Flat wire embedded stator for electric machine

Abstract

The application discloses a flat wire embedded stator for a motor, which comprises a stator core, wherein z stator slots are uniformly arranged in an array along the circumferential direction of the stator core, and the stator slots are sequentially numbered in a clockwise or counterclockwise direction; the stator slots comprise n conductor layers, and the conductor layers are sequentially numbered from the conductor layer closest to the outer circumferential surface of the stator core to the conductor layer closest to the inner circumferential surface of the stator core; a stator winding is arranged in the stator core, and the stator winding comprises m phase windings; each phase winding comprises a strip parallel branch; and each strip parallel branch comprises a plurality of hairpin coils. The application solves the problems that the number of parallel branches of the existing flat copper wire winding cannot be randomly switched and the manufacturing difficulty is great; the winding of the application is uniformly distributed in the stator core, the manufacturing difficulty of the winding is greatly reduced, and the product performance is improved and the production line cost is controlled.

Description

Technical Field

[0001] This invention relates to the field of flat wire motor technology, and in particular to a flat wire stator for motors. Background Technology

[0002] Currently, flat copper wire drive motors have become the mainstream trend in the automotive industry. To meet the demand for compact vehicles, flat wire motors can significantly reduce the axial dimensions of the motor, and their reduction in size and cost greatly enhances their market competitiveness. Especially in terms of performance, flat wire motors have superior performance, efficiency, and NVH indicators compared to round wire motors. Therefore, the development of flat wire motors is attracting increasing attention from the industry.

[0003] The Chinese patent document CN112583165A, entitled "Motor Stator Winding and Stator and Motor Using the Same," provides a motor stator winding and a stator and motor using the same, belonging to the field of motors. It includes a first coil group, a fourth coil group, and at least two second coil groups arranged coaxially. The first and fourth coil groups are both arranged in the same layer on the radially inner and outer first layers of the stator core. Both the first and fourth coil groups have long and short pitches. In the same stator winding, the structures of multiple second coil groups may be the same or different. For two adjacent second coil groups, the pitch between the two welded ends of the two conductors is a long pitch. For the second coil and the first coil group, or the second coil group and the fourth coil group, the pitch between the two welded ends of the two conductors is a whole pitch. However, this Chinese patent (CN112583165A) involves multiple coil group types, resulting in higher costs, greater manufacturing difficulties, and inconvenient switching of the number of parallel branches. Summary of the Invention

[0004] This invention solves the problems of inconvenient switching of the number of parallel branches in existing flat copper wire windings and high manufacturing difficulty. It proposes a flat wire embedded stator for motors, in which the windings are evenly distributed in the stator core, greatly reducing the manufacturing difficulty of the windings and facilitating the improvement of product performance and the control of production line costs.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: a flat wire-inserted stator for a motor, comprising a stator core, wherein z stator slots are uniformly arranged in an array along the circumference of the stator core, and the stator slots are numbered in a clockwise or counterclockwise order; each stator slot comprises n conductor layers, and the slot layers are numbered sequentially from the conductor layer closest to the outer circumference to the conductor layer closest to the inner circumference of the stator core; the stator core is internally provided with stator windings, including m-phase windings, each phase winding including a parallel branches, and each branch containing several hairpin coils.

[0006] In this invention, a plurality of stator slots are arranged along the circumferential direction on the stator core, and the stator slots are numbered sequentially along a certain direction of the circumference. A plurality of conductor layers are arranged in each stator slot, and the conductor layers are numbered from the conductor layer closest to the outer circumference to the conductor layer closest to the inner circumference in ascending order. The stator windings arranged inside the stator core are evenly distributed, and the multiple parallel branches of each phase winding of the m-phase winding are connected by hairpin coils. This invention allows the number of parallel branches of the windings to be switched at will.

[0007] Preferably, the hairpin coil includes a first hairpin coil and a second hairpin coil, the first hairpin coil has a span of y stator slots, the second hairpin coil has a span of y+3 stator slots, and the span between the sequentially connected hairpin coils is y+1 stator slots.

[0008] In this invention, the hairpin coil includes two types: a first hairpin coil and a second hairpin coil. The two have different spans, namely y stator slots and y+3 stator slots, respectively.

[0009] Preferably, the hairpin coil includes a first straight edge and a second straight edge, the first straight edge and the second straight edge of the same hairpin coil are respectively distributed in adjacent slot layers, and a fold-back part is provided at the middle position of each branch, the fold-back part is connected by the welding end of the same slot layer.

[0010] In this invention, both the first hairpin coil and the second hairpin coil include a first straight edge and a second straight edge. One end of the first straight edge and the second straight edge are directly connected, and the other end of the first straight edge and the second straight edge are respectively connected to adjacent slot layers.

[0011] Preferably, the nth conductor layer slot is located on one side close to the inner circumference of the stator core, and the nth slot layer is the layer where the lead wire is located.

[0012] In this invention, the lead wire of the a-th branch is located in the n-th slot layer.

[0013] Preferably, each of the parallel branches includes the same number of first and second hairpin coils.

[0014] In this invention, in each of the a parallel branches, the number of first and second hairpin coils used in each parallel branch is the same.

[0015] Preferably, the m-phase windings are all connected in the same way, and the two phase windings are evenly arranged in the stator core at a distance of x degrees.

[0016] In this invention, the connection method of each phase winding in the m-phase winding is the same, and the angle between the two phase windings needs to be calculated according to the actual scheme.

[0017] As a preferred embodiment, if z is 72, n is 6, a is 4, and m is 3, let ij represent the j-th groove layer in the i-th groove;

[0018] The winding arrangement of the first branch is as follows: the 6th layer of slot 10 and the 6th layer of slot 19 are both layers where the lead wires are located. 10-6→21-5→30-6→38-5→47-6→55-5→64-4→3-3→12-4→20-3→29-4→37-3→46-2→57-1→66-2→2-1→11-2→19-1→28-1→20-2→11-1→3-2→66-1→55-2→46-3→38-4→29-3→21-4→12-3→1-4→64-5→56-6→47-5→39-6→30-5→19-6; 10-6→21-5 indicates that the 6th layer of slot 10 is connected to the 5th layer of slot 21.

[0019] In this invention, taking the 6-layer stator scheme of an 8-pole 72-slot motor as an example, the windings are divided into four groups to achieve four parallel windings, which are evenly arranged in the stator core. The parallel branches include the first branch, the second branch, the third branch and the fourth branch, and the lead wires of each branch are all located on the 6th layer.

[0020] As a preferred option, the winding arrangement of the second branch is as follows: the 6th layer of slot 28 and the 6th layer of slot 37 are both layers where the lead wires are located, 28-6→39-5→48-6→56-5→65-6→1-5→10-4→21-3→30-4→38-3→47-4→55-3→64-2→3-1→12-2→20-1→29-2→37-1→46-1→38-2→29-1→21-2→12-1→1-2→64-3→56-4→47-3→39-4→30-3→19-4→10-5→2-6→65-5→57-6→48-5→37-6.

[0021] In this invention, the lead wires of the second branch winding are located in the 6th layer of slot 28 and the 6th layer of slot 37.

[0022] As a preferred option, the winding arrangement of the third branch is as follows: the 6th layer of slot 46 and the 6th layer of slot 55 are both layers where the lead wires are located, 46-6→57-5→66-6→2-5→11-6→19-5→28-4→39-3→48-4→56-3→65-4→1-3→10-2→21-1→30-2→38-1→47-2→55-1→64-1→56-2→47-1→39-2→30-1→19-2→10-3→2-4→65-3→57-4→48-3→37-4→28-5→20-6→11-5→3-6→66-5→55-6.

[0023] In this invention, the lead wires of the winding of the third branch are located in the 6th layer of slot 46 and the 6th layer of slot 55.

[0024] As a preferred option, the winding arrangement of the fourth branch is as follows: the 6th layer of slot 64 and the 6th layer of slot 1 are both layers where the lead wires are located, 64-6→3-5→12-6→20-5→29-6→37-5→46-4→57-3→66-4→2-3→11-4→19-3→28-2→39-1→48-2→56-1→65-2→1-1→10-1→2-2→65-1→57-2→48-1→37-2→28-3→20-4→11-3→3-4→66-3→55-4→46-5→38-6→29-5→21-6→12-5→1-6.

[0025] In this invention, the lead wires of the fourth branch winding are located in the 6th layer of slot 64 and the 6th layer of slot 1.

[0026] The beneficial effects of this invention are: for the flat wire embedded stator for motors of this invention, the problem of the inconvenience of switching the number of parallel branches of existing flat copper wire windings is solved; the windings are evenly distributed in the stator core, which greatly reduces the manufacturing difficulty of the windings and is conducive to improving product performance and controlling production line costs. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the structure of a flat wire embedded stator for an electric motor according to the present invention;

[0028] Figure 2 This is a diagram showing the arrangement of the first branch winding of the U-phase of a flat wire-insulated stator for an electric motor according to the present invention.

[0029] Figure 3 This is a diagram showing the arrangement of the second branch winding of the U-phase of a flat wire-insulated stator for an electric motor according to the present invention.

[0030] Figure 4 This is a diagram showing the arrangement of the third branch winding of the U-phase of a flat wire-insulated stator for an electric motor according to the present invention.

[0031] Figure 5 This is a diagram showing the arrangement of the fourth branch winding of the U-phase in a flat wire embedded stator for an electric motor according to the present invention. Detailed Implementation

[0032] Example 1:

[0033] This embodiment proposes a flat wire embedded stator for a motor, referencing... Figures 1 to 5The system includes a stator core, on which z stator slots are evenly arranged in an array along the circumference of the stator core. The stator slots are numbered in a clockwise or counterclockwise order. Each stator slot includes n conductor layers, which are numbered sequentially from the conductor layer closest to the outer circumference to the conductor layer closest to the inner circumference. The stator core contains stator windings, including m phase windings. Each phase winding includes a parallel branches, and each branch contains several hairpin coils. In this embodiment, z is 72, n is 6, a is 4, and m is 3. Therefore, a total of 72 stator slots are arrayed in the circumference of the stator core. Each stator slot has 6 conductor layers. The slot layer closest to the outer circumference is numbered 1, and the slot layer closest to the inner circumference is numbered 6. The stator windings inside the stator core are three-phase windings, and each single-phase winding has 4 parallel branches.

[0034] In this invention, the hairpin coil includes a first hairpin coil and a second hairpin coil. The first hairpin coil has a span of y stator slots, the second hairpin coil has a span of y+3 stator slots, and the span between sequentially connected hairpin coils is y+1 stator slots. In this embodiment, y is 8, so the span of the first hairpin coil is 8 stator slots, the span of the second hairpin coil is 11 stator slots, and the span between sequentially connected hairpin coils is 9 stator slots.

[0035] The hairpin coil includes a first straight side and a second straight side. The first and second straight sides of the same hairpin coil are respectively distributed in adjacent slot layers. A foldback section is provided in the middle of each branch, and the foldback sections are connected by welding ends of the same slot layer. In this embodiment, both the first and second hairpin coils include a first straight side and a second straight side. One end of the first and second straight sides is directly connected, and the other end of the first and second straight sides is respectively connected to adjacent slot layers. Specifically, in this embodiment... Figure 2 The turning point is located at 19-1→28-1 on the first branch road.

[0036] The nth conductor layer slot is located on one side near the inner circumference of the stator core, and the nth slot layer is where the lead-out wires are located. In this embodiment, the lead-out wires of the ath branch are all located in the nth slot layer.

[0037] Each parallel branch contains the same number of first and second hairpin coils. In this embodiment, in the a parallel branches, the number of first and second hairpin coils used in each parallel branch is the same.

[0038] refer to Figure 1 , Figure 1In the diagram, a and b represent structural diagrams from two different perspectives, one above the other. The connection methods for all m-phase windings are identical, and the two-phase windings are evenly arranged within the stator core at intervals of x degrees. In this embodiment, m is 3, x is 45 degrees, and the three-phase windings are represented as the U-phase winding, V-phase winding, and W-phase winding, with identical connection methods among them. The angle between the two-phase windings needs to be calculated based on the actual design.

[0039] In this invention, taking the 6-layer stator scheme of an 8-pole 72-slot motor as an example, if z is 72, n is 6, a is 4, and m is 3, ij represents the j-th slot layer in the i-th slot; taking the U-phase of a three-phase winding as an example: the parallel branches include the first branch, the second branch, the third branch, and the fourth branch.

[0040] refer to Figure 2 The winding arrangement of the first branch is as follows: the 6th layer of slot 10 and the 6th layer of slot 19 are both layers where the lead wires are located. 10-6→21-5→30-6→38-5→47-6→55-5→64-4→3-3→12-4→20-3→29-4→37-3→46-2→57-1→66-2→2-1→11-2→19-1→28-1→20-2→11-1→3-2→66-1→55-2→46-3→38-4→29-3→21-4→12-3→1-4→64-5→56-6→47-5→39-6→30-5→19-6; 10-6→21-5 indicates that the 6th layer of slot 10 is connected to the 5th layer of slot 21. In this invention, among the 6 slot layers, the 1st and 2nd layers form one group, the 3rd and 4th layers form another group, and the 5th and 6th layers form another group. The 1st, 3rd and 5th layers are represented by dashed lines, and the 2nd, 4th and 6th layers are represented by solid lines. The horizontal direction represents the slot sequence of the stator slots, starting from 1 and ending at 72 from left to right.

[0041] refer to Figure 3 The winding arrangement of the second branch is as follows: the 6th layer of slot 28 and the 6th layer of slot 37 are both layers where the lead wires are located. 28-6→39-5→48-6→56-5→65-6→1-5→10-4→21-3→30-4→38-3→47-4→55-3→64-2→3-1→12-2→20-1→29-2→37-1→46-1→38-2→29-1→21-2→12-1→1-2→64-3→56-4→47-3→39-4→30-3→19-4→10-5→2-6→65-5→57-6→48-5→37-6.

[0042] refer to Figure 4The winding arrangement of the third branch is as follows: the 6th layer of slot 46 and the 6th layer of slot 55 are both layers where the lead wires are located. 46-6→57-5→66-6→2-5→11-6→19-5→28-4→39-3→48-4→56-3→65-4→1-3→10-2→21-1→30-2→38-1→47-2→55-1→64-1→56-2→47-1→39-2→30-1→19-2→10-3→2-4→65-3→57-4→48-3→37-4→28-5→20-6→11-5→3-6→66-5→55-6.

[0043] refer to Figure 5 The winding arrangement of the fourth branch is as follows: the 6th layer of slot 64 and the 6th layer of slot 1 are both layers where the lead wires are located. 64-6→3-5→12-6→20-5→29-6→37-5→46-4→57-3→66-4→2-3→11-4→19-3→28-2→39-1→48-2→56-1→65-2→1-1→10-1→2-2→65-1→57-2→48-1→37-2→28-3→20-4→11-3→3-4→66-3→55-4→46-5→38-6→29-5→21-6→12-5→1-6.

[0044] In this embodiment, a plurality of stator slots are arranged along the circumferential direction on the stator core, and the stator slots are numbered sequentially along a certain direction of the circumference. A plurality of conductor layers are arranged in each stator slot, and the slot layers of the conductor layers are numbered from the conductor layer closest to the outer circumference to the conductor layer closest to the inner circumference in ascending order. The stator windings arranged inside the stator core are evenly distributed, and the multiple parallel branches of each phase winding of the m-phase winding are connected by hairpin coils. This invention allows the number of parallel branches of the windings to be switched at will.

[0045] In this embodiment, there are two types of hairpin coils: a first hairpin coil and a second hairpin coil. The two have different spans, namely y stator slots and y+3 stator slots, respectively.

[0046] In this embodiment, taking the 6-layer stator scheme of an 8-pole 72-slot motor as an example, the windings are divided into four groups to achieve four parallel windings, which are evenly arranged in the stator core. The parallel branches include the first branch, the second branch, the third branch, and the fourth branch.

[0047] The preferred embodiments of the present invention have been described in detail above. It should be understood that those skilled in the art can make numerous modifications and variations based on the concept of the present invention without creative effort. Therefore, all technical solutions that can be obtained by those skilled in the art based on the concept of the present invention through logical analysis, reasoning, or limited experimentation on the basis of existing technology should be within the scope of protection defined by the claims.

Claims

1. A flat wire-insulated stator for an electric motor, characterized in that, The system includes a stator core, on which z stator slots are arranged in a uniform array along the circumference of the stator core. The stator slots are numbered in a clockwise or counterclockwise order. Each stator slot includes n conductor layers, which are numbered sequentially from the conductor layer closest to the outer circumference to the conductor layer closest to the inner circumference. The stator core contains stator windings, including m phase windings. Each phase winding includes a parallel branches, and each branch contains several hairpin coils. z is 72, n is 6, a is 4, m is 3, and ij represents the j-th layer in the i-th slot; The first branch winding arrangement is as follows: the 6th layer of slot 10 and the 6th layer of slot 19 are the layers where the lead wires are located. 10-6→21-5→30-6→38-5→47-6→55-5→64-4→3-3→12-4→20-3→29-4→37-3→46-2→57-1→66-2→2-1→11-2→19-1→28-1→20-2→11-1→3-2→66-1→55-2→46-3→38-4→29-3→21-4→12-3→1-4→64-5→56-6→47-5→39-6→30-5→19-6; 10-6→21-5 indicates that the 6th layer of slot 10 is connected to the 5th layer of slot 21.

2. A flat wire-inserted stator for a motor according to claim 1, characterized in that, The hairpin coil includes a first hairpin coil and a second hairpin coil. The first hairpin coil has a span of y stator slots, the second hairpin coil has a span of y+3 stator slots, and the hairpin coils connected in sequence have a span of y+1 stator slots.

3. A flat wire-inserted stator for a motor according to claim 2, characterized in that, The hairpin coil includes a first straight edge and a second straight edge. The first straight edge and the second straight edge of the same hairpin coil are respectively distributed in adjacent slot layers. A foldback part is provided at the middle position of each branch. The foldback parts are connected by welding ends of the same slot layer.

4. A flat wire-inserted stator for a motor according to claim 1 or 2, characterized in that, The nth coil layer slot is located on one side close to the inner circumference of the stator core, and the nth slot layer is where the lead wires are located.

5. A flat wire-inserted stator for a motor according to claim 2 or 3, characterized in that, Each of the parallel branches contains the same number of first and second hairpin coils.

6. A flat wire-inserted stator for a motor according to claim 1, characterized in that, The connection methods of the m-phase windings are all the same, and the two phase windings are evenly arranged in the stator core at a spacing of x degrees.

7. A flat wire-inserted stator for a motor according to claim 1, characterized in that, The winding arrangement of the second branch is as follows: the 6th layer of slot 28 and the 6th layer of slot 37 are both layers where the lead wires are located. 28-6→39-5→48-6→56-5→65-6→1-5→10-4→21-3→30-4→38-3→47-4→55-3→64-2→3-1→12-2→20-1→29-2→37-1→46-1→38-2→29-1→21-2→12-1→1-2→64-3→56-4→47-3→39-4→30-3→19-4→10-5→2-6→65-5→57-6→48-5→37-6.

8. A flat wire-inserted stator for a motor according to claim 1 or 7, characterized in that, The winding arrangement of the third branch is as follows: the 6th layer of slot 46 and the 6th layer of slot 55 are both layers where the lead wires are located. 46-6→57-5→66-6→2-5→11-6→19-5→28-4→39-3→48-4→56-3→65-4→1-3→10-2→21-1→30-2→38-1→47-2→55-1→64-1→56-2→47-1→39-2→30-1→19-2→10-3→2-4→65-3→57-4→48-3→37-4→28-5→20-6→11-5→3-6→66-5→55-6.

9. A flat wire-inserted stator for a motor according to claim 1 or 7, characterized in that, The winding arrangement of the fourth branch is as follows: the 6th layer of slot 64 and the 6th layer of slot 1 are both layers where the lead wires are located. 64-6→3-5→12-6→20-5→29-6→37-5→46-4→57-3→66-4→2-3→11-4→19-3→28-2→39-1→48-2→56-1→65-2→1-1→10-1→2-2→65-1→57-2→48-1→37-2→28-3→20-4→11-3→3-4→66-3→55-4→46-5→38-6→29-5→21-6→12-5→1-6.

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