Flat wire motor stator assembly

Abstract

The application provides a flat wire winding motor stator assembly, which comprises a stator core and a multi-phase flat wire winding; at least one winding unit exists between each parallel branch in each phase flat wire winding for slotting winding, so that the relative relationship of the stator slots where each parallel branch is located in each phase flat wire winding is alternated to realize the cross-line form of large coil wrapping small coil formed by slotting winding at the end of the stator core; the flexible slotting cross-line connection between the branches effectively solves the current balance problem of the multi-branch, and has the characteristics of less wire type, simple end connection, simplified manufacturing process and improved motor reliability.

Description

Technical Field

[0001] This invention belongs to the field of electric motors, and relates to stator windings, and particularly to a stator assembly for a flat wire winding motor. 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 an endless stream; the winding scheme design is very different when the number of stator winding layers is odd and even; and when there are multiple branches in each phase, it will lead to unbalanced current in each branch. Summary of the Invention

[0003] The purpose of this invention is to provide a stator assembly for a flat wire winding motor, which solves the problem of current balance in multiple branches of a flat wire motor.

[0004] To achieve the above and other related objectives, the present invention provides a stator assembly for a flat wire winding motor, comprising: a stator core and a multi-phase flat wire winding; wherein the stator core has a plurality of stator slots; a stator tooth is formed between each pair of adjacent stator slots, and n layers of flat copper wire are wound in each stator slot; n is any integer greater than or equal to 3; the flat wire winding is wound in the stator slots, and each phase of the flat wire winding includes at least two parallel branches; each parallel branch includes at least one winding unit; at least one winding unit in each phase of the flat wire winding performs staggered winding between each parallel branch, so that the relative relationship of the stator slots in each phase of the flat wire winding is interactive, so as to realize that the staggered winding at the end of the stator core forms a cross-wire form in which a large coil wraps a small coil.

[0005] In one embodiment of the present invention, for a single-phase flat wire winding, when it includes two parallel branches, each parallel branch includes at least one coil with a span of k = y + 1 or a span of k = y - 1, and the spans included in the two parallel branches are different; for a single-phase flat wire winding, when the number of parallel branches is greater than two, each parallel branch includes at least one coil with a span of k = y + 1 or a span of k = y - 1, and the spans included in different parallel branches are not exactly the same.

[0006] In one embodiment of the present invention, the staggered winding is located at any crossover line in the same layer or a crossover line in an adjacent layer.

[0007] In one embodiment of the present invention, during the stator slot winding process, the stator slot where the starting end of the coil of the preceding parallel branch is located is adjacent to the stator slot where the starting end of the coil of the following parallel branch is located, and the winding of the coil of the preceding parallel branch is carried out before the winding of the coil of the following parallel branch.

[0008] In one embodiment of the present invention, during the staggered winding process, the span k of any cross-line of the preceding parallel branch is adjusted so that the preceding parallel branch enters the stator slot corresponding to the following parallel branch and is wound layer by layer; at the same time, the span k of the following parallel branch at the current corresponding cross-line is adjusted so that the following parallel branch enters the stator slot corresponding to the preceding parallel branch before the span adjustment and is wound layer by layer.

[0009] In one embodiment of the present invention, during the normal winding process of the winding unit, when n is an odd number, in one winding unit, starting from the first layer of the first stator slot, a flat copper wire lead enters the second layer of the second stator slot from the first direction with a span k, and winds layer by layer between the first stator slot and the second stator slot; after winding to the nth layer of the first stator slot, it enters the nth layer of the second stator slot with a span k; then, it enters the (n-1)th layer of the third stator slot from the first direction with a span k, and winds layer by layer between the second stator slot and the third stator slot until it winds to the first layer of the second stator slot, thus completing the winding of one winding unit; after winding to the first layer of the second stator slot, it enters the first layer of the first stator slot of the next winding unit from the first direction with a span k, and begins the winding of the next winding unit; the first stator slot of the next winding unit is the third stator slot of the previous winding unit; in the same parallel branch, the span k may be the same or different.

[0010] In one embodiment of the present invention, during the normal winding process of the winding unit, when n is an even number, in one winding unit, starting from the first layer of the first stator slot, a flat copper wire lead enters the second layer of the second stator slot from the second direction with a span k, and winds layer by layer between the first stator slot and the second stator slot; after winding to the nth layer of the second stator slot, it enters the nth layer of the third stator slot from the second direction with a span k; then, it winds layer by layer decreasing between the second stator slot and the third stator slot until it winds to the first layer of the second stator slot, thus completing the winding of one winding unit; after winding to the first layer of the second stator slot, it enters the first layer of the first stator slot of the next winding unit from the second direction with a span k, and begins the winding of the next winding unit; the first stator slot of the next winding unit is the third stator slot of the previous winding unit; in the same parallel branch, the span k may be the same or different.

[0011] In one embodiment of the present invention, the span k is at least any one of the following: k = y + 1, k = y, k = y - 1; wherein, the formula for calculating y is:

[0012] y = z / 2p;

[0013] Where z represents the total number of stator slots and p represents the number of pole pairs of the motor.

[0014] In one embodiment of the present invention, under the same phase, before the span k of different parallel branches changes, the number of winding turns completed by different parallel branches is the same.

[0015] In one embodiment of the present invention, each winding unit includes a same-layer crossover wire located in the first layer, a same-layer crossover wire located in the nth layer, and at least one adjacent-layer crossover wire. When n is odd, the same-layer crossover wire located in the first layer and the same-layer crossover wire located in the nth layer are located at different end sides of the stator core. When n is even, the same-layer crossover wire located in the first layer and the same-layer crossover wire located in the nth layer are located at the same end side of the stator core.

[0016] In one embodiment of the present invention, the ends of the flat wire winding are connected in any of the following ways: U-shaped wire, welding, busbar; the target connection includes at least any of the following: cross-line connection of each branch, star point connection, lead wire connection.

[0017] As described above, the flat wire winding motor stator assembly of the present invention has the following beneficial effects:

[0018] (1) Compared with the prior art, the present invention effectively solves the problem of current balance of multiple branches by flexibly connecting the cross-line of the branches through staggered slots, and has the characteristics of fewer types of wires and simple end connection, which simplifies the manufacturing process and improves the reliability of the motor.

[0019] (2) The flat wire winding motor stator assembly provided by the present invention has a winding scheme that can be applied to any odd-numbered and even-numbered winding structure with a layer number greater than or equal to three. The winding layer number and connection design that match the motor performance are more flexible, and the layer number can be flexibly selected according to the requirements. Attached Figure Description

[0020] Figure 1 The image shown is a top view of the stator core of the present invention in one embodiment.

[0021] Figure 2 The diagram shown illustrates the winding of each phase flat wire winding of the present invention, comprising two parallel branches in one embodiment.

[0022] Figure 3 The diagram shown illustrates the winding of each phase flat wire winding of the present invention, comprising three parallel branches in one embodiment.

[0023] Figure 4 The diagram shown is a schematic representation of the slotted winding of the present invention in one embodiment.

[0024] Figure 5The diagram shown is a schematic representation of the slotted winding of the present invention in another embodiment.

[0025] Figure 6 The diagram shown illustrates the normal winding of the present invention in one embodiment.

[0026] Figure 7 The diagram shown is a schematic representation of the normal winding of the present invention in another embodiment. 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 flat wire winding motor stator assembly of the present invention is used to solve the problem of current balance in multiple branches of a flat wire motor. The principle and implementation method of the flat wire winding motor stator assembly of the present invention will be described in detail below, so that those skilled in the art can understand the flat wire winding motor stator assembly of the present invention without creative effort.

[0030] See Figures 1 to 7 Compared with the prior art, the flat wire winding motor stator assembly provided in this embodiment effectively solves the problem of current balance in multiple branches through flexible staggered cross-wire connections between branches. It also features fewer wire types and simpler end connections, simplifying the manufacturing process and improving motor reliability. The flat wire winding motor stator assembly provided by this invention can be applied to any odd-numbered and even-numbered layer winding structures with three or more layers. The number of winding layers and connection design are more flexible in matching motor performance, and the number of layers can be flexibly selected according to requirements.

[0031] like Figure 1 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] Specifically, the stator core 11 has a plurality of stator slots 12; stator teeth 13 are formed between each pair of adjacent stator slots 12, and n layers of flat copper wire (not shown in the figure) are wound in each stator slot 12; n is any integer greater than or equal to 3; the flat wire winding is wound in the stator slots 12, and each phase of the flat wire winding includes at least two parallel branches; each parallel branch includes at least one winding unit (not shown in the figure).

[0033] In this embodiment, at least one winding unit is used for staggered winding between each parallel branch in each phase of the flat wire winding, so that the relative relationship of the stator slots 12 where each parallel branch is located in each phase of the flat wire winding is interactive, so as to realize that the staggered winding forms a cross-line form of large coil wrapping small coil at the end of the stator core 11, ensuring that the current distribution of each branch is balanced.

[0034] In one embodiment, the staggered winding is located on any same-layer crossover or adjacent-layer crossover.

[0035] It should be noted that by one or more staggered windings, the number of coils in each branch winding of each phase located in the leading and lagging slots is the same, thereby achieving current balance in multiple branches of each phase.

[0036] It should be noted that the concepts of "lead slot" and "lag slot" are relative. The "lead slot" can be understood as the stator slot wound before the "lag slot".

[0037] In one embodiment, during the coil winding process, the span k of each crossover (from one stator slot 12 to another stator slot 12) is at least, but not limited to, any one of the following: k = y + 1, k = y, k = y - 1; where y is the motor pole pitch, and the formula for calculating y is:

[0038] y = z / 2p;

[0039] Where z represents the total number of stator slots and p represents the number of pole pairs of the motor.

[0040] The total number of stator slots 12 (z) is proportional to twice the number of motor pole pairs (2×p).

[0041] For example, the span k can also take the values ​​y-2, y+2, y+3, etc.

[0042] In this embodiment, for a single phase of the flat wire winding, when it includes two parallel branches, each of the parallel branches includes at least one coil with a span of k = y + 1 or a span of k = y - 1, and the spans included in the two parallel branches are different.

[0043] like Figure 2As shown, in one embodiment, under the same phase, before the span k of different parallel branches changes, the number of turns completed by different parallel branches is the same; specifically, a coil 141 with a span k = y + 1 in one parallel branch includes two pins 151 and 154, and a coil 142 with a span k = y - 1 in another parallel branch includes two pins 152 and 153. Pins 151 and 152 are located in the same layer in adjacent stator slots 12, and pins 153 and 154 are located in the same layer in adjacent stator slots 12. The layers where pins 151 and 152 are located are the same layers or any adjacent layers as the layers where pins 153 and 154 are located. The coil 141 with a span k = y + 1 and its pins 151 and 154 spatially wrap around the coil 142 with a span k = y - 1 and its pins 152 and 153, forming a large coil wrapping a small coil.

[0044] In this embodiment, for a single-phase flat wire winding, when the number of parallel branches is greater than two, each parallel branch includes at least one coil with a span k = y + 1 or a span k = y - 1, and the spans included in different parallel branches are not exactly the same.

[0045] like Figure 3 As shown, in one embodiment, the flat wire winding motor stator assembly includes a 72-slot motor with an 8-pole (p=4) structure, and the flat wire winding is divided into three phases U, V, and W, with three parallel branches for each phase.

[0046] In this embodiment, the motor pole pitch y = z / 2p = 72 / (2×4) = 9.

[0047] Specifically, under the same phase, before the span k of different parallel branches changes, the number of turns completed in different parallel branches is the same; taking a parallel branch including a coil with a span k = y + 1 (i.e., k = 9 + 1 = 10) as an example, the coil 161 of this parallel branch with a span k = y + 1 includes two pins 171 and 175; the second parallel branch also has a coil 162 with a span k = y + 1 (i.e., k = 9 + 1 = 10), which includes two pins 172 and 176; the third parallel branch includes a coil 163 with a span k = y - 2 (i.e., k = 9 - 2 = 7), which includes two pins 173 and 176. 4; wherein, pins 171, 172, and 173 are located in the same layer of three adjacent stator slots 12, and pins 174, 175, and 176 are located in the same layer of three adjacent stator slots 12, and the layer where pins 171, 172, and 173 are located is the same layer as the layer where pins 174, 175, and 176 are located or any adjacent layer; coils 161 and 162 with a span of k = y + 1 and their pins 171, 175, 172, and 176 spatially wrap around coil 163 with a span of k = y - 2 and its pins 173 and 174, forming a large coil wrapping a small coil. Figure 3 (This is only an illustrative representation; it does not show all the structures.)

[0048] like Figure 4 and Figure 5 As shown, in one embodiment, during the stator slot winding process, the stator slot where the starting end of the coil of the preceding parallel branch is located is adjacent to the stator slot where the starting end of the coil of the following parallel branch is located, and the winding of the coil of the preceding parallel branch is ahead of the winding of the coil of the following parallel branch.

[0049] like Figure 4 and Figure 5 As shown, during the staggered winding process, the span k of any cross line of the preceding parallel branch is adjusted so that the preceding parallel branch enters the stator slot corresponding to the following parallel branch and is wound layer by layer; at the same time, the span k of the following parallel branch to the current cross line is adjusted so that the following parallel branch enters the stator slot corresponding to the preceding parallel branch before the span adjustment and is wound layer by layer.

[0050] It should be noted that the "previous parallel branch" and "next parallel branch" mentioned above are definitions of the parallel branches included in each phase flat wire winding. Once it is defined which parallel branch in each phase flat wire winding is the previous parallel branch and which is the next parallel branch, it is equivalent to determining the previous and next parallel branches. No matter how the subsequent coils are wound, the previous parallel branch is always the previous parallel branch and the next parallel branch is always the next parallel branch. That is, the "previous" and "next" here do not change with the winding of the coils.

[0051] In one embodiment, under the same phase, before the span k of different parallel branches changes, the number of winding turns completed by different parallel branches is the same.

[0052] In this embodiment, the winding of a coil from one stator slot to another stator slot is defined as one turn. That is, for a single-phase flat wire winding, before the span k of different parallel branches changes, the number of turns that different parallel branches have completed is the same.

[0053] In one embodiment, when k = y + 1, the two pins of the corresponding coil and when k = y - 1 are located in any layer or adjacent layer of the stator slot, and when k = y + 1, the two pins of the corresponding coil and when k = y - 1 are located in adjacent stator slots.

[0054] Specifically, during the misaligned winding process, when the span k of any crossover of the preceding parallel branch is adjusted from y to y+1, and the span k of the following parallel branch at the current corresponding crossover is adjusted from y to y-1, the number of winding turns completed by the preceding parallel branch and the following parallel branch is the same. This ensures that the two pins of the coil corresponding to k=y+1 and the two pins of the coil corresponding to k=y-1 are located in any layer or adjacent layer in the stator slot 12, and the two pins of the coil corresponding to k=y+1 and the two pins of the coil corresponding to k=y-1 are located in adjacent stator slots 12.

[0055] In one embodiment, the winding layers from the opening to the bottom of the stator slot 12 are defined as layers 1 to n.

[0056] like Figure 6As shown, in one embodiment, during the normal winding process of the winding unit, when n is an odd number, in one winding unit, starting from the first layer of the first stator slot, a flat copper wire lead enters the second layer of the second stator slot from the first direction with a span k, and winds layer by layer between the first and second stator slots; after winding to the nth layer of the first stator slot, it enters the nth layer of the second stator slot with a span k; then, it enters the (n-1)th layer of the third stator slot from the first direction with a span k, and winds layer by layer between the second and third stator slots, decreasing until it winds to the first layer of the second stator slot, thus completing the winding of one winding unit; after winding to the first layer of the second stator slot, it enters the first layer of the first stator slot of the next winding unit from the first direction with a span k, and begins the winding of the next winding unit; the first stator slot of the next winding unit is the third stator slot of the previous winding unit; in the same parallel branch, the span k may be the same or different.

[0057] In this embodiment, the winding unit pattern is 1-2-3-…-nn-…-3-2-1.

[0058] like Figure 7 As shown, in one embodiment, during the normal winding process of the winding unit, when n is an even number, in one winding unit, starting from the first layer of the first stator slot, a flat copper wire lead enters the second layer of the second stator slot from the second direction with a span k, and winds layer by layer between the first and second stator slots; after winding to the nth layer of the second stator slot, it enters the nth layer of the third stator slot from the second direction with a span k; then, it winds layer by layer decreasing between the second and third stator slots until it winds to the first layer of the second stator slot, completing the winding of one winding unit; after winding to the first layer of the second stator slot, it enters the first layer of the first stator slot of the next winding unit from the second direction with a span k, and begins the winding of the next winding unit; the first stator slot of the next winding unit is the third stator slot of the previous winding unit; in the same parallel branch, the span k may be the same or different.

[0059] In this embodiment, the winding unit pattern is 1-2-3-…-nn-…-3-2-1.

[0060] In one embodiment, the first direction and the second direction are the same.

[0061] In one embodiment, each winding unit includes a same-layer crossover line located in the first layer, a same-layer crossover line located in the nth layer, and at least one adjacent-layer crossover line. When n is odd, the same-layer crossover line located in the first layer and the same-layer crossover line located in the nth layer are located at different end sides of the stator core. When n is even, the same-layer crossover line located in the first layer and the same-layer crossover line located in the nth layer are located at the same end side of the stator core.

[0062] In one embodiment, the ends of the flat wire winding are connected to the target in one of the following ways, but not limited to: U-shaped wire, welding, or busbar.

[0063] In one embodiment, the target connection includes at least, but is not limited to, any of the following: branch cross-line connection, star point connection, and lead-out line connection.

[0064] The following specific embodiments will further explain the misslot winding process of the flat wire winding motor stator assembly of the present invention.

[0065] like Figure 4 and Figure 5 As shown, in one embodiment, the flat wire winding motor stator assembly includes 48 positioning slots 12 (numbered sequentially as No. 1, No. 2... No. 48), the motor has an 8-pole (p=4) structure, and the flat wire winding is divided into three phases U, V, and W, with two parallel branches for each phase.

[0066] It should be noted that the numbering order of stator slot 12 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.

[0067] In this embodiment, the winding layers from the opening to the bottom of the stator slot 12 are defined as layers 1 to n in sequence; the motor pole pitch y = z / 2p = 48 / (2×4) = 6.

[0068] like Figure 1 and Figure 4 As shown, in one embodiment, the example is a stator slot 12 with 5 layers of windings and two parallel branches with staggered slots located in adjacent layers.

[0069] Specifically, the first parallel branch starts from the first layer of stator slot 12 numbered 37, enters the second layer of stator slot 12 numbered 43(37+6) with a span of k=y=6, and continues to enter the third layer of stator slot 12 numbered 37(43-6) with a span of k=y=6.

[0070] The second parallel branch starts from the first layer of stator slot 12 numbered 38, enters the second layer of stator slot 12 numbered 44(38+6) with a span of k=y=6, and continues to enter the third layer of stator slot 12 numbered 38(44-6) with a span of k=y=6.

[0071] At this time, the first parallel branch enters the fourth layer of stator slot 12 numbered 44(37+7) with a span of k = y + 1 = 7 (stator slot 12 numbered 44 should normally be the stator slot (38+6) that the second parallel branch is currently winding). At the same time, the second parallel branch enters the fourth layer of stator slot 12 numbered 43(38+5) with a span of k = y - 1 = 5 (stator slot 12 numbered 43 should normally be the stator slot (37+6) that the first parallel branch is currently winding before the span adjustment (from the original span k = y = 6 to the span k = y + 1 = 7).

[0072] Next, the first parallel branch continues to enter the 5th layer of stator slot 12 numbered 38(44-6) with a span of k=y=6. Then, it enters the 5th layer of stator slot 12 numbered 44(38+6) with a span of k=y=6. It continues to wind layer by layer between stator slot 12 numbered 44 and stator slot 12 numbered 2 (44+6-48=2, 44→48→2) with a span of k=y=6.

[0073] The second parallel branch continues to enter the 5th layer of stator slot 12 numbered 37(43-6) with a span of k=y=6. Then, it enters the 5th layer of stator slot 12 numbered 43(37+6) with a span of k=y=6. It continues to wind layer by layer between stator slot 12 numbered 43 and stator slot 12 numbered 1 (43+6-48=1, 43→48→1) with a span of k=y=6.

[0074] like Figure 1 and Figure 2 As shown, in this embodiment, the first parallel branch includes a winding coil 141 with a span of 7, whose pins 151 and 154 are located in the third layer of stator slot 12 numbered 37 and the fourth layer of stator slot 12 numbered 44, respectively; the second parallel branch includes a winding coil 142 with a span of 5, whose pins 152 and 153 are located in the third layer of stator slot 12 numbered 38 and the fourth layer of stator slot 12 numbered 43, respectively; the coil 141 with a span of 7 and its pins 151 and 154 spatially wrap around the coil 142 with a span of 5 and its pins 152 and 153, forming a large coil wrapping a small coil.

[0075] It should be noted that the first parallel branch mentioned above corresponds to the "previous parallel branch" mentioned above; the second parallel branch corresponds to the "rear parallel branch" mentioned above; the stator slot 12 where the coil starting end of the first parallel branch is located (stator slot 12 numbered 37) is adjacent to the stator slot where the coil starting end of the second parallel branch is located (stator slot 12 numbered 38), and the coil winding of the first parallel branch goes before the coil winding of the second parallel branch.

[0076] like Figure 1 and Figure 5 As shown, in one embodiment, the example is a stator slot 12 with 6 layers of windings and two parallel branches with staggered slots located on the same layer.

[0077] Specifically, the first parallel branch is wound layer by layer between stator slot 12 numbered 37 and stator slot 12 numbered 43 (37+6) with a span of k = y = 6. When the 6th layer of stator slot 12 numbered 43 is wound, it enters the 6th layer of stator slot 12 numbered 2 (43+7-48, 43→48→2) with a span of k = y + 1 = 7. Then, it is wound layer by layer between stator slot 12 numbered 2 and stator slot 12 numbered 44 with a span of k = y = 6.

[0078] The second parallel branch winding is wound layer by layer between stator slot 12 numbered 38 and stator slot 12 numbered 44 (38+6) with a span of k = y = 6. When it reaches the 6th layer of stator slot 12 numbered 44, it enters the 6th layer of stator slot 12 numbered 1 (44+5-48, 44→48→1) with a span of k = y-1 = 5. Then, it is wound layer by layer between stator slot 12 numbered 1 and stator slot 12 numbered 43 with a span of k = y = 6.

[0079] like Figure 1 and Figure 2 As shown, the first parallel branch includes a winding coil 141 with a span of 7, whose pins 151 and 154 are located in the 6th layer of stator slot 12 numbered 43 and the 6th layer of stator slot 12 numbered 2, respectively; the second parallel branch includes a winding coil 142 with a span of 5, whose pins 152 and 153 are located in the 6th layer of stator slot 12 numbered 44 and the 6th layer of stator slot 12 numbered 1, respectively; the coil 141 with a span of 7 and its pins 151 and 154 spatially wrap around the coil 142 with a span of 5 and its pins 152 and 153, forming a large coil wrapping a small coil.

[0080] It should be noted that in the above embodiment, the two parallel branches of each phase flat wire winding are located in adjacent stator slots 12. In order to ensure the balanced current distribution of the two parallel branches, the two parallel branch windings need to be staggered in at least one of the winding units. The span of any cross-wire of the leading parallel branch winding during the winding process is adjusted to k = y - 1 or k = y + 1 to enter the stator slot 12 where the lagging parallel branch winding should be located. At the same time, the lagging parallel branch winding is placed in an adjacent stator slot 12. The span of this crossover is adjusted to k = y - 1 or k = y + 1 to enter the stator slot 12 where the leading parallel branch winding should be located, so that the relative relationship of the stator slots where the two parallel branches are located is interactive. This staggered slot winding forms a crossover form where a large coil wraps a small coil at the end of the stator core 11. This staggered slot winding can be located in any crossover in the same layer or adjacent layer. Through one or more staggered layer windings, the number of coils in each branch winding of each phase in the leading and lagging slots is the same, thereby achieving current balance between the two branches of each phase.

[0081] The normal winding process of the flat wire winding motor stator assembly of the present invention will be further explained below through specific embodiments.

[0082] (1) When an odd number of windings are wound in the stator slot 12, take 5 layers as an example.

[0083] like Figure 1 and Figure 6 As shown, the winding of the winding unit starts from the first layer of the initial stator slot 12 (corresponding to the first stator slot 12 mentioned above, and the number of this initial stator slot is defined as 19), and enters the second layer of stator slot 12 numbered 25 (19+6) (corresponding to the second stator slot 12 mentioned above) with a span k = 6. It continues to wind layer by layer between stator slot 12 numbered 19 and stator slot 12 numbered 25 with a span k = 6. When the fifth layer of stator slot 12 numbered 19 is reached, it enters the second layer of stator slot 12 numbered 25 with a span k = 6. The fifth layer is then entered with a span of k = 6 into the fourth layer of stator slot 12 numbered 31 (19+6+6) (corresponding to the third stator slot 12 mentioned above). The winding continues with a span of k = 6 between stator slot 12 numbered 25 and stator slot 12 numbered 31, decreasing layer by layer. When the first layer of stator slot 12 numbered 25 is reached, the first layer of the initial stator slot 12 (i.e., stator slot 12 numbered 31) of the next winding unit is entered with a span of k = 6 to start the winding of the next winding unit. This completes the winding of one winding unit.

[0084] In this embodiment, the winding unit pattern is 1-2-3-4-5-5-4-3-2-1 layers.

[0085] Each winding unit includes a same-layer crossover located in the first layer, a same-layer crossover located in the fifth layer, and multiple adjacent-layer crossovers, wherein the same-layer crossover located in the first layer and the same-layer crossover located in the fifth layer are located at different end sides of the stator core 11.

[0086] (2) When an even number of windings are wound in the stator slot 12, take 6 layers as an example.

[0087] like Figure 1 and Figure 7 As shown, the winding of the winding unit starts from the first layer of the initial stator slot 12 (corresponding to the first stator slot 12 mentioned above, and the number of this initial stator slot is defined as 19), and enters the second layer of stator slot 12 numbered 25 (19+6) (corresponding to the second stator slot 12 mentioned above) with a span k = 6. It continues to wind layer by layer between stator slot 12 numbered 19 and stator slot 12 numbered 25 with a span k = 6. When the winding reaches the 6th layer of stator slot 12 numbered 25, it enters the 31st layer with a span k = 6. The winding begins with the 6th layer of stator slot 12 (19+6+6), then with a span k=6, it enters the 5th layer of stator slot 12 (25). The winding continues with a span k=6, decreasing layer by layer between stator slot 12 (31) and stator slot 12 (25). After winding to the 1st layer of stator slot 12 (25), the winding begins with a span k=6, entering the 1st layer of the initial stator slot 12 (i.e., stator slot 12 (31)) of the next winding unit. This completes the winding of one winding unit.

[0088] In this embodiment, the winding unit pattern is 1-2-3-4-5-6-6-5-4-3-2-1 layers.

[0089] Each winding unit includes a same-layer crossover in the first layer, a same-layer crossover in the sixth layer, and multiple adjacent-layer crossovers, wherein the same-layer crossover in the first layer and the same-layer crossover in the sixth layer are located on the same end side of the stator core 11.

[0090] In summary, compared with the prior art, the flat wire winding motor stator assembly of the present invention effectively solves the problem of current balance in multiple branches through flexible staggered cross-wire connections between branches. It also features fewer wire types and simpler end connections, simplifying the manufacturing process and improving motor reliability. Furthermore, the flat wire winding motor stator assembly provided by the present invention can be applied to any odd-numbered and even-numbered layer winding structure with three or more layers, allowing for more flexible design of the number of winding layers and connections to match motor performance. The number of layers can be flexibly selected according to requirements. Therefore, the present invention effectively overcomes the various shortcomings of the prior art and has high industrial application value.

[0091] 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 stator assembly for a flat wire winding motor, characterized in that, include: Stator core and multi-phase flat wire windings; among which, The stator core has multiple stator slots; a stator tooth is formed between each pair of adjacent stator slots, and n layers of flat copper wire are wound in each stator slot; where n is any integer greater than or equal to 3; The flat wire winding is wound in the stator slot, and each phase of the flat wire winding includes at least two parallel branches; Each of the parallel branches includes at least one winding unit; In each phase of the flat wire winding, there is at least one winding unit for staggered winding between each parallel branch, so that the relative relationship of the stator slots where each parallel branch is located in each phase of the flat wire winding is interactive, so as to realize that the staggered winding forms a cross-wire form in which a large coil wraps a small coil at the end of the stator core. During the normal winding process of the winding unit, when n is an odd number, in one of the winding units, starting from the first layer of the first stator slot, a flat copper wire lead enters the second layer of the second stator slot from the first direction with a span k, and is wound layer by layer between the first stator slot and the second stator slot. After winding to the nth layer of the first stator slot, it enters the nth layer of the second stator slot with a span of k; Then, with a span k, it enters the (n-1)th layer of the third stator slot from the first direction, and winds layer by layer between the second and third stator slots until it winds to the first layer of the second stator slot, thus completing the winding of one winding unit. After winding to the first layer of the second stator slot, the next winding unit is started from the first layer of the first stator slot of the next winding unit with a span k from the first direction; the first stator slot of the next winding unit is the third stator slot of the previous winding unit; in the same parallel branch, the span k may be the same or different. During the normal winding process of the winding unit, when n is an even number, in one of the winding units, starting from the first layer of the first stator slot, a flat copper wire lead enters the second layer of the second stator slot from the second direction with a span k, and is wound layer by layer between the first stator slot and the second stator slot. After winding to the nth layer of the second stator slot, it enters the nth layer of the third stator slot from the second direction with a span k; Then, the winding is gradually reduced layer by layer between the second and third stator slots until the first layer of the second stator slot is wound, thus completing the winding of one winding unit. After winding to the first layer of the second stator slot, the next winding unit is started from the first layer of the first stator slot of the next winding unit from the second direction with a span k; the first stator slot of the next winding unit is the third stator slot of the previous winding unit; in the same parallel branch, the span k may be the same or different.

2. The flat wire winding motor stator assembly according to claim 1, characterized in that, For a single-phase flat wire winding, when it includes two parallel branches, each of the parallel branches includes at least one coil with a span of k=y+1 or a coil with a span of k=y-1, and the spans included in the two parallel branches are different. For a single-phase flat wire winding, when the number of parallel branches is greater than two, each parallel branch includes at least one coil with a span of k=y+1 or a span of k=y-1, and the spans included in different parallel branches are not exactly the same.

3. The flat wire winding motor stator assembly according to claim 1, characterized in that, The slotted winding is located on any crossover line in the same layer or a crossover line in an adjacent layer.

4. The flat wire winding motor stator assembly according to claim 1, characterized in that, During the staggered winding process, the stator slot where the starting end of the coil of the preceding parallel branch is located is adjacent to the stator slot where the starting end of the coil of the following parallel branch is located, and the winding of the coil of the preceding parallel branch is ahead of the winding of the coil of the following parallel branch.

5. The flat wire winding motor stator assembly according to claim 4, characterized in that, During the staggered winding process, the span k of any cross-line of the preceding parallel branch is adjusted so that the preceding parallel branch enters the stator slot corresponding to the following parallel branch and is wound layer by layer. Simultaneously, the span k of the subsequent parallel branch to the current corresponding cross line is adjusted so that the subsequent parallel branch enters the stator slot where the previous parallel branch was located before the span was adjusted, and is wound layer by layer.

6. The flat wire winding motor stator assembly according to any one of claims 1 to 5, characterized in that, The span k is at least one of the following: k = y + 1, k = y, k = y - 1; where y is calculated using the following formula: y = z / 2p; Where z represents the total number of stator slots and p represents the number of pole pairs of the motor.

7. The flat wire winding motor stator assembly according to claim 6, characterized in that, Under the same phase, before the span k of different parallel branches changes, the number of winding turns completed by different parallel branches is the same.

8. The flat wire winding motor stator assembly according to claim 1, characterized in that, Each winding unit includes a same-layer crossover line located in the first layer, a same-layer crossover line located in the nth layer, and at least one adjacent-layer crossover line. When n is odd, the same-layer crossover line located in the first layer and the same-layer crossover line located in the nth layer are located at different end sides of the stator core. When n is even, the same-layer crossover line located in the first layer and the same-layer crossover line located in the nth layer are located at the same end side of the stator core.

9. The flat wire winding motor stator assembly according to claim 1, characterized in that, The ends of the flat wire winding are connected in any of the following ways: U-shaped wire, welding, busbar; the target connection includes at least any of the following: cross-line connection of each branch, star point connection, lead wire connection.

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