Flat wire motor stator and winding structure

Abstract

The present application relates to the technical field of generator, in particular to a kind of flat wire motor stator and winding structure.The present application provides a kind of flat wire motor stator.The stator core is stacked using a certain number of silicon steel sheets, which can be riveted, welded or bonded in various ways, and 48 rectangular slots of the same size are opened on the stator core in a circumferential array. Considering insulation, a certain thickness of slot insulation paper is inserted into the rectangular slot. Insert 2n (n is a natural number) conductors per slot into the 48 rectangular slots. In order to realize the electrical connection between the conductors in the 48 rectangular slots, hairpin or welding and other methods are needed. The existing use of profiled wire to realize the bridging between the electrical will inevitably increase the welding difficulty and multiple welding, reduce the production efficiency. The present application uses end copper plate short circuit to replace the profiled wire bridge, simplifies the hairpin type, and increases the reliability of the connection.

Description

Technical Field

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

[0002] As one of the core three-electric systems in new energy vehicles, the electric motor accounts for about 10% of the total vehicle value. It is predicted that automobile production and sales will reach approximately 32 million units by 2025, 38 million units by 2030, and 40 million units by 2035. The plan is for new energy vehicles to account for 20% (6.4 million units) by 2025 and 50% (20 million units) by 2035. The remaining half will be hybrid vehicles. This means that traditional gasoline-powered vehicles will cease production and sales by 2035, and every vehicle will have at least one drive motor. Therefore, it is clear that the electric motor market for new energy vehicles will experience tremendous growth.

[0003] As a core component of new energy vehicles, the electric drive system's future trends include lightweighting, high efficiency, miniaturization, and low cost. Integration of the electric drive system and the use of flat wire in the motor are the main technological routes to achieve lightweighting and miniaturization. Flat wire winding motors utilize flat copper wire with a larger cross-sectional area in the stator windings. The windings are first shaped like hairpins, inserted into the stator slots, and then the ends of the hairpins are welded together. Compared to traditional round wire motors, they offer advantages such as high power density, high energy conversion efficiency, good NVH performance (low electromagnetic noise, quieter vehicle), and excellent heat dissipation, significantly reducing vehicle weight and energy consumption while improving overall performance and driving experience.

[0004] The windings of existing flat wire motors are mostly introduced from the inside of the stator slot and exited from the outside, introduced from the outside and exited from the inside, or introduced from the inside and exited from the inner layer. It is rare for them to be introduced from the outside and exited from the outside. The current commutation of a certain phase branch of the existing flat wire stator winding is mostly done by using non-shaped wires, and the non-shaped wires are mostly installed at the end of the stator winding.

[0005] The existing method of using irregularly shaped wires to achieve electrical bridging will inevitably increase the difficulty of welding and require multiple welding operations, thus reducing production efficiency. Summary of the Invention

[0006] To address the above problems, the present invention provides a flat wire motor stator and winding structure.

[0007] A flat wire motor stator, comprising:

[0008] The stator core 1 of the flat wire motor is made of multiple silicon steel sheets stacked together. The stator core 1 includes a stator yoke, a stator tooth section and a stator tooth head.

[0009] The stator slots are formed by the stator yoke, the stator teeth and the stator teeth head, and the stator slots are filled with insulating paper 2.

[0010] Where n is an integer multiple of 6, n≥12, and n is a positive integer;

[0011] The stator core also includes 2k core slots, where k ≥ 2 and k is a positive integer;

[0012] A straight conductor segment is provided in the stator slot of the stator core 1; the straight conductor segment at one end of the stator core 1 is connected by a U-shaped hairpin to form a hairpin end 3, and the straight conductor segment at the other end is formed by a twisted and outward welding method to form a welded end 4.

[0013] Furthermore, the outermost layer of the welding end 4 is connected to a flat wire motor three-phase lead wire 6.

[0014] Furthermore, there are three three-phase lead wires 6, which are led out directly from the side of the welding end 4 by twisting and bending.

[0015] Furthermore, the outermost layer of the stator slot of the stator core 1 is provided with a three-phase neutral connection point for the motor;

[0016] By using neutral busbar 5, the tail wires of the two branches of each phase of the UVW three-phase lead-out line in parallel are connected together.

[0017] A stator winding structure for a flat wire motor, employing the aforementioned flat wire motor stator.

[0018] Each phase winding branch consists of at least two sub-branch windings, which are connected in parallel. Each sub-branch winding is formed by connecting the first sub-branch coil unit and the second sub-branch coil unit in series.

[0019] Furthermore, the first sub-branch coil unit includes a first sub-branch forward coil unit and a first sub-branch reverse coil unit. Both the first sub-branch forward coil unit and the first sub-branch reverse coil unit are composed of several long-pitch hairpin coils, several short-pitch hairpin coils, and at least one outer commutation copper busbar connected in series.

[0020] Furthermore, the first sub-branch forward coil unit is wound sequentially from the first layer to the 2kth layer. Between the iron core slots of the 1st and 2nd layers, short-pitch hairpin coils and long-pitch hairpin coils are alternately connected. Between the kth layer and the k+1th layer, short-pitch hairpin coils and long-pitch hairpin coils are alternately connected. Between the 2kth layer and the 2k-1th layer, short-pitch hairpin coils and long-pitch hairpin coils are alternately connected. Here, k≥2 and k is a positive integer.

[0021] The first sub-branch reverse coil unit is wound sequentially from the 2kth layer to the first layer. The first sub-branch reverse coil unit is alternately connected between the iron core slots of the 1st and 2nd layers by short-pitch hairpin coils and long-pitch hairpin coils, between the kth layer and the k+1th layer by short-pitch hairpin coils and long-pitch hairpin coils, and between the 2kth layer and the 2k-1th layer by short-pitch hairpin coils and long-pitch hairpin coils.

[0022] The first sub-branch forward coil unit and the first sub-branch reverse coil unit are connected in series through the outer commutation copper busbar.

[0023] Furthermore, the second sub-branch coil unit includes a second sub-branch forward coil unit and a second sub-branch reverse coil unit. The first sub-branch forward coil unit and the first sub-branch reverse coil unit are both composed of 2m long-pitch hairpin coils, several short-pitch hairpin coils, a commutation copper busbar and at least one lead-out hairpin coil connected in series, where m≥6 and m is a positive integer.

[0024] Furthermore, the second sub-branch forward coil unit is wound sequentially from the first layer to the 2kth layer. Between the iron core slots of the first and second layers, short-pitch hairpin coils and long-pitch hairpin coils are alternately connected. Between the kth layer and the k+1th layer, short-pitch hairpin coils and long-pitch hairpin coils are alternately connected. Between the 2kth layer and the 2k-1th layer, short-pitch hairpin coils and long-pitch hairpin coils are alternately connected. Here, k≥2 and k is a positive integer.

[0025] The second sub-branch reverse coil unit is wound sequentially from the 2kth layer to the first layer. The first sub-branch reverse coil unit is alternately connected between the iron core slots of the 1st and 2nd layers by short-pitch hairpin coils and long-pitch hairpin coils, between the kth layer and the k+1th layer by short-pitch hairpin coils and long-pitch hairpin coils, and between the 2kth layer and the 2k-1th layer by short-pitch hairpin coils and long-pitch hairpin coils.

[0026] The second sub-branch forward coil unit and the second sub-branch reverse coil unit are connected in series through the outer commutation copper busbar.

[0027] Furthermore, the first sub-branch coil unit and the second sub-branch coil unit are connected by an inner commutation copper busbar. The first sub-branch coil unit contains 2m short-pitch hairpin coils and long-pitch hairpin coils, and the second sub-branch coil unit contains 2m-1 short-pitch hairpin coils, long-pitch hairpin coils, and 1 lead wire hairpin coil, where m ≥ 6 and m is a positive integer.

[0028] Furthermore, the short-pitch hairpin coil has a span of 5, and the long-pitch hairpin coil has a span of 7.

[0029] A flat wire motor includes: the flat wire motor adopts the above-mentioned motor stator or stator winding structure.

[0030] This invention has at least the following beneficial effects:

[0031] This invention uses an end copper plate short circuit to replace the bridging of irregular wires, which simplifies the types of hair clips and increases the reliability of the connection.

[0032] Other features and advantages of the invention will be set forth in the following description, and will be apparent in part from the description, or may be learned by practicing the invention. The objects and other advantages of the invention may be realized and obtained by means of the structures pointed out in the description and the drawings. Attached Figure Description

[0033] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0034] Figure 1 This is a schematic diagram of the structure of the flat wire motor stator of the present invention;

[0035] Figure 2 This is a schematic diagram of the stator winding structure of a flat wire motor according to an embodiment of the present invention;

[0036] Figure 3 This is an unfolded diagram of the three-phase winding of the present invention;

[0037] Figure 4 An unfolded diagram of the single-phase winding of the present invention is shown.

[0038] Figure 5 This is a magnified view of a portion of the welded end;

[0039] Figure 6 This is a diagram illustrating the issuance of a card across 5 slots;

[0040] Figure 7 This is a diagram illustrating the card issuance across 7 slots;

[0041] Figure 8 Schematic diagram of neutral point lead wire release and three-phase lead wire release;

[0042] Figure 9 This is an installation diagram of the U-shaped hairpin and stator core of the present invention;

[0043] Figure 10 This is an installation diagram of the three-phase leads, neutral busbar, and stator core of the present invention;

[0044] Figure 11This is an installation diagram of the three-phase copper plate, lead wire clips, and stator core of the present invention;

[0045] Figure 12 Schematic diagram of injection-molded copper plate with U, V, and W phases;

[0046] Figure 13 Schematic diagram of the neutral point copper busbar;

[0047] Figure 14 A single-phase winding structure diagram of the stator winding structure of a flat wire motor;

[0048] In the diagram: 1: Stator core, 2: Slot insulation paper, 3: Hairpin end, 4: Welding end, 5: Neutral busbar, 6: Three-phase lead wire. Detailed Implementation

[0049] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0050] The windings of existing flat wire motors are mostly introduced from the inside of the stator slot and exited from the outside, introduced from the outside and exited from the inside, or introduced from the inside and exited from the inner layer. It is rare for them to be introduced from the outside and exited from the outside. The current commutation of a certain phase branch of the existing flat wire stator winding is mostly done by using non-shaped wires, and the non-shaped wires are mostly installed at the end of the stator winding.

[0051] The existing method of using irregularly shaped wires to achieve electrical bridging will inevitably increase the difficulty of welding and require multiple welding operations, thus reducing production efficiency.

[0052] Therefore, the present invention proposes a flat wire motor stator and winding structure, including a flat wire motor stator, a flat wire motor stator winding structure, and a flat wire motor.

[0053] This invention uses an end copper plate short circuit to replace the bridging of irregular wires, which simplifies the types of hair clips and increases the reliability of the connection.

[0054] Firstly, such as Figure 1 As shown, the present invention provides a flat wire motor stator, comprising:

[0055] The stator core 1 of the flat wire motor is made of multiple silicon steel sheets stacked together. The stator core 1 includes a stator yoke, a stator tooth section and a stator tooth head.

[0056] The stator slots are formed by the stator yoke, the stator teeth, and the stator tooth heads;

[0057] Where n is an integer multiple of 6, n≥12, and n is a positive integer.

[0058] The stator core also includes 2k core slots, where k ≥ 2 and k is a positive integer.

[0059] Preferably, slot insulating paper 2 is provided inside the stator slot.

[0060] In one embodiment, the stator of the flat wire motor has a straight conductor segment disposed in the stator slot of the stator core 1;

[0061] The straight conductor at one end of the stator core 1 is connected by a U-shaped hairpin to form a hairpin end 3, and the straight conductor at the other end is welded to form a welded end 4 by twisting and expanding the welding.

[0062] In one embodiment, the outermost layer of the welding end 4 is connected to a flat wire motor three-phase lead wire 6.

[0063] Preferably, there are three three-phase lead wires 6, which are led out directly from the side of the welding end 4 by twisting and bending.

[0064] Preferably, the outermost layer of the stator slot of the stator core 1 is provided with a three-phase neutral connection point of the motor;

[0065] By using neutral busbar 5, the tail wires of the two branches of each phase of the UVW three-phase lead-out line in parallel are connected together.

[0066] Secondly, such as Figure 2 As shown, the present invention provides a flat wire motor stator winding structure, including: a flat wire motor stator as described above;

[0067] Each phase winding branch consists of at least two sub-branch windings, which are connected in parallel. Each sub-branch winding is formed by connecting the first sub-branch coil unit and the second sub-branch coil unit in series.

[0068] In practical implementation, the unfolded diagram of the three-phase winding is as follows: Figure 3 As shown, the unfolded diagram of a single-phase winding is as follows: Figure 4 As shown; a magnified view of the welded end is shown below. Figure 5 As shown;

[0069] U-shaped hair clips include, for example Figure 6 The cross-slot hair clip shown is as follows: Figure 7 The card shown spans 7 slots, and as shown Figure 8 The neutral point lead wire and the three-phase lead wire shown are both U-shaped symmetrical structures. The neutral point lead wire and the three-phase lead wire are asymmetrical U-shaped structures with one side longer than the other, and the longer side is the lead-out side.

[0070] Installation of hair clips spanning 5 slots and 7 slots, as follows: Figure 9 As shown in the diagram, the one with a slightly wider outer side is a 7-slot hairpin, and the one with a slightly narrower inner side is a 5-slot hairpin. Figure 10 This is an installation diagram of the three-phase leads and the neutral busbar in the stator core. Figure 11 This is an installation diagram for connecting the lead wires to the three-phase copper plates.

[0071] In one embodiment, the first sub-branch coil unit includes a first sub-branch forward coil unit and a first sub-branch reverse coil unit. Both the first sub-branch forward coil unit and the first sub-branch reverse coil unit are composed of several long-pitch hairpin coils, several short-pitch hairpin coils, and at least one outer commutation copper busbar connected in series.

[0072] Preferably, the first sub-branch forward coil unit is wound sequentially from the first layer to the 2kth layer. Between the iron core slots of the 1st and 2nd layers, short-pitch hairpin coils and long-pitch hairpin coils are alternately connected. Between the kth and k+1th layers, short-pitch hairpin coils and long-pitch hairpin coils are alternately connected. Between the 2kth and 2k-1th layers, short-pitch hairpin coils and long-pitch hairpin coils are alternately connected. Where k≥2 and k is a positive integer.

[0073] The first sub-branch reverse coil unit is wound sequentially from the 2kth layer to the first layer. The first sub-branch reverse coil unit is alternately connected between the iron core slots of the 1st and 2nd layers by short-pitch hairpin coils and long-pitch hairpin coils, between the kth layer and the k+1th layer by short-pitch hairpin coils and long-pitch hairpin coils, and between the 2kth layer and the 2k-1th layer by short-pitch hairpin coils and long-pitch hairpin coils.

[0074] The first sub-branch forward coil unit and the first sub-branch reverse coil unit are connected in series through the outer commutation copper busbar.

[0075] In one embodiment, the second sub-branch coil unit includes a second sub-branch forward coil unit and a second sub-branch reverse coil unit. The first sub-branch forward coil unit and the first sub-branch reverse coil unit are both composed of 2m long-pitch hairpin coils, several short-pitch hairpin coils, a commutation copper busbar and at least one lead-out hairpin coil connected in series, where m≥6 and m is a positive integer.

[0076] Preferably, the second sub-branch forward coil unit is wound sequentially from the first layer to the 2kth layer. Between the iron core slots of the first and second layers, short-pitch hairpin coils and long-pitch hairpin coils are alternately connected. Between the kth layer and the k+1th layer, short-pitch hairpin coils and long-pitch hairpin coils are alternately connected. Between the 2kth layer and the 2k-1th layer, short-pitch hairpin coils and long-pitch hairpin coils are alternately connected. Where k≥2 and k is a positive integer.

[0077] The second sub-branch reverse coil unit is wound sequentially from the 2kth layer to the first layer. The first sub-branch reverse coil unit is alternately connected between the iron core slots of the 1st and 2nd layers by short-pitch hairpin coils and long-pitch hairpin coils, between the kth layer and the k+1th layer by short-pitch hairpin coils and long-pitch hairpin coils, and between the 2kth layer and the 2k-1th layer by short-pitch hairpin coils and long-pitch hairpin coils.

[0078] The second sub-branch forward coil unit and the second sub-branch reverse coil unit are connected in series through the outer commutation copper busbar.

[0079] In one embodiment, the first sub-branch coil unit and the second sub-branch coil unit are connected by an inner commutation copper busbar. The first sub-branch coil unit includes 2m short-pitch hairpin coils and long-pitch hairpin coils, and the second sub-branch coil unit includes 2m-1 short-pitch hairpin coils, long-pitch hairpin coils, and 1 lead wire hairpin coil, where m ≥ 6 and m is a positive integer.

[0080] Preferably, the short-pitch hairpin coil has a span of 5, and the short-pitch hairpin uses a 5-slot hairpin, such as... Figure 6 As shown; the long-distance hairpin coil has a span of 7, and the long-distance hairpin uses a 7-slot hairpin, as shown. Figure 7 As shown; both the 7-slot and 5-slot hair clips have a U-shaped symmetrical structure, with the 7-slot hair clip having a wider distance between the two U-shaped prongs compared to the 5-slot hair clip.

[0081] Thirdly, the present invention provides a flat wire motor, comprising: the flat wire motor adopting the above-mentioned motor stator or stator winding structure.

[0082] To enable those skilled in the art to better understand the present invention, the principles of the present invention are explained below in conjunction with the accompanying drawings:

[0083] The windings of existing flat wire motors are mostly introduced from the inside of the stator slot and exited from the outside, introduced from the outside and exited from the inside, or introduced from the inside and exited from the inner layer. It is rare for them to be introduced from the outside and exited from the outside. The current commutation of a certain phase branch of the existing flat wire stator winding is mostly done by using non-shaped wires, and the non-shaped wires are mostly installed at the end of the stator winding.

[0084] Existing methods of using irregularly shaped wires to achieve electrical bridging inevitably increase welding difficulty and require multiple welding operations, reducing production efficiency. This invention uses end-plate shorting to replace the irregularly shaped wire bridging, simplifying the types of hair clips and increasing connection reliability.

[0085] This invention provides a flat-wire motor stator. The stator core is made of a certain number of stacked silicon steel sheets, which can be formed by riveting, welding, or bonding. Forty-eight rectangular slots of the same size are arranged in a circumferential array on the stator core. For insulation, slot insulating paper of a certain thickness is inserted into the rectangular slots. Flat copper conductors are inserted into the 48 rectangular slots, with 2n (n being a natural number) conductors inserted into each slot. To achieve electrical connection between the conductors in the 48 rectangular slots, methods such as hairpins or welding are required. The 48-slot stator winding has one parallel branch. The conductors connected to each branch in the slot can have various spans, such as equal spans of 6, spans of 5 or 7 in a cycle, etc., distributed along the circumference of the stator according to the aforementioned span pattern. Assuming that 2n conductors can be inserted into each slot, each slot has 2n layers of conductors, with the layer closest to the bottom of the slot being the outer layer and the layer closest to the slot opening being the inner layer. The conductors in the slots corresponding to each branch are installed in a cyclical manner in the rectangular slots according to the span pattern, until one circumference is completed and the system switches to the next pair of adjacent layers for cyclical installation. Specifically, the input and output lines of the three-phase stator windings of the flat-wire motor are arranged in the outermost layer of the rectangular slots. Also specifically, in the commutation connection of each branch, several reverse-rotating hairpin coils are used for electrical bridging; these reverse-rotating hairpin coils are located in the innermost and outermost layers of the rectangular slots.

[0086] like Figure 1 As shown, the stator core 1 of a flat wire motor is made of multiple stacked silicon steel sheets, comprising a stator yoke, a stator tooth section, and a stator tooth head. These three parts of the stator core form 48 stator slots. For insulation purposes, slot insulation paper 2 of a certain length and thickness is inserted into each slot.

[0087] Figure 2 The diagram shows the winding coil of the entire flat wire motor, which includes a straight conductor segment inserted into the stator core slot. The straight conductor segment at one end of the core is connected by a U-shaped hairpin, and the straight conductor segment at the other end can be formed into welded end 4 by twisting and expanding the welding.

[0088] The three-phase lead 6 of the flat wire motor is located on the outermost layer of the welding end, such as... Figure 2 As shown, the three-phase leads have three leads located at the outermost layer of the stator core slots. The single-phase winding unfolded diagram is shown below, using simple methods such as twisting and bending. Figure 4 As shown, the three-phase connection terminals of the flat wire motor can be directly led out from the side of the welded end, thereby effectively reducing the axial length of the entire flat wire motor winding.

[0089] This invention uses end-plate shorting to replace the bridging of irregularly shaped wires, simplifying the types of hair clips and increasing connection reliability. U, V, and W phase injection-molded copper plates are shown below. Figure 12 As shown; the neutral point copper busbar is as follows Figure 13 As shown.

[0090] from Figure 4 In the single-phase winding diagram, it can be seen that the current flows in from the innermost lead wire of slot 14, then sequentially from layer 1 → layer 2 → layer 1 → layer 2 → layer 1 → layer 2 (a total of 4 lead wires), then across layers to layer 3 → layer 4 → layer 3 → layer 4 → layer 3 → layer 4 → layer 3 → layer 4 (a total of 4 lead wires), then across layers to layer 5 → layer 6 → layer 5 → layer 1 Layer 6 → Layer 5 → Layer 6 (4 hairpins in total), then flows through the outermost hairpin of slot 20 to the three-phase copper busbar, then through the three-phase copper busbar to the outermost hairpin of slot 27, continuing sequentially from Layer 6 → Layer 5 → Layer 6 → Layer 5 → Layer 6 → Layer 5 → Layer 6 → Layer 5 (4 hairpins in total), then flows across layers to → Layer 4 → Layer 3 → Layer 4 → Layer 3 → Layer 4 → Layer 3 → Layer 4 → Layer 3 → Layer 4 → Layer 3 → Layer 4 → Layer 3 → Layer 4 → Layer 5 Layer 4 → Layer 3 (4 hairpins in total), then flow across layers to → Layer 2 → Layer 1 → Layer 2 → Layer 1 → Layer 2 → Layer 1 (4 hairpins in total), then flow through the innermost hairpin of slot 21 to the three-phase copper busbar, then turn to the innermost hairpin of slot 15 via the three-phase copper busbar, continuing from Layer 1 → Layer 2 → Layer 1 → Layer 2 → Layer 1 → Layer 2 (4 hairpins in total), then flow across layers to → Layer 3 Layer 1 → Layer 4 → Layer 3 → Layer 4 → Layer 3 → Layer 4 → Layer 3 → Layer 4 (4 hairpins in total), then flow across layers to → Layer 5 → Layer 6 → Layer 5 → Layer 6 → Layer 5 → Layer 6 (4 hairpins in total), then flow through the outermost hairpin of slot 21 to the three-phase copper busbar, then turn to the outermost hairpin of slot 26 via the three-phase copper busbar, continuing sequentially from layer 6 → layer 5 → layer 6 → layer 4. Figure 4In the single-phase winding diagram, it can be seen that the current flows in from the innermost lead wire of slot 14, then sequentially from layer 1 → layer 2 → layer 1 → layer 2 → layer 1 → layer 2 (a total of 4 leads), then across layers to layer 3 → layer 4 → layer 3 → layer 4 → layer 3 → layer 4 → layer 3 → layer 4 (a total of 4 leads), then across layers to layer 5 → layer 6 → layer 5 → layer 6 → layer 5 → layer 6 (a total of 4 leads), and then through the outermost lead wire of slot 20 to the three-phase copper busbar. The copper busbar turns to the outermost hairpin of slot 27, continuing sequentially from layer 6 → layer 5 → layer 6 → layer 5 → layer 6 → layer 5 → layer 6 → layer 5 (a total of 4 hairpins), then flows across layers to layer 4 → layer 3 → layer 4 → layer 3 → layer 4 → layer 3 → layer 4 → layer 3 (a total of 4 hairpins), then flows across layers to layer 2 → layer 1 → layer 2 → layer 1 → layer 2 → layer 1 (a total of 4 hairpins), then flows through the innermost hairpin of slot 21 to the three-phase copper busbar, and then turns to slot 15. The innermost hairpin of the slot continues from layer 1 → layer 2 → layer 1 → layer 2 → layer 1 → layer 2 (a total of 4 hairpins), then flows across layers to layer 3 → layer 4 → layer 3 → layer 4 → layer 3 → layer 4 → layer 3 → layer 4 (a total of 4 hairpins), then flows across layers to layer 5 → layer 6 → layer 5 → layer 6 → layer 5 → layer 6 (a total of 4 hairpins), then flows through the outermost hairpin of slot 21 to the three-phase copper busbar, then turns to the outermost hairpin of slot 26, continuing sequentially from layer 6 → layer 5 Layer 1 → Layer 6 → Layer 5 → Layer 6 → Layer 5 → Layer 6 → Layer 5 (4 hairpins in total) Layer 5 → Layer 6 → Layer 5 → Layer 6 → Layer 5 (4 hairpins in total), then flow across layers to → Layer 4 → Layer 3 → Layer 4 → Layer 3 → Layer 4 → Layer 3 → Layer 4 → Layer 3 (4 hairpins in total), then flow across layers to → Layer 2 → Layer 1 → Layer 2 → Layer 1 → Layer 2 → Layer 1 (4 hairpins in total), finally the wire is led out from the innermost layer of slot 20 and connected to the neutral point copper busbar, thus completing the single-phase current flow.

[0091] The single-phase winding structure diagram corresponding to the single-phase winding development diagram is as follows: Figure 14 As shown.

[0092] In this invention, the three-phase neutral connection point of the motor is also located on the outermost layer of the stator core slot. Electrical short-circuiting of the three coil branches can be achieved through a simple neutral busbar 5. This design does not require any space occupied in the axial direction at the ends.

[0093] In the three-phase UVW circuit, the current flow in each phase branch flows in through the three-phase leads, passes through the outermost ordinary hairpins sequentially from layer 1 → layer 2 → layer 1 → layer 2 → layer 1 → layer 2 (a total of 4 hairpins), then crosses layers to layer 3 → layer 4 → layer 3 → layer 4 → layer 3 → layer 4 → layer 4 → layer 3 → layer 4 (a total of 4 hairpins), then crosses layers to layer 5 → layer 6 → layer 5 → layer 6 → layer 5 → layer 6 (a total of 4 hairpins). (One hairpin), the first time it turns through the outermost end copper plate, 6th layer → 5th layer → 6th layer → 5th layer → 6th layer → 5th layer → 6th layer → 5th layer (a total of 4 hairpins), then flows across layers to → 4th layer → 3rd layer → 4th layer → 3rd layer → 4th layer → 3rd layer → 4th layer → 3rd layer (a total of 4 hairpins), then flows across layers to → 2nd layer → 1st layer → 2nd layer → 1st layer → 2nd layer → 1st layer (a total of 4 hairpins), the first time The flow is redirected via the innermost end copper plate: Layer 1 → Layer 2 → Layer 1 → Layer 2 → Layer 1 → Layer 2 (4 hairpins in total), then flows across layers to Layer 3 → Layer 4 → Layer 3 → Layer 4 → Layer 3 → Layer 4 → Layer 3 → Layer 4 (4 hairpins in total), then flows across layers to Layer 5 → Layer 6 → Layer 5 → Layer 6 → Layer 5 → Layer 6 (4 hairpins in total), and redirects again via the outermost end copper plate. Layer 6 → Layer 5 → Layer 6 → Layer 5 → Layer 6 → Layer 5 → Layer 6 → Layer 5 (4 hairpins in total), then flow across layers to → Layer 4 → Layer 3 → Layer 4 → Layer 3 → Layer 4 → Layer 3 → Layer 4 → Layer 3 (4 hairpins in total), then flow across layers to → Layer 2 → Layer 1 → Layer 2 → Layer 1 → Layer 2 → Layer 1 (3 hairpins in total), finally connected through the lead wire hairpins, and the final connection is made through the neutral point copper busbar.

[0094] Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A flat motor stator winding structure, characterized in that, each phase winding branch is composed of at least two sub-branch windings, each sub-branch winding is connected in parallel, and each sub-branch winding is formed by a first sub-branch coil unit and a second sub-branch coil unit in series; the first sub-branch coil unit comprises a first sub-branch forward coil unit and a first sub-branch reverse coil unit, and each of the first sub-branch forward coil unit and the first sub-branch reverse coil unit is formed by a plurality of long-distance hairpin coils, a plurality of short-distance hairpin coils, and at least one outer layer commutation copper bar in series; the first sub-branch forward coil unit is wound from the first layer to the 2kth layer, the short-distance hairpin coils and the long-distance hairpin coils are alternately connected between the first layer and the second layer, the short-distance hairpin coils and the long-distance hairpin coils are alternately connected between the kth layer and the k+1th layer, and the short-distance hairpin coils and the long-distance hairpin coils are alternately connected between the 2kth layer and the 2k-1th layer, wherein k≥2 and k is a positive integer; the first sub-branch reverse coil unit is wound from the 2kth layer to the first layer, the short-distance hairpin coils and the long-distance hairpin coils are alternately connected between the first layer and the second layer, the short-distance hairpin coils and the long-distance hairpin coils are alternately connected between the kth layer and the k+1th layer, and the short-distance hairpin coils and the long-distance hairpin coils are alternately connected between the 2kth layer and the 2k-1th layer; the first sub-branch forward coil unit and the first sub-branch reverse coil unit are connected in series through the outer layer commutation copper bar; the first sub-branch coil unit and the second sub-branch coil unit are connected through the inner layer commutation copper bar, the first sub-branch coil unit comprises 2m short-distance hairpin coils and long-distance hairpin coils, the second sub-branch coil unit comprises 2m-1 short-distance hairpin coils and long-distance hairpin coils, and 1 lead-out hairpin coil, and m≥6 and m is a positive integer; the short-distance hairpin coil has a span of 5, and the long-distance hairpin coil has a span of 7.

2. A stator winding structure for a flat wire motor according to claim 1, characterized in that the second sub-branch coil unit comprises a second sub-branch forward coil unit and a second sub-branch reverse coil unit, and each of the first sub-branch forward coil unit and the first sub-branch reverse coil unit is formed by 2m long-distance hairpin coils, a plurality of short-distance hairpin coils, a commutation copper bar, and at least one lead-out hairpin coil in series, wherein m≥6 and m is a positive integer.

3. A stator winding structure for a flat wire motor according to claim 2, characterized in that the second sub-branch forward coil unit is wound from the first layer to the 2kth layer, the short-distance hairpin coils and the long-distance hairpin coils are alternately connected between the first layer and the second layer, the short-distance hairpin coils and the long-distance hairpin coils are alternately connected between the kth layer and the k+1th layer, and the short-distance hairpin coils and the long-distance hairpin coils are alternately connected between the 2kth layer and the 2k-1th layer, wherein k≥2 and k is a positive integer; The second sub-branch reverse coil unit is wound from the 2kth layer to the first layer in sequence, the first sub-branch reverse coil unit is connected by the short-distance hairpin coil and the long-distance hairpin coil alternately between the first layer and the second layer core slot, the short-distance hairpin coil and the long-distance hairpin coil are connected alternately between the kth layer and the k+1th layer, and the short-distance hairpin coil and the long-distance hairpin coil are connected alternately between the 2kth layer and the 2k-1th layer; The second sub-branch forward coil unit and the second sub-branch reverse coil unit are connected in series through the outer layer commutating copper bar.

4. A flat wire motor stator characterized by, A flat wire motor stator winding structure comprising the flat wire motor stator winding structure of any one of claims 1-3. A flat wire motor stator core (1) composed of a plurality of silicon steel sheets, the stator core (1) comprising a stator yoke portion, a stator tooth portion, and a stator tooth head portion; n stator slots are formed by the stator yoke portion, the stator tooth portion, and the stator tooth head portion, and the stator slots are provided with insulating paper (2); n is an integer multiple of 6, n≥12, and n is a positive integer; The stator core further comprises 2k layers of core slots, k≥2, and k is a positive integer; The stator core (1) is provided with straight segment conductors in the stator slots; the straight segment conductors at one end of the stator core (1) are connected to form a hairpin end (3) by U-shaped hairpin connection, and the straight segment conductors at the other end are connected to form a welding end (4) by a twisted head outward expansion welding method.

5. The flat wire motor stator of claim 4, wherein The welding end (4) is connected with three-phase lead-out wires (6) of the flat wire motor.

6. The flat wire motor stator of claim 5, wherein The three-phase lead-out wires (6) are three in total, and the three-phase lead-out wires (6) of the flat wire motor are directly led out from the side of the welding end (4) by a twisted head bending method.

7. The flat wire motor stator of claim 4 or 5, wherein The stator core (1) is provided with three-phase neutral connection points at the outermost layer of the stator slots; Through the neutral bar (5), the tail wires of the two branches of each phase of the UVW three-phase lead-out wires are connected together.

8. A flat wire motor characterized by The flat wire motor adopts the motor stator or the stator winding structure of any one of claims 1-7. ​

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