Novel flat wire winding structure

Abstract

The invention discloses a novel flat wire winding structure, which belongs to the technical field of motors and comprises a stator iron core, the upper side and the lower side of the stator iron core are a connecting side and an inserting side of a flat wire winding respectively, a plurality of uniformly distributed axial slots are formed in the inner side surface of the stator iron core along the circumferential direction, and the slot number of the axial slots is m; the flat wire winding structure is provided with an axial slot, a flat wire U-shaped hairpin is inserted in the axial slot, the number of winding poles of the flat wire winding structure is 2p, the flat wire U-shaped hairpin adopts a cross-layer transposition structure of two adjacent layers, the flat wire U-shaped hairpin comprises two pitch structures of which the long pitch X1 is equal to (m / 2p) + 1 and the short pitch X2 is equal to (m / 2p)-1, the winding potential of the flat wire winding structure is balanced and free of circulating current, the required flat wires are few in types, the corresponding required molds are few, and the production cost is low. And meanwhile, by using a long-pitch and short-pitch concentric wiring mode, an integral pitch structure is avoided, odd harmonics can be remarkably reduced, and finally, the NVH performance and stability of the motor are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of motors, and more particularly to a novel flat wire winding structure. Background Art

[0002] As one of the key components of new energy vehicles, the performance of automotive drive motors is crucial to the performance of the entire vehicle. Compared with conventional round wire motors, flat wire motors have higher slot fill rate, higher power density and better heat dissipation capacity, so they gradually replace round wire motors and become the new favorite in the field of automotive drives. However, with the rapid development of new energy vehicles, end users have put forward higher requirements for the comfort of the entire vehicle, so the performance requirements of the drive motors by the OEMs are getting higher and higher, not only requiring the drive motors to meet the requirements of high speed and high efficiency, but also to have energy saving and low noise performance. Compared with traditional fuel vehicles, new energy vehicles have no "masking effect" of the engine assembly, the background noise is small, and the noise of the drive motor becomes more prominent, so the demand for optimization of NVH performance is getting higher and higher. At present, the winding method of the existing flat wire motor stator winding mostly contains a full-pitch structure. Although the performance is better, it will make the motor odd harmonics account for a large proportion, which is easy to cause vibration and noise problems. On the other hand, as the number of mass-produced models of different types in the new energy market has increased significantly, the production efficiency and cost of flat wire motors have become increasingly important. In the design and manufacture of flat wire motors, there are currently different winding wiring methods in the industry, and different wiring methods will have a direct impact on the complexity of flat wire winding production. In the existing technology, there are many types of flat wires required for winding and the process is complicated, resulting in high initial mold investment and later manufacturing costs. Therefore, it is urgent to reduce costs and improve production efficiency by optimizing wiring methods; After searching, it was found that the publication number "CN118659564A" records "a flat wire winding structure, belonging to the field of motor technology, which includes a stator core, the upper and lower sides of the stator core are the connection side and the insertion side of the flat wire respectively, and a number of evenly distributed axial slots are opened on the inner side of the stator core along the circumferential direction. The number of winding poles of the flat wire winding structure is 2p, the number of slots of the axial slots is m, and each axial slot is provided with 2n layers of conductors. A flat wire U-shaped hairpin is inserted in the axial slot. The flat wire U-shaped hairpin includes three pitch structures of full pitch Y1=m / 2p, long pitch Y2≥Y1+1 and short pitch Y3≤Y1-1, and Y2-Y3=m / 2p / 3. The flat wire U-shaped hairpin adopts a cross-layer structure of two adjacent layers. The present invention adopts a single-branch triangle wiring method or a single-branch star wiring method or a double-branch star wiring method. The potentials of the three methods are balanced, there is no circulating current problem, and the winding structure is simple without special-shaped wires; At the same time, the above patent specification records Example 7: A flat wire winding structure with 10 poles, 60 slots and 6 layers of conductors is provided, and a single-branch triangle connection method is used for wiring, and the method is as follows: A. 66667 66665 (6 to 5 layers); 66667 66665 (4 to 3 layers); 66667 66665 (2 to 1 layer), this is a reverse cross-layer electrical connection structure, among which: 5, 6, and 7 are three pitches of the flat wire U-shaped hairpin; B. 56666 76666 (1 to 2 layers); 56666 76666 (3 to 4 layers); 56666 76666 (5 to 6 layers), this is a forward cross-layer electrical connection structure, among which: 5, 6, 7 are three pitches of the flat wire U-shaped hairpin; From the above, it can be seen that in the technical solution of the flat wire winding of the above-mentioned patent, the flat wire U-shaped hairpin adopts the technical solution of "three pitch structures of full pitch Y1=m / 2p, long pitch Y2≥Y1+1 and short pitch Y3≤Y1-1". The pitch structure of the flat wire U-shaped hairpin requires more, which leads to an increase in the corresponding production molds and ultimately increases the investment cost. At the same time, due to the variety of flat wire U-shaped hairpins and relatively complex processes, it will affect the production efficiency. How to further reduce the investment cost and improve the production efficiency and process convenience is the first technical problem that needs to be solved urgently; At the same time, research has found that the technical solutions using the above three pitch structures will affect the NVH performance and stability of the motor. Therefore, how to improve the NVH performance and stability of the motor by optimizing the pitch structure of the flat wire winding is the second technical problem that needs to be solved urgently. Summary of the invention

[0003] Technical issues to be solved In view of the problems existing in the prior art, the purpose of the present invention is to provide a new flat wire winding structure, and the present invention has the following technical effects: 1. The present invention reduces the number of molds by reducing the types of flat wire U-shaped hairpins, thereby reducing the initial cost investment. At the same time, the wiring is simpler, the difficulty of the process wiring is reduced, the process is simple, reliable, and not prone to errors, and the production cycle of mass production is shortened, which saves production costs and improves production efficiency; 2. The present invention uses a long-distance + short-distance concentric wiring mode to avoid the full-distance structure, which can effectively and significantly reduce odd harmonics (vibration and noise), especially the 5th and 7th harmonics, greatly improving the NVH performance and stability of the motor;

[0004] To solve the above problems, the present invention adopts the following technical solutions: A novel flat wire winding structure comprises a stator core, wherein the upper and lower sides of the stator core are respectively a connection side and an insertion side of the flat wire winding, and a plurality of evenly distributed axial slots are provided on the inner side surface of the stator core in a circumferential direction, the number of winding poles of the flat wire winding structure is 2p, the number of slots of the axial slots is m, each of the axial slots is provided with insulating paper and 2n layers of conductor, and the 2nth layer, the 2n-1th layer, the 2n-2th layer, ..., the 1st layer are arranged from the outside to the inside along the axis direction of the stator core, wherein: p≥4, n≥2, and p, m and n are all natural numbers; wherein: A flat wire U-shaped hairpin is inserted into the axial slot, and the flat wire U-shaped hairpin includes two pitch structures of long pitch X1=(m / 2p)+1 and short pitch X2=(m / 2p)-1, wherein: X1 and X2 are both integers, and the pitch unit is "cross slot"; The flat wire U-shaped hairpin adopts a cross-layer structure of two adjacent layers; The flat wire U-shaped hairpin is inserted through the insertion side and then electrically connected on the connection side by twisting and bending, and finally forms a three-phase winding of the flat wire winding structure: a U-phase winding, a V-phase winding and a W-phase winding. The lead-out wire ends of the U-phase winding, the V-phase winding and the W-phase winding are electrically short-circuited through a neutral point copper bar; The flat wire winding structure adopts a double-branch star connection mode or a double-branch delta connection mode.

[0005] As a preferred solution of the present invention, the cross-layer structure of two adjacent layers includes: 1 turns to 2 layers, ..., 2n-3 turns to 2n-2 layers, 2n-1 turns to 2n layers in a forward cross-layer structure; A reverse cross-layer structure of 2n to 2n-1 layer, 2n-2 to 2n-3 layer, ..., 2 to 1 layer.

[0006] As a preferred solution of the present invention, the flat wire U-shaped hairpin includes a flat wire U-shaped hairpin body, the bottom of the flat wire U-shaped hairpin body is a twisted segment to form a cross-layer structure, and the flat wire U-shaped hairpin body is inserted into the axial slot and bent to obtain two bending segments, the bending segment span K=m / 4p, and the two bending segments have a first state and a second state, wherein: The first state is: the two bending sections have opposite bending directions; The second state is that the two bending sections have the same bending direction.

[0007] As a preferred solution of the present invention, each of the axial slots is provided with any one of 4 layers, 6 layers, 8 layers, 10 layers and 12 layers of conductors.

[0008] As a preferred solution of the present invention, the flat wire winding structure is 12 poles and 72 slots, the number of poles of the flat wire winding is 12, the number of slots of the axial slots is 72, and each of the axial slots is provided with 8 layers of conductors, and it is obtained by calculation that: p=6, m=72; Substituting p=6 and m=72 into X1=(m / 2p)+1, X2=(m / 2p)-1, and K=m / 4p, it is calculated that the long pitch X1 of the flat wire U-shaped hairpin is 7 slots, the short pitch X1 is 5 slots, and the bending section span K is 3 slots.

[0009] As a preferred solution of the present invention, the flat wire U-shaped hairpin adopts: The forward cross-layer structure of 1 to 2 layers, 3 to 4 layers, 5 to 6 layers, 7 to 8 layers; Reverse cross-layer structure of 8 to 7 layers, 6 to 5 layers, 4 to 3 layers, and 2 to 1 layer.

[0010] As a preferred solution of the present invention, in the first branch of the U-phase winding: When the flat wire U-shaped hairpin adopts a 1-to-2-layer forward cross-layer structure, the pitches are 7, 5, 7, 5, 7, 5 in sequence; When the flat wire U-shaped hairpin adopts a 3-to-4-layer forward cross-layer structure, the pitches are 7, 5, 7, 5, 7, 5 in sequence; When the flat wire U-shaped hairpin adopts a 5-to-6-layer forward cross-layer structure, the pitches are 7, 5, 7, 5, 7, 5 in sequence; When the flat wire U-shaped hairpin adopts a 7-to-8-layer forward cross-layer structure, the pitches are 7, 5, 7, 5, 7, 5 in sequence; When the flat wire U-shaped hairpin adopts an 8-to-7-layer reverse cross-layer structure, the pitches are 5, 7, 5, 7, 5, 7 in sequence; When the flat wire U-shaped hairpin adopts a 6-to-5-layer reverse cross-layer structure, the pitches are 5, 7, 5, 7, 5, 7 in sequence; When the flat wire U-shaped hairpin adopts a 4-to-3-layer reverse cross-layer structure, the pitches are 5, 7, 5, 7, 5, 7 in sequence; When the flat wire U-shaped hairpin adopts a 2-to-1 reverse cross-layer structure, the pitches are 5, 7, 5, 7, 5, 7 in sequence; The second branch of the U-phase winding is wired in the same manner as the first branch, and the second branch differs from the first branch by one slot.

[0011] As a preferred solution of the present invention, when the flat wire winding adopts a double-branch star connection mode, "&" represents the connection part between the two flat wire U-shaped hairpins, and "ij" represents the jth layer in the i-th axial slot, then: The electrical connection mode of the first branch of the U-phase winding double branch is: The connection mode of the 1-to-2-layer forward cross-layer structure is: U1+&15.1&22.2&28.1&33.2&39.1&46.2&52.1&57.2&63.1&70.2&4.1&9.2; The connection mode of the 3-to-4-layer forward cross-layer structure is: 15.3&22.4&28.3&33.4&39.3&46.4&52.3&57.4&63.3&70.4&4.3&9.4; The connection mode of the 5-to-6-layer forward cross-layer structure is: 15.5&22.6&28.5&33.6&39.5&46.6&52.5&57.6&63.5&70.6&4.5&9.6; The connection mode of the 7-to-8-layer forward cross-layer structure is: 15.7&22.8&28.7&33.8&39.7&46.8&52.7&57.8&63.7&70.8&4.7&9.8; The 8-to-7-layer reverse cross-layer structure connection method is: 15.8&10.7&4.8&69.7&63.8&58.7&52.8&45.7&39.8&34.7&28.8&21.7; The connection mode of 6-to-5-layer reverse cross-layer structure is: 15.6&10.5&4.6&69.5&63.6&58.5&52.6&45.5&39.6&34.5&28.6&21.5; The 4-to-3-layer reverse cross-layer structure connection method is: 15.4&10.4&4.4&69.3&63.4&58.3&52.4&45.3&39.4&34.3&28.4&21.3; The 2-to-1 reverse cross-layer structure connection method is: 15.2&10.1&4.2&69.1&63.2&58.1&52.2&45.1&39.2&34.1&28.2&21.1&U1-; The electrical connection mode of the second branch of the U-phase winding double branch is: The connection mode of the 1-to-2-layer forward cross-layer structure is: U2+&16.1&21.2&27.1&34.2&40.1&45.2&51.1&58.2&64.1&69.2&3.1&10.2; The connection mode of the 3-to-4-layer forward cross-layer structure is: 16.3&21.4&27.3&34.4&40.3&45.4&51.3&58.4&64.3&69.4&3.3&10.4; The connection mode of the 5-to-6-layer forward cross-layer structure is: 16.5&21.6&27.5&34.6&40.5&45.6&51.5&58.6&64.5&69.6&3.5&10.6; The connection mode of the 7-to-8-layer forward cross-layer structure is: 16.7&21.8&27.7&34.8&40.7&45.8&51.7&58.8&64.7&69.8&3.7&10.8; The 8-to-7-layer reverse cross-layer structure connection method is: 16.8&9.7&3.8&70.7&64.8&57.7&51.8&46.7&40.8&33.7&27.8&22.7; The 6-to-5-layer reverse cross-layer structure connection method is: 16.6&9.5&3.6&70.5&64.6&57.5&51.6&46.5&40.6&33.5&27.6&22.5; The 4-to-3-layer reverse cross-layer structure connection method is: 16.4&9.4&3.4&70.3&64.4&57.3&51.4&46.3&40.4&33.3&27.4&22.3; The 2-to-1 reverse cross-layer structure connection method is: 16.2&9.1&3.2&70.1&64.2&57.1&51.2&46.1&40.2&33.1&27.2&22.1&U2-; The wiring rules of the V-phase winding and the W-phase winding are the same as those of the U-phase winding, wherein: the V-phase winding is obtained by rotating 4 slots relative to the U-phase winding in the direction of increasing slot positions, and the W-phase winding is obtained by rotating 8 slots relative to the U-phase winding in the direction of increasing slot positions; U1+ and U2+ are connected to serve as the U-phase winding input terminal; V1+ and V2+ are connected to serve as the V-phase winding input terminal; W1+ and W2+ are connected to serve as the W-phase winding input terminal; U1-, U2-, V1-, V2-, W1- and W2- are connected to the neutral point copper bus and serve as the neutral point of the double-branch star connection.

[0012] Compared with the prior art, the advantages of the present invention are: 1. The flat wire U-shaped hairpin of the present invention adopts a cross-layer structure of two adjacent layers. The flat wire U-shaped hairpin includes two pitch structures of long pitch X1=(m / 2p)+1 and short pitch X2=(m / 2p)-1. Few types of flat wires are required, so fewer corresponding molds are required, thereby reducing the initial cost investment. At the same time, the wiring is simple, which reduces the difficulty of plugging in the wires. The process is simple, reliable and not prone to errors. At the same time, the present invention can effectively shorten the production cycle of mass production, save production costs, and ultimately improve production efficiency; 2. The present invention uses a concentric wiring mode of two pitch structures, long pitch + short pitch, and then avoids the full pitch structure, which can significantly reduce odd harmonics, especially the 5th harmonic and the 7th harmonic, and ultimately improve the NVH performance and stability of the motor. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 It is a first perspective stereogram of the present invention; Figure 2 It is a second viewing angle stereogram of the present invention; Figure 3 It is a schematic diagram of the installation of the unidirectional winding in the present invention; Figure 4 This is a schematic diagram of the installation of a flat wire U-shaped hairpin with a pitch of 7 spans and two bending sections with opposite bending directions in the present invention; Figure 5 This is a schematic diagram of the installation of a flat wire U-shaped hairpin with a pitch of 5 spans and two bending sections with opposite bending directions in the present invention; Figure 6 This is a schematic diagram of the installation of a flat wire U-shaped hairpin with a pitch of 7 spans and two bending sections with the same bending direction in the present invention; Figure 7 This is a schematic diagram of the installation of a flat wire U-shaped hairpin with a pitch of 5 spans and two bending sections with the same bending direction in the present invention; Figure 8 This is a schematic diagram of a flat wire U-shaped hairpin with a pitch of 7 spans and two bending sections with opposite bending directions in the present invention; Fig. 9 This is a schematic diagram of a flat wire U-shaped hairpin with a pitch of 5 spans and two bending sections with opposite bending directions in the present invention; Fig.10 A schematic diagram of a flat wire U-shaped hairpin with a pitch of 7 spans and two bending sections with the same bending direction in the present invention; Fig.11 This is a schematic diagram of a flat wire U-shaped hairpin with a pitch of 5 spans and two bending sections with the same bending direction in the present invention; Fig.12 This is a schematic diagram of an unbent flat wire U-shaped hairpin in the initial state of the present invention; Fig.13 This is a winding expansion diagram of a 12-pole, 72-slot, 8-layer double-branch star connection mode in Example 2 of the present invention; Fig.14 It is a schematic diagram of the structure of 757 in Embodiment 2 of the present invention; Fig.15 It is a schematic diagram of the structure of 575 in Embodiment 2 of the present invention; Fig.16 This is a winding expansion diagram of a 12-pole, 72-slot, 8-layer double-branch triangle connection mode in Example 3 of the present invention; Description of the numbers in the figure: 100. stator core; 200, insertion side; 300, connection side; 400, input line; 500, neutral point copper busbar; 600, flat wire U-shaped hairpin; 601, flat wire U-shaped hairpin body; 602, twisted section; 603, bent section. DETAILED DESCRIPTION

[0014] The technical solutions in the embodiments of the present invention will be described clearly and completely below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0015] Example 1: Please refer to Figure 1 and Figure 2 A novel flat wire winding structure includes a stator core 100, wherein the upper and lower sides of the stator core 100 are a connection side 300 and an insertion side 200 of the flat wire respectively, and a plurality of evenly distributed axial slots are provided on the inner side surface of the stator core 100 along the circumferential direction, the number of winding poles of the flat wire winding structure is 2p, the number of slots of the axial slots is m, each axial slot is provided with insulating paper and 2n layers of conductor, and along the axis direction of the stator core 100, from the outside to the inside, they are the 2nth layer, the 2n-1th layer, the 2n-2th layer, ..., the 1st layer, wherein: p≥4, n≥2, and p, m and n are all natural numbers, and it should be noted that: the upper and lower involved here, its viewing angle is based on Figure 1 To illustrate the example; See also Figure 1 , Figure 3-Figure 7 A flat wire U-shaped hairpin 600 is inserted into the axial slot, and the flat wire U-shaped hairpin 600 includes two pitch structures of a long pitch X1=(m / 2p)+1 and a short pitch X2=(m / 2p)-1, wherein: X1 and X2 are both integers, and the pitch unit is "cross-slot"; See also Fig.12In the initial state, the flat wire U-shaped hairpin 600 includes a flat wire U-shaped hairpin body 601, the bottom of the flat wire U-shaped hairpin body 601 is a twisted section 602 to form a cross-layer structure, and the two lead-out ends of the flat wire U-shaped hairpin body 601 in the initial state are straight line segments. The flat wire U-shaped hairpin 600 in the initial state is inserted through the insertion side 200 as a whole, and is led out at the connection side 300, and then two bent sections 603 are obtained by twisting and bending, and then electrical connection is achieved with other twisted and bent flat wire U-shaped hairpins 600, and the span of the bent section 603 is K= m / 4p; In this embodiment: the flat wire U-shaped hairpin 600 is inserted through the insertion side 200 and twisted and bent, and then electrically connected at the connection side 300, and finally forms a three-phase winding of a flat wire winding structure: a U-phase winding, a V-phase winding and a W-phase winding, wherein the output ends of the U-phase winding, the V-phase winding and the W-phase winding are electrically short-circuited through a neutral copper bar 500, and the input ends of the U-phase winding, the V-phase winding and the W-phase winding each have an input wire 400; In this embodiment: the flat wire winding structure adopts a double-branch star connection method or a double-branch delta connection method: See also Figure 1 , Figure 4-Figure 8 The flat wire U-shaped hairpin 600 adopts a cross-layer electrical connection structure between two adjacent layers. Specifically, the cross-layer electrical connection structure between two adjacent layers includes: 1 turns to 2 layers, ..., 2n-3 turns to 2n-2 layers, 2n-1 turns to 2n layers in a forward cross-layer structure; Reverse cross-layer structure of 2n to 2n-1 layer, 2n-2 to 2n-3 layer, ..., 2 to 1 layer; It should be noted that the above “two adjacent layers” refer to two adjacent layers in different axial slots, and do not refer to two adjacent sides in the same axial slot, such as: The flat wire U-shaped hairpin 600 with a pitch of 7 cross slots has the first layer in the 15th axial slot spanning to the second layer in the 22nd axial slot. The first layer and the second layer are constructed as "two adjacent layers", which is a forward cross-layer electrical connection structure; another example: The flat wire U-shaped hairpin 600 with a pitch of 5 cross slots has the 8th layer in the 15th axial slot cross to the 7th layer in the 10th axial slot. The 8th layer and the 7th layer are constructed as "two adjacent layers", which is a reverse cross-layer electrical connection structure. See also Figure 8-Figure 12 The flat wire U-shaped hairpin 600 includes a flat wire U-shaped hairpin body 601, the bottom of the flat wire U-shaped hairpin body 601 is a twisted section 602 to form a cross-layer structure, and the flat wire U-shaped hairpin body 601 is inserted into the axial slot and twisted to obtain two bent sections 603, and the two bent sections 603 have a first state and a second state, wherein: See also Figure 8 and Fig. 9 , the first state is: the two bending sections 603 are bent in opposite directions; See also Fig.10 and Fig.11 , the second state is: the two bending sections 603 have the same bending direction; It should be noted that: in each phase winding single branch, the flat wire U-shaped hairpin 600 in the second state is used only once, and the hairpin is used only when the connection of the electrical fold is changed from the forward cross-layer to the reverse cross-layer. The flat wire U-shaped hairpin 600 in the first state is used in the remaining cases, which is described in detail in Example 2. Any one of 4-layer, 6-layer, 8-layer, 10-layer and 12-layer conductors is arranged in each axial slot.

[0016] Example 2: Please refer to Figure 2 This embodiment is based on the first embodiment and takes the flat wire winding with 12 poles, 72 slots and 8 conductor layers as an example to explain in detail: The flat wire winding structure is 12 poles and 72 slots. The number of winding poles of the flat wire winding structure is 12, the number of axial slots is 72, and each axial slot is provided with 8 layers of conductors. After calculation, it is obtained that: p=6, m=72; Substituting p=6, m=72 into X1=(m / 2p)+1, X2=(m / 2p)-1, K= m / 4p, it is calculated that the long pitch X1 of the flat wire U-shaped hairpin 600 is 7 slots, the short pitch X1 is 5 slots, and the bending section 603 is 3 slots; Therefore, the flat wire U-shaped hairpin 600 adopts: The forward cross-layer structure of 1 to 2 layers, 3 to 4 layers, 5 to 6 layers, 7 to 8 layers, and the reverse cross-layer structure of 8 to 7 layers, 6 to 5 layers, 4 to 3 layers, 2 to 1 layer; In the first branch of the U-phase winding: When the flat wire U-shaped hairpin 600 adopts a 1-to-2-layer forward cross-layer structure, the pitches are 7, 5, 7, 5, 7, 5 in sequence, and this method is recorded as "757575 (1-to-2 layers)". When the flat wire U-shaped hairpin 600 adopts a 3-to-4-layer forward cross-layer structure, the pitches are 7, 5, 7, 5, 7, 5 in sequence, and this method is recorded as "757575 (3-to-4 layers)". When the flat wire U-shaped hairpin 600 adopts a 5-to-6-layer forward cross-layer structure, the pitches are 7, 5, 7, 5, 7, 5, and the structure is recorded as "757575 (5-to-6 layers)". When the flat wire U-shaped hairpin 600 adopts a 7-to-8-layer forward cross-layer structure, the pitches are 7, 5, 7, 5, 7, 5 in sequence, and the structure is recorded as "757575 (7-to-8 layers)". When the flat wire U-shaped hairpin 600 adopts an 8-turn 7-layer reverse cross-layer structure, the pitches are 5, 7, 5, 7, 5, 7 in sequence, and this method is recorded as "575757 (8-turn 7-layer)". When the flat wire U-shaped hairpin 600 adopts a reverse cross-layer structure of 6 turns to 5 layers, the pitches are 5, 7, 5, 7, 5, 7 in sequence, and this method is recorded as "575757 (6 turns to 5 layers)"; When the flat wire U-shaped hairpin 600 adopts a reverse cross-layer structure of 4 turns to 3 layers, the pitches thereof are 5, 7, 5, 7, 5, 7 in sequence, and the structure is recorded as "575757 (4 turns to 3 layers)". When the flat wire U-shaped hairpin 600 adopts a reverse cross-layer structure of 2 turns to 1 layer, the pitches thereof are 5, 7, 5, 7, 5, 7 in sequence, and this method is recorded as "575757 (2 turns to 1 layer)"; Based on the above records, Fig.13 In the state shown, the present invention adopts the following method: A. 757575 (1 to 2 layers); 757575 (3 to 4 layers); 757575 (5 to 6 layers); 757575 (7 to 8 layers), this is a forward cross-layer electrical connection structure, where 5 and 7 are two pitches of the flat wire U-shaped hairpin 600; B. 575757 (8 to 7 layers); 575757 (6 to 5 layers); 575757 (4 to 3 layers); 575757 (2 to 1 layer), this is a reverse cross-layer electrical connection structure, where 5 and 7 are two pitches of the flat wire U-shaped hairpin 600; For the sake of Fig.13 To elaborate: This embodiment takes "757 (1 to 2 layers)" in "757575 (1 to 2 layers)" as an example to explain in detail: See also Fig.13 and Fig.14 In "757 (1 to 2 layers)", a flat wire U-shaped hairpin 600 with a pitch of 7 slots, a flat wire U-shaped hairpin 600 with a pitch of 5 slots, and a flat wire U-shaped hairpin 600 with a pitch of 7 slots are used. Among them, the flat wire U-shaped hairpin 600 with a pitch of 7 slots and the flat wire U-shaped hairpin 600 with a pitch of 7 slots have the same specifications. Fig.14 The flat wire U-shaped hairpin 600 in the shown states are all in the first state; This embodiment takes "575 (8 to 7 floors)" in "575757 (8 to 7 floors)" as an example to explain in detail: See also Fig.13 and Fig.15In "575 (8 to 7 layers)", a ⑥ flat wire U-shaped hairpin 600 with a pitch of 5 slots, a ⑤ flat wire U-shaped hairpin 600 with a pitch of 7 slots, and a ④ flat wire U-shaped hairpin 600 with a pitch of 5 slots are used. Fig.15 The No. ⑥ flat wire U-shaped hairpin 600 in the shown state is the second state; The above case is based on the first branch of the U-phase winding as an example. In the first branch of the U-phase winding, there is only one flat wire U-shaped hairpin 600 in the second state, which serves as a reverse folded hairpin. Similarly, there is only one reverse folded hairpin in the first branches of the V-phase winding and the W-phase winding. It should also be noted that: no matter it is 1 to 2 layers or 2 to 1 layer, as long as the pitch is the same, the specifications of the flat wire U-shaped hairpin 600 are the same, that is, the flat wire U-shaped hairpin 600 of 1 to 2 layers and a pitch of 7 cross slots is the same as the flat wire U-shaped hairpin 600 of 2 to 1 layer and a pitch of 7 cross slots; However, in the case of 1-to-2-layer and 3-to-4-layer, even if the pitch is the same, the flat wire U-shaped hairpin 600 adopts different specifications, that is, although the number of cross slots is the same, the spacing is different, that is, the flat wire U-shaped hairpin 600 of 1-to-2-layer with a pitch of 7 cross slots is different from the flat wire U-shaped hairpin 600 of 3-to-4-layer with a pitch of 7 cross slots; When the flat wire winding structure adopts a double-branch star connection mode, "&" represents the connection between the two flat wire U-shaped hairpins 600, and "ij" represents the jth layer in the i-th axial slot, then: The electrical connection method of the first branch of the U-phase winding double branch is: The connection mode of the 1-to-2-layer forward cross-layer structure is: U1+&15.1&22.2&28.1&33.2&39.1&46.2&52.1&57.2&63.1&70.2&4.1&9.2; The connection mode of the 3-to-4-layer forward cross-layer structure is: 15.3&22.4&28.3&33.4&39.3&46.4&52.3&57.4&63.3&70.4&4.3&9.4; The connection mode of the 5-to-6-layer forward cross-layer structure is: 15.5&22.6&28.5&33.6&39.5&46.6&52.5&57.6&63.5&70.6&4.5&9.6; The connection mode of the 7-to-8-layer forward cross-layer structure is: 15.7&22.8&28.7&33.8&39.7&46.8&52.7&57.8&63.7&70.8&4.7&9.8; The 8-to-7-layer reverse cross-layer structure connection method is: 15.8&10.7&4.8&69.7&63.8&58.7&52.8&45.7&39.8&34.7&28.8&21.7; The connection mode of 6-to-5-layer reverse cross-layer structure is: 15.6&10.5&4.6&69.5&63.6&58.5&52.6&45.5&39.6&34.5&28.6&21.5; The 4-to-3-layer reverse cross-layer structure connection method is: 15.4&10.4&4.4&69.3&63.4&58.3&52.4&45.3&39.4&34.3&28.4&21.3; The 2-to-1 reverse cross-layer structure connection method is: 15.2&10.1&4.2&69.1&63.2&58.1&52.2&45.1&39.2&34.1&28.2&21.1&U1-; The electrical connection method of the second branch of the U-phase winding double branch is: The connection mode of the 1-to-2-layer forward cross-layer structure is: U2+&16.1&21.2&27.1&34.2&40.1&45.2&51.1&58.2&64.1&69.2&3.1&10.2; The connection mode of the 3-to-4-layer forward cross-layer structure is: 16.3&21.4&27.3&34.4&40.3&45.4&51.3&58.4&64.3&69.4&3.3&10.4; The connection mode of the 5-to-6-layer forward cross-layer structure is: 16.5&21.6&27.5&34.6&40.5&45.6&51.5&58.6&64.5&69.6&3.5&10.6; The connection mode of the 7-to-8-layer forward cross-layer structure is: 16.7&21.8&27.7&34.8&40.7&45.8&51.7&58.8&64.7&69.8&3.7&10.8; The 8-to-7-layer reverse cross-layer structure connection method is: 16.8&9.7&3.8&70.7&64.8&57.7&51.8&46.7&40.8&33.7&27.8&22.7; The 6-to-5-layer reverse cross-layer structure connection method is: 16.6&9.5&3.6&70.5&64.6&57.5&51.6&46.5&40.6&33.5&27.6&22.5; The 4-to-3-layer reverse cross-layer structure connection method is: 16.4&9.4&3.4&70.3&64.4&57.3&51.4&46.3&40.4&33.3&27.4&22.3; The 2-to-1 reverse cross-layer structure connection method is: 16.2&9.1&3.2&70.1&64.2&57.1&51.2&46.1&40.2&33.1&27.2&22.1&U2-.

[0017] Similarly, the wiring rules of the V-phase winding and the W-phase winding are the same as those of the U-phase winding, wherein the V-phase winding is obtained by rotating 4 slots relative to the U-phase winding in the direction of increasing slot positions, and the W-phase winding is obtained by rotating 8 slots relative to the U-phase winding in the direction of increasing slot positions; U1+ and U2+ are connected as the input terminal of the U phase winding; V1+ and V2+ are connected as the V-phase winding input terminal; W1+ and W2+ are connected as the input terminal of W phase winding; U1-, U2-, V1-, V2-, W1- and W2- are connected to the neutral point copper bus (500) and serve as the neutral point of the double-branch star connection.

[0018] Example 3: Please refer to Fig.16 , Example 3 provides a winding expansion diagram of a flat wire winding structure with 12 poles, 72 slots and 8 conductor layers under a double-branch triangle connection method: contrast Fig.13 and Fig.16 It can be seen that: This embodiment is based on the embodiment 2. Without changing the wiring form of the embodiment 2 and without adding a new type of U-shaped hairpin, it only needs to change the input end and output end in the embodiment 2 to: U1+, U2+, W1- and W2- are connected together as the U-phase winding input terminal; V1+, V2+, U1- and U2- are connected together as the V-phase winding input terminal; W1+, W2+, V1- and V2- are connected together as the W-phase winding input terminal, thus forming a double-branch triangle wiring method.

[0019] Embodiment 4: The above embodiments all use 1 to 2 layers as the initial starting point, that is, the above embodiments all insert the flat wire U-shaped hairpin 600 from the innermost layer, and the input line 400 is on the innermost side. The reverse is also possible, that is, the present embodiment can use 8 to 7 layers as the initial starting point, and the technical solution of the present embodiment can be obtained by reversing the above embodiments, that is, the present embodiment inserts the flat wire U-shaped hairpin 600 from the outermost layer, and the input line 400 is on the outermost side.

[0020] The above description is only a preferred specific implementation manner of the present invention, but the protection scope of the present invention is not limited thereto. Any technician familiar with the technical field can make equivalent replacements or changes according to the technical scheme and improved concepts of the present invention within the technical scope disclosed by the present invention, and they should be covered by the protection scope of the present invention.

Claims

1. A novel flat wire winding structure, comprising a stator core (100), wherein the upper and lower sides of the stator core (100) are respectively a connection side (300) and an insertion side (200) of the flat wire winding, and the inner side surface of the stator core (100) is provided with a plurality of evenly distributed axial slots along a circumferential direction, the number of winding poles of the flat wire winding structure is 2p, the number of slots of the axial slots is m, each of the axial slots is provided with insulating paper and 2n layers of conductor, and the 2nth layer, the 2n-1st layer, the 2n-2nd layer, ..., the 1st layer are arranged from the outside to the inside along the axis direction of the stator core (100), wherein: p≥4, n≥2, and p, m and n are all natural numbers; characterized in that: A flat wire U-shaped hairpin (600) is inserted into the axial slot, and the flat wire U-shaped hairpin (600) comprises two pitch structures: a long pitch X1=(m / 2p)+1 and a short pitch X2=(m / 2p)-1, wherein: X1 and X2 are both integers, and the pitch unit is "cross-slot"; The flat wire U-shaped hairpin (600) adopts a cross-layer structure of two adjacent layers; The flat wire U-shaped hairpin (600) is inserted through the insertion side (200) and is then electrically connected at the connection side (300) by twisting and bending, thereby finally forming a three-phase winding of the flat wire winding structure: a U-phase winding, a V-phase winding, and a W-phase winding. The lead-out wire ends of the U-phase winding, the V-phase winding, and the W-phase winding are electrically short-circuited via a neutral point copper bar (500); The flat wire winding structure adopts a double-branch star connection mode or a double-branch delta connection mode.

2. A novel flat wire winding structure according to claim 1, characterized in that: The cross-layer structure of two adjacent layers includes: 1 turns to 2 layers, ..., 2n-3 turns to 2n-2 layers, 2n-1 turns to 2n layers; A reverse cross-layer structure of 2n to 2n-1 layer, 2n-2 to 2n-3 layer, ..., 2 to 1 layer.

3. A novel flat wire winding structure according to claim 2, characterized in that: The flat wire U-shaped hairpin (600) comprises a flat wire U-shaped hairpin body (601), the bottom of the flat wire U-shaped hairpin body (601) is a twisted section (602) forming a cross-layer structure, and after the flat wire U-shaped hairpin body (601) is inserted into the axial slot, it is twisted and bent to obtain two bent sections (603), the span of the bent sections is K=m / 4p, and the two bent sections (603) have a first state and a second state, wherein: The first state is: the two bending sections (603) are bent in opposite directions; The second state is that the two bending sections (603) have the same bending direction.

4. A novel flat wire winding structure according to claim 3, characterized in that: Any one of 4 layers, 6 layers, 8 layers, 10 layers and 12 layers of conductors is arranged in each of the axial slots.

5. A novel flat wire winding structure according to claim 4, characterized in that: The flat wire winding structure is 12 poles and 72 slots. The number of poles of the flat wire winding is 12, the number of slots of the axial slots is 72, and each of the axial slots is provided with 8 layers of conductors. After calculation, it is obtained that: p=6, m=72; Substituting p=6 and m=72 into X1=(m / 2p)+1, X2=(m / 2p)-1, and K=m / 4p, it is calculated that the long pitch X1 of the flat wire U-shaped hairpin (600) is 7 slots, the short pitch X1 is 5 slots, and the bending section span K is 3 slots.

6. A novel flat wire winding structure according to claim 5, characterized in that: The flat wire U-shaped hairpin (600) adopts: The forward cross-layer structure of 1 to 2 layers, 3 to 4 layers, 5 to 6 layers, 7 to 8 layers; Reverse cross-layer structure of 8 to 7 layers, 6 to 5 layers, 4 to 3 layers, and 2 to 1 layer.

7. A novel flat wire winding structure according to claim 6, characterized in that: In the first branch of the U-phase winding: When the flat wire U-shaped hairpin (600) adopts a 1-to-2-layer forward cross-layer structure, the pitches thereof are 7, 5, 7, 5, 7, 5 in sequence; When the flat wire U-shaped hairpin (600) adopts a 3-to-4-layer forward cross-layer structure, the pitches thereof are 7, 5, 7, 5, 7, 5 in sequence; When the flat wire U-shaped hairpin (600) adopts a 5-to-6-layer forward cross-layer structure, the pitches are 7, 5, 7, 5, 7, 5 in sequence; When the flat wire U-shaped hairpin (600) adopts a 7-to-8-layer forward cross-layer structure, the pitches are 7, 5, 7, 5, 7, 5 in sequence; When the flat wire U-shaped hairpin (600) adopts an 8-to-7-layer reverse cross-layer structure, the pitches are 5, 7, 5, 7, 5, 7 in sequence; When the flat wire U-shaped hairpin (600) adopts a 6-to-5-layer reverse cross-layer structure, the pitches are 5, 7, 5, 7, 5, 7 in sequence; When the flat wire U-shaped hairpin (600) adopts a 4-to-3-layer reverse cross-layer structure, the pitches are 5, 7, 5, 7, 5, 7 in sequence; When the flat wire U-shaped hairpin (600) adopts a 2-to-1-layer reverse cross-layer structure, the pitches thereof are 5, 7, 5, 7, 5, 7 in sequence; The second branch of the U-phase winding is wired in the same manner as the first branch of the U-phase winding, and the second branch differs from the first branch by one slot.

8. A novel flat wire winding structure according to claim 7, characterized in that: When the flat wire winding adopts a double-branch star connection mode, "&" represents the connection position between two flat wire U-shaped hairpins (600), and "ij" represents the jth layer in the i-th axial slot, then: The electrical connection mode of the first branch of the U-phase winding double branch is: The forward cross-layer structure connection mode of 1 to 2 layers is: U1+ & 15.1 & 22.2 & 28.1 & 33.2 & 39.1 & 46.2 & 52.1 & 57.2 & 63.1 & 70.2 & 4.1 & 9.2; The connection mode of the 3-to-4-layer forward cross-layer structure is: 15.3 & 22.4 & 28.3 & 33.4 & 39.3 & 46.4 & 52.3 & 57.4 & 63.3 & 70.4 & 4.3 & 9.4; The 5-to-6-layer forward cross-layer structure connection method is: 15.5 & 22.6 & 28.5 & 33.6 & 39.5 & 46.6 & 52.5 & 57.6 & 63.5 & 70.6 & 4.5 & 9.6; The 7-to-8-layer forward cross-layer structure connection method is: 15.7 & 22.8 & 28.7 & 33.8 & 39.7 & 46.8 & 52.7 & 57.8 & 63.7 & 70.8 & 4.7 & 9.8; The 8-to-7-layer reverse cross-layer structure connection method is: 15.8 & 10.7 & 4.8 & 69.7 & 63.8 & 58.7 & 52.8 & 45.7 & 39.8 & 34.7 & 28.8 & 21.7; The 6-to-5-layer reverse cross-layer structure connection method is: 15.6 & 10.5 & 4.6 & 69.5 & 63.6 & 58.5 & 52.6 & 45.5 & 39.6 & 34.5 & 28.6 & 21.5; The 4-to-3-layer reverse cross-layer structure connection method is: 15.4 & 10.4 & 4.4 & 69.3 & 63.4 & 58.3 & 52.4 & 45.3 & 39.4 & 34.3 & 28.4 & 21.3; The 2-to-1 reverse cross-layer structure connection method is: 15.2 & 10.1 & 4.2 & 69.1 & 63.2 & 58.1 & 52.2 & 45.1 & 39.2 & 34.1 & 28.2 & 21.1 & U1-; The electrical connection mode of the second branch of the U-phase winding double branch is: The connection mode of the 1-to-2-layer forward cross-layer structure is: U2+ & 16.1 & 21.2 & 27.1 & 34.2 & 40.1 & 45.2 & 51.1 & 58.2 & 64.1 & 69.2 & 3.1 & 10.2; The connection mode of the 3-to-4-layer forward cross-layer structure is: 16.3 & 21.4 & 27.3 & 34.4 & 40.3 & 45.4 & 51.3 & 58.4 & 64.3 & 69.4 & 3.3 & 10.4; The 5-to-6-layer forward cross-layer structure connection method is: 16.5 & 21.6 & 27.5 & 34.6 & 40.5 & 45.6 & 51.5 & 58.6 & 64.5 & 69.6 & 3.5 & 10.6; The 7-to-8-layer forward cross-layer structure connection method is: 16.7 & 21.8 & 27.7 & 34.8 & 40.7 & 45.8 & 51.7 & 58.8 & 64.7 & 69.8 & 3.7 & 10.8; The 8-to-7-layer reverse cross-layer structure connection method is: 16.8 & 9.7 & 3.8 & 70.7 & 64.8 & 57.7 & 51.8 & 46.7 & 40.8 & 33.7 & 27.8 & 22.7; The 6-to-5-layer reverse cross-layer structure connection method is: 16.6 & 9.5 & 3.6 & 70.5 & 64.6 & 57.5 & 51.6 & 46.5 & 40.6 & 33.5 & 27.6 & 22.5; The 4-to-3-layer reverse cross-layer structure connection method is: 16.4 & 9.4 & 3.4 & 70.3 & 64.4 & 57.3 & 51.4 & 46.3 & 40.4 & 33.3 & 27.4 & 22.3; The 2-to-1 reverse cross-layer structure connection method is: 16.2 & 9.1 & 3.2 & 70.1 & 64.2 & 57.1 & 51.2 & 46.1 & 40.2 & 33.1 & 27.2 & 22.1 & U2-; The wiring rules of the V-phase winding and the W-phase winding are the same as those of the U-phase winding, wherein: the V-phase winding is obtained by rotating 4 slots relative to the U-phase winding in the direction of increasing slot positions, and the W-phase winding is obtained by rotating 8 slots relative to the U-phase winding in the direction of increasing slot positions; U1+ and U2+ are connected to serve as the U-phase winding input terminal; V1+ and V2+ are connected to serve as the V-phase winding input terminal; W1+ and W2+ are connected to serve as the W-phase winding input terminal; U1-, U2-, V1-, V2-, W1- and W2- are connected to the neutral point copper bus (500) and serve as the neutral point of the double-branch star connection.

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