A winding structure of a stator of a flat wire motor

Abstract

The application provides a winding structure of a flat wire motor stator, and belongs to the technical field of flat wire motors, and comprises a stator core and a three-phase winding; the inner surface of the stator core is provided with a plurality of stator slots, and the three-phase winding is arranged in the stator slots; the three-phase winding is provided with 2n layers, n>=3 and n is a natural number; the first layer and the 2nth layer of the three-phase winding are provided with a plurality of anti-twist hairpins with a span of 9, or a span of 11 and a span of 8 arranged alternately. The single-phase winding of the application adopts a three-way parallel mode, and uses an outer layer and a secondary outer layer outlet mode in arrangement and installation, and the leading end and the neutral end are very concentrated, which is beneficial to the installation and wiring of the flat wire motor with 54 stator slots and 6 layers; the anti-twist hairpin of the first layer and the last layer of the application is installed with a span of 9, the U-shaped hairpin of the middle layer is installed in a mode of combination of two spans of 8 and a span of 11, so that the flat wire motor with 54 slots and 6 layers can replace the bridging of special-shaped wires, and the outlet end structure is simplified.

Description

Technical Field

[0001] This invention belongs to the field of flat wire motor technology, and specifically relates to a winding structure of a flat wire motor stator. Background Technology

[0002] As a key component of electric vehicles, the performance of automotive drive motors is crucial to the overall vehicle performance. Currently, motors are developing towards higher speeds, lighter weight, and higher efficiency. Compared to conventional loose-wire windings, flat-wire windings offer higher slot fill factor, higher power density, and better heat dissipation, and are therefore increasingly being used in automotive drive motors.

[0003] The current commutation of a certain phase branch of the existing flat wire stator winding with 6 layers and 54 stator slots is mostly done using non-standard wires, and these non-standard wires are mostly installed at the ends of the stator winding; the three-phase leads and neutral point leads are relatively dispersed. Summary of the Invention

[0004] To address the above problems, this invention proposes a winding structure for a flat wire motor stator.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] A winding structure for a flat wire motor stator includes a stator core and three-phase windings;

[0007] The inner surface of the stator core is provided with a plurality of stator slots, and the three-phase windings are arranged in the stator slots;

[0008] The three-phase winding has 2n layers, where n ≥ 3 and n is a natural number;

[0009] The first and 2n layers of the three-phase winding are provided with several anti-twist hairpins with a span of 9, or with alternating spans of 11 and 8.

[0010] The second to the 2n-1th layers of the three-phase winding are provided with several U-shaped hairpins with spans of 8 and 11;

[0011] The three-phase winding is also provided with lead-out terminals and a neutral terminal;

[0012] The neutral terminal is located inside the lead-out terminal.

[0013] Preferably, the stator slots are provided with 54 slots.

[0014] Preferably, the reverse twisting hairpin includes a lead wire hairpin, a first reversing hairpin, and a second reversing hairpin for reversing connection;

[0015] One lead wire hairpin and several first commutation hairpins are uniformly installed in the first layer of the three-phase winding with a structure in which the spans 9, or the spans 11 and 8 are alternately arranged.

[0016] One end of the lead wire clip is used to form a lead end;

[0017] Several second commutation hairpins are installed on the 2n layer of the three-phase winding in a configuration with alternating spans of 9, 11, and 8.

[0018] Preferably, the lead wire clip, the first reversing clip, and the second reversing clip are all composed of a U-shaped conductor and a connecting end disposed in the opening of the U-shaped conductor and arranged in the same direction;

[0019] The lengths of the connecting ends of the lead wires are not equal;

[0020] The connection ends of the first reversing card and the second reversing card face opposite directions.

[0021] Preferably, the U-shaped hairpin includes a cross-layer hairpin and a neutral line hairpin;

[0022] Both the cross-layer card and the neutral line card are used for cross-layer connections;

[0023] One end of the neutral wire hairpin is located in the second layer and is used to form the neutral end.

[0024] Preferably, both the cross-layer hairpin and the neutral wire hairpin consist of a U-shaped conductor and a connecting end that is connected to the opening of the U-shaped conductor and is disposed opposite to it;

[0025] The connecting ends of the cross-layer card issuers are of equal length;

[0026] The connection lengths of the neutral wire hairpins are not equal.

[0027] Preferably, each single-phase winding in the three-phase winding is provided with three parallel branches.

[0028] Preferably, the sum of the number of lead wire clips and the number of the first reversing clips is equal to the number of the second reversing clips.

[0029] Preferably, the stator core is cylindrical and is formed by stacking several silicon steel sheets.

[0030] Preferably, insulating paper is provided inside the stator slot.

[0031] The beneficial effects of this invention are:

[0032] 1. This invention proposes a flat wire stator winding scheme. The single-phase winding adopts a three-way parallel connection. The outer layer and the second outer layer lead-out method are used in the layout and installation. The lead-out end and the neutral end are very concentrated, which is beneficial to the installation and wiring of the flat wire motor with 6 layers and 54 stator slots.

[0033] 2. The first and last layers of the reverse twist hairpins of the present invention are installed with a span of 9, and the U-shaped hairpins of the middle layer are installed by a combination of two spans of 8 and spans of 11, so that the 54-slot 6-layer flat wire motor can replace the bridging of irregular wires, simplify the structure of the wire end and increase the reliability of the connection.

[0034] 3. The first and last layers of the reverse twist hairpins of the present invention are installed with alternating spans of 8 and 11, which provides a new winding structure for the 6-layer 54-slot flat wire motor, allowing the lead-out end and neutral end to be arranged in a layout of spans of 8 and 11, which is compact, conducive to wire output, and reliable connection.

[0035] 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

[0036] 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.

[0037] Figure 1 A schematic diagram of the winding structure of a flat wire motor stator according to the present invention is shown;

[0038] Figure 2 A schematic diagram of the lead wire hairpin of the present invention is shown;

[0039] Figure 3 A schematic diagram of the first reversing card issuing structure of the present invention is shown;

[0040] Figure 4 A schematic diagram of the cross-layer hair clip of the present invention is shown;

[0041] Figure 5 A schematic diagram of the second reversing card issuing structure of the present invention is shown;

[0042] Figure 6 A schematic diagram of the neutral line hairpin structure of the present invention is shown;

[0043] Figure 7 A schematic diagram of the single-phase winding structure of the present invention is shown;

[0044] Figure 8 This diagram illustrates the installation of the first layer of the hairpin according to the present invention.

[0045] Figure 9 The diagram shows the installation schematics of the second and third layers of the card issuing device according to the present invention;

[0046] Figure 10 The diagram shows the installation schematics of the fourth and fifth layers of the card issuing device according to the present invention;

[0047] Figure 11 A schematic diagram of the sixth layer of the hairpin installation of the present invention is shown;

[0048] Figure 12 A single-phase winding development diagram of the present invention is shown.

[0049] In the diagram: 1. Stator core; 101. Stator slot; 2. Lead-out end; 3. Neutral end; 4. Welding end; 5. Carding end; 6. Lead-out carding; 7. First commutation carding; 8. Cross-layer carding; 9. Second commutation carding; 10. Neutral line carding. Detailed Implementation

[0050] 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.

[0051] A winding structure for a flat wire motor stator, such as Figure 1 As shown, it includes a stator core 1 and a three-phase winding; the inner surface of the stator core 1 is provided with a plurality of stator slots 101, and the three-phase winding is disposed in the stator slots 101; the three-phase winding is provided with 2n layers, where n≥3 and n is a natural number; the first layer and the 2nth layer of the three-phase winding are provided with a plurality of anti-twist hairpins with a span of 9 or an alternating span of 11 and 8; the second layer to the 2n-1th layer of the three-phase winding are provided with a plurality of U-shaped hairpins with a span of 8 and a span of 11; the three-phase winding is also provided with a lead-out end 2 and a neutral end 3; the neutral end 3 is located inside the lead-out end 2.

[0052] It should be noted that, in Figure 2In this design, there are 54 stator slots 101 arranged in a circular array on the stator core 1. For insulation purposes, insulating paper of a certain length and thickness is inserted into each stator slot 101. The stator core 1 is cylindrical and composed of several stacked silicon steel sheets. The stator core 1 is constructed using a certain number of silicon steel sheets, which can be joined by riveting, welding, or bonding. Flat copper conductors are inserted into the 54 stator slots 101, with 2n (n being a natural number) conductors per slot. To achieve electrical connections between the conductors in the 54 rectangular slots, methods such as hairpins or welding are used. Assuming 2n conductors can be inserted into each slot, each slot has 2n layers of conductors, with the layer closest to the bottom of the stator slot 101 being the outer layer and the layer closest to the opening being the inner layer. The conductors in the slot corresponding to each branch are installed in the stator slots 101 according to the specified span pattern, with adjacent layers arranged in a cyclical manner.

[0053] It should be noted that the three-phase winding has a total of 6 layers. The anti-torsion hairpin at the lead-out terminal 2 of the first layer is connected to the U-shaped hairpin. Then, the U-shaped hairpin connects across layers starting from the second layer until it connects to the anti-torsion hairpin of the sixth layer. Then, it reverses and returns to the anti-torsion hairpin of the first layer, and so on, until it connects to the neutral terminal 3. In addition, the three-phase winding is divided into U-phase, V-phase and W-phase, and each phase winding is set up with three branches connected in parallel.

[0054] It should be further explained that in this invention, the bottom of the stator slot 101 is the first layer, and the opening of the stator slot 101 is the 2nth layer. Of course, it can also be set in reverse.

[0055] Furthermore, the anti-torsion hairpin includes a lead wire hairpin 6, a first commutation hairpin 7, and a second commutation hairpin 9 for commutation connection; a lead wire hairpin 6 and several first commutation hairpins 7 are uniformly installed in the first layer of the three-phase winding with a structure in which spans 9, or spans 11 and 8 are alternately arranged; one end of the lead wire hairpin 6 is used to form a lead end 2; several second commutation hairpins 9 are installed in the 2n layer of the three-phase winding with a structure in which spans 9, or spans 11 and 8 are alternately arranged.

[0056] Furthermore, such as Figure 2 , Figure 3 and Figure 5 As shown, the lead wire hairpin 6, the first reversing hairpin 7, and the second reversing hairpin 9 are all composed of a U-shaped conductor and connecting ends disposed at the opening of the U-shaped conductor and arranged in the same direction; in Figure 2 In the process, the connecting ends of the lead wire hairpin 6 are of unequal length, with the longer connecting end forming the lead wire end 2, and the shorter end connecting to the U-shaped hairpin. The connecting ends of the first reversing hairpin 7 and the second reversing hairpin 9 face opposite directions. Figure 3 In the middle, the connecting end of the first reversing hairpin 7 is set to the right, used to connect to the U-shaped hairpin of the second layer, while... Figure 5In the middle, the connecting end of the second reversing hairpin 9 is set to the left, and is used to connect to the U-shaped hairpin of the fifth layer.

[0057] Furthermore, the U-shaped hairpin includes a cross-layer hairpin 8 and a neutral line hairpin 10; both the cross-layer hairpin 8 and the neutral line hairpin 10 are used for cross-layer connection. If one end of the cross-layer hairpin 8 is located in the 2n-2 layer, then the other end is located in the 2n-3 layer or the 2n-1 layer to achieve cross-layer connection; while the neutral line hairpin 10 is used for cross-layer connection between the first layer and the second layer.

[0058] Furthermore, such as Figure 4 and Figure 6 As shown, both the cross-layer hairpin 8 and the neutral wire hairpin 10 consist of a U-shaped conductor and a connecting end that is connected to the opening of the U-shaped conductor and is positioned away from it; in Figure 4 In this configuration, the connecting ends of the cross-layer hairpins 8 are of equal length and are used to connect with the anti-twist hairpins, other cross-layer hairpins 8, and the neutral wire hairpin 10. For example... Figure 6 As shown, the connecting ends of the neutral hairpin 10 are of different lengths, with the longer connecting ends used to form the neutral end 3, and the shorter connecting ends welded to the connecting ends of the cross-layer hairpin 8.

[0059] It should be noted that the winding coil includes a U-shaped conductor inserted into the stator slot 101, and the other end of the connection can be formed by twisting and expanding the welding to form a welding end 4, while the closed end of the U-shaped conductor constitutes the hairpin end 5.

[0060] Furthermore, the sum of the number of lead-out wire clips 6 and the number of first reversing wire clips 7 is equal to the number of second reversing wire clips 9.

[0061] The following is combined with Figures 8-11 An embodiment of the three-phase winding structure of the present invention with 6 layers and 54 stator slots 101 will be described, wherein the first layer and the sixth layer both adopt a span of 9, as detailed below:

[0062] like Figure 8 The diagram shows the installation of the first layer of reverse twisting hairpins. There are a total of 9 lead wire hairpins 6, which are arranged in groups of 3 parallel lead wire hairpins 6 to form the lead end 2 of a single-phase winding. Then there are 18 first commutation hairpins 7, with 6 corresponding to each single-phase winding, which are installed in the stator slot 101 with a span of 9.

[0063] like Figure 9 The diagram shows the installation of U-shaped hair clips in the second and third layers. The cross-layer hair clips 8 are connected from the second layer to the third layer in the manner of span 8 + span 11 + span 8, with a total of 54 clips, 27 in each layer.

[0064] like Figure 10The diagram shows the installation of the U-shaped hair clips for the fourth and fifth layers. The cross-layer hair clips 8 are connected from the fourth layer to the fifth layer in the manner of span 8 + span 11 + span 8, with a total of 54 clips, 27 of which are on each layer.

[0065] like Figure 11 As shown, there are 27 second reversing hairpins 9 on the sixth layer, installed with a span of 9.

[0066] Another embodiment of the three-phase winding structure of the present invention with 6 layers and 54 stator slots 101 is as follows: the first and sixth layers adopt a combination of spans of 11 and 8, respectively. The number of lead wire clips 6, first commutation clips 7, and second commutation clips 9 remains unchanged. The second to fifth layers are also equipped with the same configuration. Figure 9 and Figure 10 The structure is installed.

[0067] The three-phase winding of this invention starts with the lead wire hairpin 6 of the first layer, connects from the first layer to the last layer, then reverses from the last layer to the first layer, and then reverses again to connect from the first layer to the sixth layer, and so on, until the final neutral wire hairpin 10 is located inside the lead wire hairpin 6. Specifically, the lead wire hairpin 6 connects two sequentially connected cross-layer hairpins 8, from the second layer to the third layer, and then from the fourth layer to the fifth layer. Then the cross-layer hairpin 8 of the fifth layer is connected to the second reversing hairpin 9 of the sixth layer to realize the reversal. Then it is reversed and connected to the first reversing hairpin 7 of the first layer through the cross-layer hairpin 8, and so on, and is connected in this cyclical manner. Finally, the neutral wire hairpin 10 is connected, so that one end of the neutral wire hairpin 10 is located in the second layer and inside the lead wire hairpin 6.

[0068] like Figure 12 The figure shows the unfolded diagram of a single-phase winding. As can be seen from the figure, the numbers 1-54 represent 54 stator slots 101, A1+, A2+, and A3+ are the lead-out terminals 2 of the single-phase winding, and A1-, A2-, and A3- are the neutral terminals 3 of the single-phase winding.

[0069] 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 winding structure for a flat wire motor stator, characterized in that, Includes stator core (1) and three-phase windings; The inner surface of the stator core (1) is provided with a plurality of stator slots (101), and the three-phase winding is disposed in the stator slots (101); The three-phase winding has 2n layers, where n ≥ 3 and n is a natural number; The first and 2n layers of the three-phase winding are provided with several anti-twist hairpins with a span of 9, or with alternating spans of 11 and 8; the anti-twist hairpins include lead wire hairpins (6), first commutation hairpins (7) and second commutation hairpins (9), which are used for commutation connection; One lead wire hairpin (6) and several first commutation hairpins (7) are uniformly installed in the first layer of the three-phase winding with a structure in which the spans 9, or the spans 11 and 8 are alternately arranged; One end of the lead wire clip (6) is used to form the lead end (2); Several second commutation hairpins (9) are installed in the 2n layer of the three-phase winding with a structure in which spans 9, or spans 11 and 8 are alternately arranged; The second to the 2n-1th layers of the three-phase winding are provided with several U-shaped hairpins with spans of 8 and 11; The three-phase winding is also provided with a lead-out end (2) and a neutral end (3); the U-shaped hairpin includes a cross-layer hairpin (8) and a neutral line hairpin (10). Both the cross-layer hairpin (8) and the neutral line hairpin (10) are used for cross-layer connections; One end of the neutral wire hairpin (10) is located in the second layer and is used to form the neutral end (3). The neutral end (3) is located inside the lead-out end (2); The sum of the number of lead wire clips (6) and the first reversing clips (7) is equal to the number of the second reversing clips (9).

2. The winding structure of a flat wire motor stator according to claim 1, characterized in that, The stator slots (101) are provided with 54 slots.

3. The winding structure of a flat wire motor stator according to claim 1, characterized in that, The lead wire clip (6), the first reversing clip (7), and the second reversing clip (9) are all composed of a U-shaped conductor and a connecting end disposed in the opening of the U-shaped conductor and disposed in the same direction; The lengths of the connecting ends of the lead wire hairpin (6) are not equal; The connection end of the first reversing hairpin (7) and the connection end of the second reversing hairpin (9) are oriented in opposite directions.

4. The winding structure of a flat wire motor stator according to claim 1, characterized in that, Both the cross-layer hairpin (8) and the neutral line hairpin (10) are composed of a U-shaped conductor and a connecting end that is connected to the opening of the U-shaped conductor and is disposed opposite to it; The connecting ends of the cross-layer card (8) are of equal length; The lengths of the connecting ends of the neutral line hairpin (10) are not equal.

5. The winding structure of a flat wire motor stator according to claim 1, characterized in that, Each single-phase winding in the three-phase winding is provided with three parallel branches.

6. The winding structure of a flat wire motor stator according to claim 1, characterized in that, The stator core (1) is cylindrical and is made of several silicon steel sheets stacked together.

7. The winding structure of a flat wire motor stator according to any one of claims 1-6, characterized in that, Insulating paper is provided inside the stator slot (101).

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