Double-layer wave winding pad and power-related component with double-layer wave winding pad
By alternately arranging conductor strips in the double-layer waveform winding pad, the design of odd-number winding layers is achieved, the problem of even-number limiting the number of conductor segments in the prior art is solved, the power and torque requirements of the motor are met, and the Weight and installation space requirements.
Patent Information
- Application Number
- CN202380040995.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Priority Date
- 2022-05-17
- Filing Date
- 2023-05-12
- Publication Date
- 2024-12-31
AI Technical Summary
The number of conductor segments of existing double-layer corrugated winding pads must be even, resulting in difficult to meet power and torque requirements, resulting in increased motor weight and installation space requirements.
A double-layer corrugated winding pad is designed, wherein the conductor strips of the first pad and the second pad are arranged alternately, the starting area and the terminating area are formed of a single pad and overlap in pairs in the intermediate region to achieve an odd number of winding layers. Wave-shaped winding pad.
A waveform winding pad with odd-numbered layers is realized, meeting the motor's specific torque and power requirements, reducing weight and installation space requirements while maintaining cost-effectiveness.
Smart Images
Figure CN119234373A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to a double-layer wave winding mat for a stator or rotor (hereinafter referred to as a power-related component) of a motor, a power-related component having such a winding mat, a motor having such a power-related component, and a vehicle having such a motor. Background Art
[0002] The electric motor for vehicles consists of a stator and a rotor as power generating components. Both components consist of mutually insulated laminated sheets stacked on top of each other, which form a cylindrical laminated sheet stack and are each configured as a ring with surrounding slots. These slots are surrounded by a plurality of individual conductors, which are usually flat wires made of copper or conductor strands made of a plurality of individual conductors connected in parallel to each other, and each form a winding of a coil.
[0003] One method of winding these coils is the wave winding technique. For this purpose, wave winding mats are usually prepared, which are inserted into the slots and then contacted. It is important here to isolate all elements of the power generation assembly from one another, for example using films or paper. Finally, the slots are closed with a cover sheet and cast with a casting medium to improve durability and insulation.
[0004] Wave winding is advantageous because this type of winding is particularly cost-effective and can be automated. Furthermore, wave winding achieves better motor performance than conventional concentrated winding.
[0005] During wave winding, the conductor is repeatedly guided through a slot, across a fixed number of slots, and through another slot. The area of the conductor that spans multiple slots is called the winding head, and the area guided in the slot is the conductor segment. The power generation component of the motor is completely wrapped by multiple conductors in multiple winding layers. Here, the winding layer of the conductor is the radial position of the conductor in the corresponding slot. For the highest efficiency, high running smoothness and high robustness, it is necessary to adjust the direction of the individual conductors with respect to each other in a targeted manner. In addition, it is also necessary to change the arrangement of the individual conductors in the winding layer in the slot step.
[0006] In order to meet specific requirements for torque and power with the motor, it is necessary to design the machine with a number of turns adapted to the structural length. For a wave winding pad, the number of turns is determined by the number of conductor segments (bars) guided in the slots of the machine and the number of conductors connected to each other in parallel in the wave winding pad according to the formula w=p*q*z / a, where w is the effective number of turns of the machine, n is the number of conductor segments per slot, a is the number of conductors connected in parallel in the wave winding pad, p is the number of pole pairs, and q is the number of slots (number of holes) per pole and phase. Therefore, n=2*p*q*r, where n is the total number of slots and r is the number of phases of the machine.
[0007] In most methods known in the prior art for producing wave winding mats, the individual conductors or conductor strands are wound offset from one another in the same winding direction, wherein they are interwoven by layer changes. If installed in the slots of a stator or rotor, the conductor segments are then all located in one winding layer and are therefore understood as a single-layer (one-layer) wave winding mat.
[0008] During this period, a method for integrating two single-layer wave winding pads with each other and making them into a double-layer wave winding pad was also developed, in which the conductors or conductor strands were wound in opposite directions and interwoven by layer transformation. Finally, a wave winding pad can be manufactured, which has only half the length and has the same effective number of turns as the same single-layer wave winding pad in the winding pattern. This means saving a lot of time, thereby reducing manufacturing costs. The disadvantage here is that the number of conductor segments (number of winding layers) per slot is no longer freely selectable, but must always be an even number, and the number of layers, the number of conductors connected in parallel in the wave winding, and the possible combinations of the number of holes are very limited. This results in most of them having to significantly exceed the power and torque requirements of the motor, which results in higher weight and installation space requirements. Summary of the invention
[0009] The object of the present invention is to modify a double-layer wave winding mat so that an odd number of winding layers for a winding can be achieved with the wave winding mat. The object of the present invention is also to provide a power-related component having such a wave winding mat, an electric machine having such a power-related component, and a vehicle having such an electric machine.
[0010] A double-layer wave-wound mat, which is formed by a first mat and an identical second mat each having at least one conductor strand, the conductor strand comprising at least one conductor, which is formed into parallel strips in a repeated winding pattern and a winding head connecting the strips to each other, wherein the strips of the first mat and the strips of the second mat are alternately arranged in first and second mat surface layers, and the purpose of the wave-wound mat is achieved in that the first mat and the second mat are arranged offset from each other in a longitudinal direction perpendicular to the strips, so that a single-layer starting area is formed only by the first mat of the wave-wound mat, and a single-layer ending area is formed only by the second mat of the wave-wound mat, and between the starting area and the ending area, the strips of the first mat and the strips of the second mat are respectively arranged in pairs overlapping each other.
[0011] The start region and the end region advantageously have the same length.
[0012] A power-related component for an electric machine, comprising a lamination stack having a plurality of radially extending slots and a double-layer wave-wound winding mat according to the invention inserted into the slots to form a plurality of concentric winding layers, the purpose of the power-related component being achieved in that a starting region is arranged in the first winding layer of the winding layers and an ending region is arranged in the last winding layer of the winding layers, and the starting region and the ending region have a total length which is equal to the length of a segment of the wave-wound winding mat arranged in one of the winding layers.
[0013] Advantageously, the starting region covers a first half in a first winding layer of the winding layers and the ending region covers a second half in a last winding layer of the winding layers.
[0014] Advantageously, the input end of at least one conductor of the first mat and the input end of at least one conductor of the second mat are arranged oppositely in the last winding layer of the winding layer, and the output end of at least one conductor of the first mat and the output end of at least one conductor of the second mat are arranged oppositely in the first winding layer of the winding layer.
[0015] The object is achieved for an electric machine in that the electric machine comprises a power-related component according to the invention.
[0016] The object is achieved for a vehicle in that the vehicle comprises an electric machine having a power-related component according to the invention.
[0017] It goes without saying that the features mentioned above and the features still to be explained below can be used not only in the combination specified but also in other combinations or alone, without departing from the scope of the present invention.
[0018] The present invention will be explained in more detail below with reference to the accompanying drawings by means of embodiments, and the accompanying drawings also disclose important features of the present invention. These embodiments are only for illustration and should not be interpreted in a limiting sense. For example, the description of the embodiment with multiple elements or assemblies should not be interpreted as meaning that all these elements or assemblies are necessary for implementation. On the contrary, other embodiments may also include alternative elements and assemblies, fewer elements or assemblies, or additional elements or assemblies. Unless otherwise indicated, the elements or assemblies of different embodiments may be combined with each other. The modifications and variations described for one of the embodiments may also be applied to other embodiments. In order to avoid repetition, the same or corresponding elements in different drawings are represented by the same reference numerals and are not explained again for many times. BRIEF DESCRIPTION OF THE DRAWINGS
[0019] Figure 1 A wave winding mat having two conductors is shown;
[0020] Figure 2 A winding pattern for an embodiment of a wave winding mat;
[0021] Figure 3 The basis for installing power-related components in the slots Figure 2 The winding pattern of the wave winding pad;
[0022] Figure 4 Schematic diagram of top view of installed wave winding pad. DETAILED DESCRIPTION
[0023] exist Figure 1 , a double-layer wave winding mat according to the present invention is shown, which is simplified to show only one conductor for each mat. The double-layer wave winding mat is formed by a first mat 1 and a second mat 2 arranged offset from each other in the longitudinal direction R. Only one conductor shown for the first mat 1 is formed by a plurality of connecting bars 3 and a winding head 4 connecting these connecting bars to each other, and is shown here as a dotted line. Only one conductor shown for the second mat 2 is formed by the same number of connecting bars 3 and a winding head 4 connecting these connecting bars to each other, and is shown here as a solid line. All connecting bars 3 extend parallel to each other, wherein adjacent connecting bars in the longitudinal direction R have a predetermined distance from each other, which is equal to a multiple of the slot spacing of the power-related component of the motor, and the wave winding mat is specifically designed for this component.
[0024] The connecting strip 3 of the first mat 1 represents Figure 2 A conductor segment of a conductor U1 , U2 , W1 , W2 , V1 or V2 having a winding pattern as shown.
[0025] The connecting strip 3 of the second mat 1 represents Figure 2 A conductor segment of conductor U3, U4, W3, W4, V3 or V4 having a winding pattern as shown.
[0026] If the conductor shown of the first mat 1 is assumed to be a U1 conductor, this conductor will be installed in every 6 slots starting from the first slot. The predetermined distance between adjacent strips 3 of the conductor is therefore equal to 6 times the slot spacing.
[0027] These conductors have layer steps in the winding head 4, so that the connecting strips 3 are arranged alternately in the first cushioning layer E1 and the second cushioning layer E2, as shown in FIG. Figure 2 For example, it can be clearly seen by the starting area through the joint position 1-24. In the double-layer area between the starting area 5 and the end area 6, the first mat 1 and the second mat are interwoven there, and the joint 3 is stacked up and down in the first mat surface E1 and the second mat surface E2. Figure 1 The upper connecting strip 3, ie, located in the second cushioning surface E2, is shown in each case.
[0028] exist Figure 2An advantageous embodiment of a wave winding mat is shown in a winding pattern. The wave winding mat has 3x48=144 mutually parallel connecting bars in the starting and ending areas and connecting bar pairs in the double-layer area between them. Each parallel connecting bar 3 or connecting bar pair is located at a numbered connecting bar position. The starting area 5 and the ending area 6 each include 48 / 2=24 connecting bars 3, so that the length of the starting area 5 and the ending area 6 are the same and are each one-fourth of the length of the double-layer area. They can also be designed to have different lengths, as long as the sum of the connecting bars 3 in the starting area 5 and the ending area 6 is equal to the number 48. The number of phases of the wave winding mat shown here is r=3, which are marked with U, V and W. The number of holes in the wave winding mat is q=2, that is, each phase and pole occupies two connecting bar positions side by side.
[0029] Figure 3 Shown according to Figure 2 The winding pattern of a wave winding mat, which is installed into the slot of the power-related component of the electric machine.
[0030] The power-related component has 48 slots, so the wave winding mat with 144 terminals or terminal pairs is installed in the slots in three complete turns. By radially pressing the wave winding mat, the terminals 3 at terminal positions 1 to 24 are located in the first winding layer L1, the terminal pairs at terminal positions 25 to 48 are located in the first and second winding layers L2, L3, and the subsequent terminals are stacked up more and more until five terminals are installed in each of the 48 slots and a five-layer winding is formed.
[0031] exist Figure 4 Schematically shows the installed wave winding mat in a top view. The single-layer starting area 5, the double-layer area and the single-layer ending area 6 can be seen by showing different radial thicknesses. The output end 8 of the conductor of the first mat 1 (which alone forms the starting area 5) and the output end 8 of the second mat 2 (at the transition to the double-layer area of the wave winding mat) are arranged relatively on the radial outside. The input end 7 of the conductor of the second mat 2 (which alone forms the ending area 6) and the input end 7 of the first mat (at the transition to the double-layer area of the wave winding mat) are arranged relatively on the radial inside.
[0032] List of Reference Numerals
[0033] 1 First pad
[0034] 2 Second pad
[0035] 3. Joining
[0036] 4 Winding head
[0037] 5 Starting Area
[0038] 6 Termination area
[0039] 7 Conductor input
[0040] 8 Conductor output
[0041] E1 First cushioning surface
[0042] E2 Second cushioning surface
[0043] L1-L5 The first to fifth winding layers
[0044] wEffective turns
[0045] The number of conductor segments per slot = the number of winding layers
[0046] aThe number of conductors connected to each other in parallel
[0047] p Pole pairs
[0048] q Number of holes
[0049] n Total number of slots
[0050] r Phase number
[0051] R Longitudinal direction
Claims
1. A double-layer wave winding mat for a power-related component of an electric machine, the wave winding mat being formed by a first mat (1) and an identical second mat (2) each having at least one conductor strand, the conductor strand comprising at least one conductor formed as parallel webs (3) and winding heads (4) connecting the webs to one another, wherein: The connecting strips (3) of the first mat (1) and the connecting strips (3) of the second mat (2) are alternately arranged in a first mat surface layer (E1) and a second mat surface layer (E2), characterized in that the first mat (1) and the second mat (2) are arranged offset from each other in a longitudinal direction (R) perpendicular to the connecting strips (3), so that a starting area (5) of a single layer is formed only by the first mat (1), and an ending area (6) of a single layer is formed only by the second mat (2), and between the starting area (5) and the ending area (6), the connecting strips (3) of the first mat (1) and the connecting strips (3) of the second mat (2) are arranged in pairs overlapping each other.
2. The double-layer wave winding pad according to claim 1, characterized in that: The starting region (5) and the ending region (6) have the same length.
3. A power-related component for an electric machine, comprising a cylindrical lamination stack having a plurality of radially extending slots and a double-layer wave winding mat according to claim 1 or 2 inserted into the slots to form a plurality of concentric winding layers (L1-L5), characterized in that: The starting area (5) is arranged in the first winding layer (L1) of the winding layers, and the terminating area (6) is arranged in the last winding layer (L5) of the winding layers, and the starting area (5) and the terminating area (6) have a total length, which is equal to the length of the segment of the wave winding pad arranged in one of the winding layers (L1-L5).
4. The power-related component for an electric motor according to claim 3, characterized in that: The starting region (5) covers a first half in the first winding layer (L1) of the winding layers, and the ending region (6) covers a second half in the last winding layer (L5) of the winding layers.
5. The power-related component according to claim 3 or 4, characterized in that: An input end of at least one conductor of the first pad (1) and an input end (7) of at least one conductor of the second pad (2) are arranged opposite to each other in the last winding layer (L5) of the winding layer, and an output end of at least one conductor of the first pad (1) and an output end (8) of at least one conductor of the second pad (2) are arranged opposite to each other in the first winding layer (L1) of the winding layer.
6. An electrical machine having power-related components according to any one of claims 3 to 5.
7. A vehicle comprising the electric machine according to claim 6.