Six-phase flat wire wave winding motor

Abstract

A six-phase flat wire wave winding motor disclosed by the present invention comprises a shell and a stator, the stator comprises a stator iron core and a phase winding wound on the stator iron core, the phase winding comprises two groups of three-phase wave windings which are arranged at an interval of 180 degrees in the circumferential direction, and each phase wave winding comprises two coil ring groups which are arranged at a staggered position of one magnetic pole in the circumferential direction. Each coil ring group comprises at least one coil ring, each coil ring comprises P single coils, and P is the number of pole pairs; each single coil comprises two supporting feet which are bent in opposite directions in the circumferential direction, the supporting feet of the P single coils are sequentially connected in series in the circumferential direction to form a coil ring, and the supporting feet located at the two ends of the coil ring form connecting feet. Wherein the connecting pin positioned on the outermost side of one coil ring group is reversely bent in a deflection manner and is connected with the connecting pin positioned on the outermost side of the other coil ring group in a welding manner side by side. The hairpin has the advantages that the structural design is reasonable, the hairpin types can be reduced, and the assembly difficulty and the manufacturing cost can be reduced.

Description

Technical Field

[0001] The invention relates to the technical field of flat wire motors, and in particular to a six-phase flat wire wave winding motor. Background Art

[0002] In recent years, miniaturization and high speed have become the main development trends of new energy electric vehicle motors. Compared with traditional permanent magnet motors, flat wire motors have the characteristics of high copper full rate in their windings, which can greatly improve the torque density and power density of the motors. The winding ends of flat wire motors are relatively short, which can further improve the utilization rate of vehicle space. The larger contact area between the wires effectively enhances the heat dissipation capacity of the motor. Therefore, flat wire motors have good application prospects in new energy electric vehicles.

[0003] Compared with three-phase motors, six-phase motors can offset specific order harmonics, reduce torque pulsation, and improve motor NVH performance; as the number of motor phases increases, the motor fault tolerance is enhanced and the working reliability is higher. The existing technology usually uses a multi-layer wave winding, where each phase winding exists in a different layer of the stator slot, and the lead wire end of each phase is set as a welding end, and the non-lead wire end is a U-shaped wire. However, as the number of motor phases increases, the difficulty of the flat wire winding process increases, and it is difficult to ensure that the span of the U-shaped coil is consistent, and the manufacturing cost increases accordingly. Summary of the invention

[0004] In view of the above-mentioned deficiencies of the prior art, the technical problem to be solved by the present invention is: how to provide a six-phase flat wave winding motor with a reasonable structural design, which can reduce the types of hairpins and help reduce the difficulty of assembly and manufacturing cost.

[0005] In order to solve the above technical problems, the present invention adopts the following technical solutions: A six-phase flat-line wave winding motor comprises a housing and a stator, wherein the stator comprises a stator core and a phase winding wound on the stator core, wherein the phase winding comprises two groups of three-phase wave windings arranged 180° apart in the circumferential direction, wherein the wave winding of each phase comprises two coil ring groups arranged circumferentially offset by one magnetic pole position, wherein each coil ring group comprises at least one coil ring, wherein the coil ring comprises P single coils uniformly arranged in the circumferential direction, where P is the number of pole pairs; wherein the single coil comprises two legs deflected and bent in opposite directions in the circumferential direction, wherein the legs of the P single coils are sequentially connected in series in the circumferential direction to form the coil ring, and the legs at both ends of the coil ring form connecting legs; wherein the innermost or outermost connecting leg on one of the coil ring groups deflects and bends in the opposite direction, and is welded side by side to the innermost or outermost connecting leg on the other coil ring group.

[0006] Furthermore, in each coil ring group, the coil rings are arranged in at least two layers radially side by side, and two adjacent layers of the coil rings are welded connected by radially side by side connecting pins, and the two connecting pins are respectively located at the Nth layer and the N+1th layer of the winding, where N is an even number.

[0007] Furthermore, the single coil includes a hairpin conductor, which includes a hairpin body that is bent in a U-shape as a whole, and the hairpin body includes two leg portions arranged parallel to each other and a head connected to one end of the two leg portions, and the other ends of the two leg portions are bent in opposite directions along the width direction of the hairpin body to form the support foot.

[0008] Furthermore, the single coil includes two hairpin conductors arranged side by side in the thickness direction, the hairpin conductor includes a hairpin body that is bent in a U-shape as a whole, the hairpin body includes two leg portions arranged parallel to each other and a head connected to one end of the two leg portions, the other ends of the two leg portions are connecting sections, and the connecting sections on the two hairpin conductors are deflected and bent in opposite directions in the width direction of the hairpin body, wherein two connecting sections are close to each other and welded together, and the other two connecting sections are deflected in opposite directions to form the supporting feet.

[0009] Furthermore, the single coil also includes an O-shaped conductor arranged side by side with the hairpin conductor in the thickness direction, the O-shaped conductor includes a hairpin body bent in a U shape, the hairpin body includes two leg portions arranged parallel to each other and a head connected to one end of the two leg portions, the other ends of the two leg portions are deflected toward the middle in the width direction of the hairpin body to form a connecting section, and the two connecting sections of the O-shaped conductor are respectively welded to two connecting sections close to each other on the two hairpin conductors.

[0010] Furthermore, the pitch of the hairpin conductor is Y-1, where Y is the pole pitch.

[0011] In summary, the present invention has the advantages of reasonable structural design, being able to reduce the types of hairpins, and being conducive to reducing assembly difficulty and manufacturing cost. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 This is a schematic diagram of the overall structure of Example 1.

[0013] Figure 2 This is a schematic diagram of the structure of the two outermost coil rings of a phase winding in Example 1.

[0014] Figure 3 and Figure 4 They are Figure 2 Schematic diagram of the structure of the two coil rings.

[0015] Figure 5This is a schematic diagram of the structure of a two-layer coil ring of a phase winding.

[0016] Figure 6 This is a schematic diagram of the structure of the phase winding of Example 1.

[0017] Figure 7 to Figure 9 Schematic diagram of the structure of the hairpin conductor in Example 2. DETAILED DESCRIPTION

[0018] The present invention is further described in detail below in conjunction with embodiments.

[0019] Embodiment 1: A six-phase flat wave winding motor, such as Figure 1 As shown, it includes a stator assembly, which includes a stator core 1 and two groups of three-phase wave windings 2 arranged 180° apart in the circumferential direction. The stator core 1 includes a main body that is generally cylindrical. A plurality of stator core slots that are radially open inward are circumferentially arranged on the inner ring of the stator core 8. The lower end of the stator core slot is an insertion side (or crown side), and the upper end is a connection side.

[0020] In this embodiment, Figure 2 to Figure 4 As shown, the number of pole pairs P=4, each phase of the wave winding includes two coil ring groups 3 that are circumferentially offset by one magnetic pole position, each of the coil ring groups 3 includes at least one coil ring 4, the coil ring 4 includes four single coils 5 evenly distributed along the circumference, the single coil 5 includes two legs 6 that are deflected and bent in opposite directions in the circumference, the legs 6 of the four single coils 5 are sequentially connected in series along the circumference to form the coil ring 4, and the legs 6 at both ends of the coil ring 4 form connecting legs 7; the outermost connecting leg 7 on one of the coil ring groups 3 is deflected and bent in the opposite direction, and is welded side by side with the outermost connecting leg 7 on the other coil ring group 3. As shown Figure 2 As shown, a connecting leg 7 indicated by a solid line is deflected in the opposite direction and bent to the outside of the connecting leg 7 indicated by a dotted line, and then the connecting legs 7 indicated by the dotted line are placed side by side and welded together.

[0021] In this embodiment, the single coil 5 includes a hairpin conductor, and the hairpin conductor includes a hairpin body that is bent in a U-shape as a whole. The hairpin body includes two leg portions 51 arranged parallel to each other and a head 52 connected to one end of the two leg portions 51. The other ends of the two leg portions 51 are bent in opposite directions along the width direction of the hairpin body to form the support foot 6.

[0022] like Figure 5As shown, in each coil ring group 3, the coil ring 4 is arranged in two layers in parallel in the radial direction, and the two adjacent layers of the coil ring 4 are welded together by radially parallel connecting pins 7, and the two connecting pins are respectively located at the Nth layer and the N+1th layer of the winding, where N is an even number. In this embodiment, each stator core slot has four leg portions, and the connecting pins are located at the second and third layers of the winding from the inside to the outside.

[0023] Figure 6 The figure shows two phase windings arranged 180° apart in the circumferential direction, and the power connection lines of the two phase windings are located at both ends of the stator radial direction. In any phase winding, the connection pin 7 located on the outside of one coil ring 4 is reversely deflected and bent, and is welded side by side with the connection pin 7 located on the outside of the other coil ring 4 in the same phase, as shown in the mark A and mark B in the figure.

[0024] In this embodiment, the outermost connecting pin on one coil ring is reversely deflected and bent to the connecting pin of another coil ring and welded side by side, so that the two can be connected in series without the need for additional jumpers. In the assembled state, it is only necessary to deflect the connecting pin that needs to be reversed outward by one layer and then bend it in the reverse direction, which is convenient for subsequent automated welding operations, thereby improving assembly efficiency and improving assembly quality. At the same time, the above structure constitutes a six-phase winding, with an electrical angle difference of 60 degrees for each phase. It can be operated with either a single winding or a double winding. The motor has a wider high-efficiency area, and the heat generated by the whole machine is greatly reduced, which makes the harmonic components lower and the noise reduced.

[0025] Embodiment 2: The main difference between this embodiment and embodiment 1 is that the structure of the single coil is different. Specifically, the single coil includes two hairpin conductors arranged side by side in the thickness direction. The hairpin conductor includes a hairpin body that is bent in a U-shape as a whole. The hairpin body includes two leg portions 51 arranged parallel to each other and a head portion 52 connected to one end of the two leg portions 51. The other ends of the two leg portions 51 are connecting sections 53. The connecting sections 53 on the two hairpin conductors are bent in opposite directions in the width direction of the hairpin body, such as Figure 7 and Figure 8 As shown, two connecting sections 53 are close to each other and welded together, and the other two connecting sections 53 are deflected in opposite directions to form the supporting feet.

[0026] The single coil further includes an O-shaped conductor arranged side by side with the hairpin conductor in the thickness direction, the O-shaped conductor includes a hairpin body bent in a U shape, the hairpin body includes two legs 51 arranged parallel to each other and a head 52 connected to one end of the two legs, and the other ends of the two legs 51 are deflected toward the middle in the width direction of the hairpin body to form a connecting section 53. Fig. 9As shown, the two connecting sections of the O-shaped conductor are respectively connected by welding to two connecting sections on the two hairpin conductors that are close to each other.

[0027] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A six-phase flat wave winding motor, comprising a housing and a stator, wherein the stator comprises a stator core and a phase winding wound on the stator core, characterized in that: The phase winding includes two groups of three-phase wave windings arranged 180° apart in the circumferential direction, and each phase of the wave winding includes two coil ring groups arranged with a magnetic pole position offset in the circumferential direction, and each of the coil ring groups includes at least one coil ring, and the coil ring includes P single coils evenly distributed in the circumferential direction, where P is the number of pole pairs; the single coil includes two legs deflected and bent in opposite directions in the circumferential direction, and the legs of the P single coils are connected in series in sequence along the circumferential direction to form the coil ring, and the legs located at both ends of the coil ring form connecting legs; the innermost or outermost connecting leg on one of the coil ring groups is deflected and bent in the opposite direction, and is welded side by side with the innermost or outermost connecting leg on the other coil ring group.

2. The six-phase flat wave winding motor according to claim 1, characterized in that: In each coil ring group, the coil rings are arranged in at least two layers radially side by side, and two adjacent layers of the coil rings are welded together by radially side by side connecting pins, and the two connecting pins are respectively located at the Nth layer and the N+1th layer of the winding, where N is an even number.

3. The six-phase flat wave winding motor according to claim 1 or 2, characterized in that: The single coil includes a hairpin conductor, which includes a hairpin body that is bent in a U-shape as a whole. The hairpin body includes two legs arranged parallel to each other and a head connected to one end of the two legs. The other ends of the two legs are bent in opposite directions along the width direction of the hairpin body to form the legs.

4. The six-phase flat wave winding motor according to claim 1 or 2, characterized in that: The single coil includes two hairpin conductors arranged side by side in the thickness direction, the hairpin conductor includes a hairpin body that is bent in a U-shape as a whole, the hairpin body includes two leg parts arranged parallel to each other and a head connected to one end of the two leg parts, the other ends of the two leg parts are connecting sections, and the connecting sections on the two hairpin conductors are bent in opposite directions in the width direction of the hairpin body, wherein two connecting sections are close to each other and welded together, and the other two connecting sections are deflected in opposite directions to form the supporting feet.

5. The six-phase flat wave winding motor according to claim 4, characterized in that: The single coil also includes an O-shaped conductor arranged side by side with the hairpin conductor in the thickness direction, the O-shaped conductor includes a hairpin body bent in a U shape, the hairpin body includes two leg parts arranged parallel to each other and a head connected to one end of the two leg parts, the other ends of the two leg parts are deflected toward the middle in the width direction of the hairpin body to form a connecting section, and the two connecting sections of the O-shaped conductor are respectively welded to two connecting sections close to each other on the two hairpin conductors.

6. The six-phase flat wave winding motor according to any one of claims 3 to 5, characterized in that: The pitch of the hairpin conductor is Y-1, where Y is the pole pitch.

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