improves the reliability of the motor.

[0020] (2) The present invention adopts a winding method of “first forward winding and then reverse winding” to achieve the technical effect of flexible winding layers and connection design.

[0021] (3) Furthermore, in the three-phase flat wire winding provided by the present invention, one phase is opposite in direction to the other two phases, which can achieve technical effects such as simple end connection and small end space occupation. Attached Figure Description

[0022] Figure 1 The diagram shown is a structural schematic of a flat wire winding motor stator assembly according to one embodiment of the present invention.

[0023] Figure 2 The image shown is a top view of a flat wire winding motor stator assembly according to an embodiment of the present invention.

[0024] Figure 3 The diagram shown is a structural schematic of a large coil wrapping a small coil across a wire in one embodiment of the present invention.

[0025] Figure 4 The diagram shown is a winding schematic of an odd-layer winding unit of the present invention in one embodiment.

[0026] Figure 5 The flowchart shown is a method for winding a flat wire winding motor stator assembly according to an embodiment of the present invention. Detailed Implementation

[0027] The following specific embodiments illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification.

[0028] It should be understood that the structures, proportions, sizes, etc., illustrated in the accompanying drawings are merely for illustrative purposes to aid those skilled in the art and to facilitate understanding and reading. They are not intended to limit the scope of the invention and therefore have no substantial technical significance. Any modifications to the structure, changes in proportions, or adjustments to size, without affecting the effectiveness and purpose of the invention, should still fall within the scope of the technical content disclosed herein. Furthermore, the terms such as "upper," "lower," "left," "right," "middle," and "one" used in this specification are merely for clarity and not intended to limit the scope of the invention. Changes or adjustments to their relative relationships, without substantially altering the technical content, should also be considered within the scope of the invention.

[0029] The present invention provides a method for winding a stator assembly of a flat wire winding motor and a flat wire winding motor to solve the problems of complex end connection structures, complex manufacturing processes, and large end space occupation in existing odd-layer flat wire windings. The following will describe in detail the method for winding a stator assembly of a flat wire winding motor and the principle and implementation of the flat wire winding motor of the present invention, enabling those skilled in the art to understand the method for winding a stator assembly of a flat wire winding motor and the flat wire winding motor of the present invention without creative effort.

[0030] See Figures 1 to 5 The flat wire winding motor stator assembly winding method provided in this embodiment, compared with the prior art, offers an odd-numbered layer flat copper wire winding scheme, freeing the motor from being limited to an even-numbered layer winding structure. This allows for greater flexibility in the number of winding layers and connection design to match motor performance, and features fewer wire types, simpler end connections, smaller end space occupation, and a simpler busbar structure. The output positions are concentrated and spatially flexible, reducing manufacturing difficulty and insulation failure risk, and improving motor reliability. This invention employs a "first forward winding, then reverse winding" method to achieve flexible winding layer and connection design. Furthermore, in the three-phase flat wire winding provided by this invention, one phase has a direction opposite to the other two, which simplifies end connections and reduces end space occupation.

[0031] like Figures 1 to 3 As shown, in one embodiment, the flat wire winding motor stator assembly of the present invention includes: a stator core 11 and a multiphase flat wire winding (not shown in the figure).

[0032] like Figures 1 to 3 As shown, in one embodiment, the stator core 11 has a plurality of stator slots 111, and stator teeth 112 are formed between each two adjacent stator slots 111; the flat wire winding includes at least one winding unit (not shown in the figure); each stator slot 111 is wound with n layers of the flat copper wire 12; the n is greater than or equal to 3, and the n is an odd number.

[0033] The winding unit includes flat copper wire 12.

[0034] like Figure 5 As shown, in one embodiment, the winding method of the flat wire winding motor stator assembly of the present invention includes the following steps:

[0035] Step S1: The lead wire (corresponding to a flat copper wire 12) of one of the winding units of the flat wire winding enters the second layer of the second stator slot from the first layer of the first stator slot along the first direction with a pitch y, and continues to be progressively stacked between the first stator slot and the second stator slot.

[0036] Step S2: After winding to the nth layer of the first stator slot, the winding proceeds in the second direction at a pitch y into the nth layer of the third stator slot, and continues to decrease layer by layer between the first and third stator slots until the first layer of the third stator slot is reached.

[0037] The second direction is opposite to the first direction.

[0038] Step S3: Starting from the first layer of the third stator slot, proceed along the second direction at a pitch k into the first layer of the first stator slot of the next target winding unit. This completes the winding of one winding unit.

[0039] Step S4: Following the methods of steps S1 to S3, wind the target winding unit until all the flat copper wires on the stator slots are wound.

[0040] It should be noted that in step S3, the value of the pitch k corresponding to each winding may be the same as or different from the value of the pitch k corresponding to the previous winding.

[0041] In one embodiment, the winding layers from the top to the bottom of the stator slot 111 are defined as layers 1 to n, or the winding layers from the bottom to the top of the stator slot 111 are defined as layers 1 to n.

[0042] In one embodiment, the pitch y is the motor pole pitch, and the formula for calculating the pitch y is:

[0043] y = z / 2p;

[0044] Where z represents the total number of stator slots; p represents the number of pole pairs of the motor; the relationship between k and y includes any of the following: k = y, k = y + 1, and k = y - 1.

[0045] The total number of stator slots (z) is a multiple of twice the number of motor pole pairs (2×p).

[0046] In one embodiment, the multiphase is three-phase, meaning that the flat wire winding motor stator assembly includes three-phase flat wire windings.

[0047] In one embodiment, the stator assembly of the flat wire winding motor may further include a six-phase flat wire winding; specifically, the six-phase flat wire winding is composed of two three-phase flat wire windings, and its working principle is equivalent to a combination of two three-phase flat wire windings; here, a three-phase flat wire winding is used as an example for explanation.

[0048] In one embodiment, the three-phase flat wire windings are wound in the stator slots 111, and two of the three-phase flat wire windings are wound in the same direction, while the remaining one-phase flat wire winding is wound in the opposite direction to the two-phase flat wire windings, so that the stator slots 111 where the output ends of all branches of the three-phase flat wire windings are located are adjacent.

[0049] In one embodiment, the lead-out ends of the three-phase flat wire windings are all located in the same layer, and are all located in the layer where the slot opening of the stator slot 111 is located, or in the layer where the bottom of the stator slot 111 is located.

[0050] In one embodiment, the number of winding units included in each phase of the flat wire winding is equal to the number of pole pairs (p) of the motor, or the number of winding units included in each phase of the flat wire winding is an integer multiple of the number of pole pairs of the motor.

[0051] In one embodiment, the target winding unit is a winding unit of another flat wire winding, or the target winding unit is another winding unit of the flat wire winding.

[0052] Specifically, when each phase of the flat wire winding includes one winding unit, the target winding unit is the winding unit of another flat wire winding; when each phase of the flat wire winding includes at least two winding units, the target winding unit is another winding unit of the flat wire winding, or a winding unit of another flat wire winding.

[0053] In one embodiment, each of the winding units includes a plurality of flat wire units; wherein the flat wire units are bent at both ends to form a hairpin shape, and the two ends of the flat wire units are inserted into different stator slots.

[0054] like Figure 3 As shown, in one embodiment, a plurality of the stator slots 111 are evenly arranged.

[0055] The method for winding flat wire winding motor stator assembly provided by this invention is applicable to winding structures of any odd number of flat wire layers, such as 3, 5, 7, and 9 layers. It effectively solves the technical problems of complex end connection structure, complex processing and manufacturing process, and large end space occupation of odd number of flat wire windings. This makes the motor no longer limited to even number of winding layers, and the winding layer number and connection design that match the motor performance are more flexible.

[0056] In one embodiment, the flat wire winding is divided into three phases: U, V, and W. The lead wires are arranged in the same layer, which is either close to the slot opening or close to the slot bottom. All branch wires are located in adjacent slots, and the wire positions are concentrated and free in space. This effectively reduces the difficulty of the end connection manufacturing process, makes the end connection wire occupy a smaller angle in the circumferential direction, saves more space, reduces the risk of insulation failure, and improves the reliability of the motor.

[0057] The flat wire motor connection scheme with odd-numbered winding layers proposed in this invention has a simple end connection wire structure, fewer wire types, and a small space occupied by the end connection busbar, which simplifies the stator assembly manufacturing process and improves the stability and reliability of the winding structure.

[0058] The following specific embodiments will further explain the winding method of the flat wire winding motor stator assembly of the present invention.

[0059] In one embodiment, the flat wire winding motor stator assembly includes 48 positioning slots 111 (numbered sequentially as No. 1, No. 2... No. 48), the motor has 4 pole pairs (p=4), three phases (U phase, V phase, W phase respectively), two parallel branches for each phase, and 5 layers of flat copper wire 12 in each stator slot 111 for illustration.

[0060] It should be noted that the numbering order of stator slot 111 here is not consistent with the order of the first, second, and third stator slots mentioned above. The "first", "second", and "third" mentioned above are only a limitation on the winding order within a winding unit and do not represent stator slots numbered 1, 2, and 3 here.

[0061] In this embodiment, the winding layers from the top to the bottom of the stator slot 111 are defined as layers 1 to 5 in sequence; the motor pole pitch y = z / 2p = 48 / (2×4) = 6; the starting slot of U-phase branch 1 (corresponding to the first stator slot mentioned above) is defined as stator slot 111, number 25.

[0062] like Figure 4As shown, one branch U1 of phase U starts from the first layer of stator slot 25 111, and enters the second layer of stator slot 31 111 in the positive direction (corresponding to the first direction mentioned above) with a pitch y = 6. Then it successively enters the third layer of stator slot 25 111, the fourth layer of stator slot 31 111, and the fifth layer of stator slot 25 111. After that, it enters the same layer in the opposite direction (corresponding to the second direction mentioned above) with a pitch y = 6. The fifth layer of stator slot 111 (19th pole) is then folded into the fourth layer of stator slot 111 (25th pole), the third layer of stator slot 111 (19th pole), the second layer of stator slot 111 (25th pole), and the first layer of stator slot 111 (19th pole). Then, in the opposite direction, the first layer of stator slot 111 (19th pole) is folded into the first layer of stator slot 111 (19th pole) with pitch k. The above method of first folding in the forward direction and then folding in the reverse direction is repeated to continue to complete the winding of the subsequent three pole pairs.

[0063] The second branch U2 of phase U is wound in the same manner in the adjacent slot (stator slot 111, number 26) of branch U1.

[0064] To ensure a balanced current distribution between the two branches, the relative front-to-back relationship of the slots containing the two branches is adjusted by adjusting the span k, where k = y + 1, y, or y - 1, forming a crossover where the larger coil wraps around the smaller coil (e.g., Figure 3 (As shown).

[0065] In this embodiment, the three spans of branch k of U1 are y, y-1, and y, respectively, and the three spans of branch k of U2 are y, y+1, and y, respectively. The ending slot of branch k of U1 is stator slot 111 of number 32, and the ending slot of branch k of U2 is stator slot 111 of number 31.

[0066] The V phase and U phase are connected in the same way. The starting slots of the two branches of the V phase are stator slot 29 (111) and stator slot 30 (111), respectively, and the ending slots are stator slot 35 (111) and stator slot 36 (111), respectively.

[0067] To reduce the circumferential space occupied by the end connection, the overall winding direction of the W phase winding is opposite to that of the U phase and V phase (in this example, the U phase and V phase windings are wound along the direction of decreasing slot number, while the W phase winding is wound along the direction of increasing slot number). The starting slots of the two branches of the W phase are slots 33 and 34, and the ending slots are slots 27 and 28, respectively.

[0068] The motor stator assembly proposed in this invention has cross-line wires on both sides of the stator core, with cross-line wires from the first layer to the first layer on one side and cross-line wires from the fifth layer to the fifth layer on the other side, resulting in an overall structure in the shape of a petal.

[0069] The 12 outgoing wires of the motor stator assembly proposed in this invention are located in the first layer of stator slots 25-36. All of their slots are adjacent and located in the first layer. They are not affected by other wire types in terms of space. The outgoing wire type design is flexible, the end lead wire connection is simple, the circumferential angle is 90°, the overall space occupies is small, the process is simple, and the reliability is high.

[0070] In one embodiment, the present invention also provides a flat wire winding motor, including a stator assembly (not shown in the figures).

[0071] Specifically, the stator assembly is wound using the aforementioned winding method for flat wire winding motor stator assemblies.

[0072] It should be noted that the winding principle of the stator assembly of this flat wire winding motor is the same as the working principle of the winding method of the stator assembly of the flat wire winding motor described above, so it will not be described in detail here.

[0073] In summary, compared with the prior art, the flat wire winding motor stator assembly winding method and the flat wire winding motor of the present invention provide an odd-numbered layer flat copper wire winding scheme, which frees the motor from being limited to an even-numbered layer winding structure. This allows for greater flexibility in the number of winding layers and connection design to match motor performance. It also features fewer wire types, simpler end connections, smaller end space occupation, and a simpler busbar structure. The output positions are concentrated and spatially flexible, reducing manufacturing difficulty and the risk of insulation failure, while improving motor reliability. The present invention employs a "first forward winding, then reverse winding" winding method to achieve the technical effect of flexible winding layer number and connection design. Furthermore, in the three-phase flat wire winding provided by the present invention, one phase is in the opposite direction to the other two phases, which can achieve technical effects such as simple end connections and smaller end space occupation. Therefore, the present invention effectively overcomes the various shortcomings of the prior art and has high industrial application value.

[0074] The above embodiments are merely illustrative of the principles and effects of the present invention and are not intended to limit the invention. Any person skilled in the art can modify or alter the above embodiments without departing from the spirit and scope of the present invention. Therefore, all equivalent modifications or alterations made by those skilled in the art without departing from the spirit and technical concept disclosed in the present invention should still be covered by the claims of the present invention.

Claims

1. A method for winding a stator assembly of a flat wire winding motor, characterized in that, The stator assembly includes: a stator core and a multi-phase flat wire winding; wherein, the stator core has multiple stator slots, and a stator tooth is formed between each two adjacent stator slots; the flat wire winding includes at least one winding unit; each stator slot is wound with n layers of flat copper wire; n is greater than or equal to 3, and n is an odd number; the method includes the following steps: Step 1: The lead wire of one winding unit of the flat wire winding is taken from the first layer of the first stator slot along the first direction and enters the second layer of the second stator slot at a pitch y, and continues to be wound layer by layer between the first stator slot and the second stator slot. Step 2: After winding to the nth layer of the first stator slot, the second direction is used to cross into the nth layer of the third stator slot at a pitch y, and the winding continues to decrease layer by layer between the first and third stator slots until the first layer of the third stator slot is wound; the second direction is opposite to the first direction. Step 3: Starting from the first layer of the third stator slot, proceed along the second direction at a pitch k into the first layer of the first stator slot of the next target winding unit. This completes the winding of one winding unit. Step 4: Following the methods described in Steps 1 to 3, wind the target winding unit until all the flat copper wires on the stator slots are wound; the pitch k value corresponding to each winding is the same as or different from the pitch k value corresponding to the previous winding.

2. The method for winding the stator assembly of a flat wire winding motor according to claim 1, characterized in that, The formula for calculating the pitch y is: y = z / 2p; Where z represents the total number of stator slots; p represents the number of pole pairs of the motor; The relationship between k and y includes any of the following: k = y, k = y + 1, and k = y - 1.

3. The method for winding the stator assembly of a flat wire winding motor according to claim 1, characterized in that, The multiphase is a three-phase system.

4. The method for winding the stator assembly of a flat wire winding motor according to claim 3, characterized in that, The three-phase flat wire windings are wound in the stator slots, and two of the three-phase flat wire windings are wound in the same direction, while the remaining one-phase flat wire winding is wound in the opposite direction to the two-phase flat wire windings, so that the stator slots where the output ends of all branches of the three-phase flat wire windings are located are adjacent.

5. The method for winding the stator assembly of a flat wire winding motor according to claim 3, characterized in that, The lead-out ends of the three-phase flat wire windings are all located on the same layer, and are located on the layer where the slot opening of the stator slot is located, or on the layer where the bottom of the stator slot is located.

6. The method for winding the stator assembly of a flat wire winding motor according to claim 3, characterized in that, The number of winding units included in each phase of the flat wire winding is equal to the number of pole pairs of the motor, or the number of winding units included in each phase of the flat wire winding is an integer multiple of the number of pole pairs of the motor.

7. The method for winding the stator assembly of a flat wire winding motor according to claim 1, characterized in that, The target winding unit is a winding unit of another flat wire winding, or the target winding unit is another winding unit of the flat wire winding.

8. The method for winding a flat wire winding motor stator assembly according to claim 1, characterized in that, The winding layers from the top to the bottom of the stator slot are numbered sequentially from layer 1 to layer n; or the winding layers from the bottom to the top of the stator slot are numbered sequentially from layer 1 to layer n.

9. The method for winding a flat wire winding motor stator assembly according to claim 1, characterized in that, Each of the winding units includes multiple flat wire units; wherein the flat wire units are bent at both ends to form a hairpin shape, and the two ends of the flat wire units are inserted into different stator slots.

10. The method for winding a flat wire winding motor stator assembly according to claim 1, characterized in that, The stator slots are evenly arranged.

11. A flat wire winding motor, characterized in that, include: Stator assembly; the stator assembly is wound using the winding method of the flat wire winding motor stator assembly according to any one of claims 1 to 10.

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