An integer-slot concentrated pitch-flat wire winding structure and a flat wire motor

Abstract

The application discloses an integer-slot concentrated pitch flat wire winding structure and a flat wire motor, and relates to the technical field of motors.The integer-slot concentrated pitch flat wire winding structure comprises one or more coil units for each branch of each phase, each coil unit is composed of four coil groups, the first coil group and the third coil group each comprise one same-layer hairpin, the second coil group comprises N / 2-1 cross-layer hairpins, two effective conductors of the cross-layer hairpin are located in adjacent layer flat wires in different slots, and the fourth coil group is obtained by rotating the second coil group by m stator slots in the circumferential direction, wherein m is the number of winding motor phases.The stator adopts the pitch winding, is matched with the concentrated winding scheme with the slot number of each pole and each phase being 1, and the motor can obtain the maximum winding coefficient;the application only needs N / 2+1 hairpins, reduces the hairpin types, and thus the purposes of reducing the processing difficulty, assembly complexity, manufacturing cost and maintenance difficulty of the flat wire winding are achieved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of electric machines, in particular to the technical field of flat wire electric machines, and more particularly to an integer-slot concentrated integral pitch flat wire winding structure and a flat wire electric machine. BACKGROUND

[0002] As a device for realizing the mutual conversion between electric energy and mechanical energy according to the principle of electromagnetic induction, an electric machine plays a vital role in various electrical appliances and mechanical fields, such as household appliances, electric vehicles, and electric cars, and can provide power sources for these devices or serve as a power generation device. According to the types of power sources, electric machines can be divided into two categories: DC machines and AC machines, and AC machines can be further divided into single-phase machines and multi-phase machines. An electric machine mainly consists of a stator and a rotor, and the stator core slot is provided with a winding.

[0003] Currently, there are mainly two types of winding forms for electric machines: wave winding and lap winding. For segmented hairpin winding electric machines using flat copper wire or rectangular cross-section copper wire, using lap winding will result in excessive number of cross-over conductors between lap windings, thereby increasing the amount of ineffective copper. Therefore, such electric machines usually choose wave winding.

[0004] For example, in the invention patent application publication with the application publication number CN118659564A and the application publication date of September 17, 2024, entitled "A flat wire winding structure", the flat wire winding structure includes a stator core, and the upper and lower sides of the stator core are respectively set as the connection side and the insertion side of the flat wire. On the inner side of the stator core, a plurality of uniformly distributed axial insertion slots are formed along the circumferential direction. The winding pole number of this flat wire winding structure is 2p, the slot number of the axial insertion slot is m, and 2n layers of conductors are arranged in each axial insertion slot, and a flat wire U-shaped hairpin is inserted in the axial insertion slot. The flat wire U-shaped hairpin includes three pitch structures: integral pitch Y1=m / 2p, long pitch Y2≥Y1+1, and short pitch Y3≤Y1-1, and satisfies the relationship Y2-Y3=m / 2p / 3, and adopts a cross-layer structure of adjacent two layers. The invention patent application adopts a single-branch delta connection or a single-branch star connection or a double-branch star connection, and through these three connection methods, the electric potential can be kept balanced, there is no circulating current problem, and the winding structure is relatively simple and does not exist special-shaped wire.

[0005] However, the above-mentioned flat wire winding structure disclosed in the prior art is only applicable to single-branch or double-branch winding motors. Meanwhile, due to the involvement of three pitch structures of full pitch, long pitch and short pitch, the types of flat wire hairpins increase, which undoubtedly increases the difficulty in processing, the complexity in assembly, the cost in manufacturing and the difficulty in subsequent maintenance of the flat wire winding and the flat wire motor. SUMMARY

[0006] In order to overcome the defects and deficiencies in the prior art, the present application provides an integer slot concentrated full-pitch flat wire winding structure and a flat wire motor. The purpose of the present application is to solve the problems of high difficulty in processing, high complexity in assembly, high cost in manufacturing and high difficulty in maintenance caused by the large number of types of flat wire hairpins used in the flat wire winding structure of the prior art.

[0007] The integer slot concentrated full-pitch flat wire winding structure of the present application has 1 slot per phase per level, all stator windings under a single rotor pole of a certain phase are in the same stator slot, there are N layers of flat wires in each stator slot, N is an even number and N is greater than or equal to 4, the flat wires under different rotor poles of the same phase are connected by hairpins, each branch of each phase contains one or more coil units, each coil unit is composed of four coil groups, the first coil group and the third coil group each contain one hairpin of the same layer, the second coil group is a diagonal span area and contains N / 2-1 span layer hairpins, the two effective conductors of the span layer hairpin are located in adjacent layer flat wires in different slots, the fourth coil group is obtained by rotating the second coil group by m stator slots in the circumferential direction, m is the number of phases of the winding motor, all hairpins are full-pitch hairpins, and the span of the two effective conductors of all welding parts of the four coils is full-pitch. The stator of the present application adopts full-pitch winding, matches the concentrated winding scheme with 1 slot per phase per pole, and the motor can obtain the maximum winding coefficient. The winding connection scheme can form a closed loop at the beginning and the end, that is, any welding end position can form a winding branch. The present application only needs N / 2+1 types of hairpins, which reduces the types of hairpins, thereby achieving the purposes of reducing the difficulty in processing, the complexity in assembly, the cost in manufacturing and the difficulty in maintenance of the flat wire winding.

[0008] In order to solve the problems in the prior art, the present application is realized by the following technical scheme.

[0009] The first aspect of the present application provides an integer slot concentrated full-pitch flat wire winding structure, comprising a stator core, the upper and lower sides of the stator core are respectively a connection side and an insertion side of the flat wire, the stator core is an integer slot stator core, the number of slots per phase per level of the flat wire winding structure is 1;

[0010] All stator windings under a single rotor pole of a certain phase are in the same stator slot, and there are N layers of flat wires in each stator slot, N is an even number, and N is greater than or equal to 4; the flat wires under different rotor poles of the same phase are connected by hairpins; each branch of each phase contains one or more coil units, each coil unit is composed of four coil groups, which are first coil group, second coil group, third coil group and fourth coil group, and the adjacent coil groups are connected in sequence through the welding ends of the two adjacent hairpins in the circumferential direction; wherein, the first coil group and the third coil group each contain a same layer hairpin, the two effective conductors of the same layer hairpin are located in the same layer flat wire in different slots, and belong to the first layer or the Nth layer flat wire respectively; the second coil group and the fourth coil group are both in the diagonal span area, and contain N / 2-1 span layer hairpins, the two effective conductors of the span layer hairpin are located in the adjacent layer flat wire in different slots, and are connected in sequence; the fourth coil group is rotated by m stator slots from the second coil group along the circumferential direction of the stator core, and m is the number of phase windings; the same layer hairpin and the span layer hairpin are both integral distance hairpins; the two effective conductors of all welding parts of the four coil groups have the same span, which is integral distance.

[0011] Further preferably, the coil units are sequentially rotated by m stator slots in the clockwise or counterclockwise direction along the circumferential direction of the stator core, m is the number of phase windings; p coil units are formed, p is the number of pole pairs; according to the slot number sequence of the stator slot, the outlet of the outgoing segment of the previous coil unit in the adjacent coil unit is connected with the inlet of the next coil unit to form a branch of a phase winding; the head and tail are separated by an integral distance in the adjacent layers.

[0012] More preferably, the corresponding welding ends are disconnected according to different outgoing positions and busbars, and the multiple coil units are connected in series and parallel to form k branches, k is a divisor of the number of pole pairs p.

[0013] More preferably, all branches of a phase winding are sequentially rotated by 1 to m-1 stator slots in the clockwise or counterclockwise direction to obtain the connection mode of the other m-1 phase windings.

[0014] Further preferably, the same layer hairpin and the span layer hairpin each include two slot effective conductors, hairpin end parts for connection, and two welding end parts for welding.

[0015] More preferably, the two effective conductors on the hairpin are in different slots of the same phase winding, and the difference in the number of stator slots spanned by the hairpin is the span of the hairpin, which is integral distance.

[0016] Further preferably, the effective conductors of the same layer hairpin located in the higher layer are in the clockwise direction of the effective conductors of the lower layer, and the effective conductors of the span layer hairpin located in the higher layer are in the clockwise direction of the effective conductors of the lower layer.

[0017] Further preferably, the same-layer hairpins are located at the effective conductors of the high layer in the counterclockwise direction of the effective conductors of the low layer, and the cross-layer hairpins are located at the effective conductors of the high layer in the counterclockwise direction of the effective conductors of the low layer.

[0018] Further preferably, the first and last ends of each cross-layer hairpin are connected in sequence, and the first-layer flat wire close to the inner side of the stator is radially inserted into the Nth-layer flat wire on the outer side of the stator along the stator core, or the Nth-layer flat wire close to the outer side of the stator is radially inserted into the first-layer flat wire on the inner side of the stator along the stator core.

[0019] The second aspect of the present application provides an integer-slot concentrated-pitch flat wire motor, which comprises the integer-slot concentrated-pitch flat wire winding structure and a rotor coaxially arranged in the stator core of the flat wire winding structure.

[0020] Compared with the prior art, the present application has the beneficial technical effects of:

[0021] 1. In the manufacturing process of the flat wire motor stator winding, different types of hairpins are usually required to be opened. However, the present application has the advantage of requiring only N / 2+1 types of hairpins to meet the construction requirements of the entire stator winding. Compared with the traditional manufacturing process which may require multiple types of hairpins, this greatly reduces the number of mold openings. The development of each type of hairpin mold involves high cost investment, including mold design, raw material procurement, processing and manufacturing, and subsequent debugging. By simplifying the types of hairpins, the present application directly saves a large number of unnecessary mold opening processes and related costs, significantly reducing the mold opening cost and saving considerable funds for enterprises in the production and manufacturing process. For example, if a similar flat wire motor stator winding is manufactured according to the traditional method, 10 different types of hairpins may be required, and the cost of opening each type of hairpin is assumed to be 50,000 yuan. Therefore, the mold opening cost is as high as 500,000 yuan. However, by using the present application, only 5 types of hairpins (assuming N is 8) are required, and the mold opening cost is only 250,000 yuan, which is a very obvious cost reduction effect.

[0022] 2. Different types of hair clips often imply different shapes, sizes, torsion angles, and assembly requirements, making the manufacturing process extremely complex. When embedding the hair clips into the stator slots and performing subsequent connection and assembly operations, the variety of complex hair clip types increases the number of operational steps and precision requirements. However, this invention greatly simplifies this process by requiring only N / 2+1 types of hair clips. Production personnel no longer need to deal with a wide variety of hair clips with different characteristics. In the processing and manufacturing stages, such as shaping, cutting, and torsion of the hair clips, they can focus more on these limited hair clip types, more easily mastering the key processing points and ensuring the stability of processing quality. In the assembly stage, accurately installing the hair clips into the stator slots and completing the correct connection is also crucial. Under traditional processes, the numerous different types of hair clips require assembly personnel to remember complex information such as the placement and connection methods of various hair clips. Even slight carelessness can lead to assembly errors, affecting the performance of the motor or even its normal operation. This invention simplifies the types of hairpins. Assembly personnel only need to be familiar with the assembly requirements of these few types of hairpins to complete the stator winding assembly work more efficiently and accurately, effectively reducing the difficulty of the manufacturing process and improving production efficiency and product quality.

[0023] 3. This invention possesses unique advantages, enabling the creation of motor solutions with varying numbers of parallel branches through ingenious series-parallel combinations of different stator winding coil groups. This flexibility is of paramount importance in the research and development and production of flat wire motors, laying a solid foundation for their platform-based development. By establishing such a platform with flexibly adjustable parallel branch numbers, enterprises can rapidly develop flat wire motor products with diverse specifications and performance requirements based on the same infrastructure, tailored to different customer needs, application scenarios, and market positioning. For example, cost-sensitive applications in small electrical appliances may require lower-power flat wire motors with fewer parallel branches; while applications with high power requirements, such as large industrial equipment, require higher-power flat wire motors with more parallel branches. This feature of the invention allows enterprises to meet these diverse needs simply by adjusting the series-parallel combinations of different stator winding coil groups without redesigning the entire motor structure, greatly improving product versatility and scalability, and driving the development of flat wire motors towards platformization.

[0024] 4. In the traditional flat wire motor production process, if you want to produce motors with different parallel branch numbers, you often need to redesign the motor winding structure, re-open the mold, re-adjust the production process and a series of tedious operations, which will undoubtedly cause the production cycle to be greatly extended. The unique series-parallel combination method of the present application realizes the motor scheme with different parallel branch numbers, avoiding these repetitive and time-consuming work. Once the basic stator winding coil group is determined, it can be quickly adjusted according to the specific needs, so as to quickly obtain the motor product with the required parallel branch number. This efficient production method greatly shortens the time interval from design to finished product, effectively reduces the production cycle of the motor, so that the enterprise can respond to market demand more quickly and improve market competitiveness.

[0025] 5. The winding coefficient of the flat wire motor of the present application reaches 1, which is a very ideal state. Winding coefficient is an important indicator to measure the efficiency of motor winding in utilizing magnetic field energy. The closer the value is to 1, the more sufficient the utilization of magnetic field energy by winding. In the present application, the winding coefficient of 1 means that the motor winding can convert the input electrical energy into magnetic field energy in the most efficient way, and there is no energy waste or loss caused by winding structure and other factors in the process of magnetic field generation and interaction. From the perspective of electromagnetic principles, when the winding coefficient is 1, the magnetic field strength generated by the current through the winding is exactly the same as the theoretically optimized magnetic field strength, which makes the motor run more stably and efficiently to generate torque, providing a solid foundation for high-performance operation of the motor.

[0026] 6. Since the winding coefficient of the flat wire motor of the present application is 1, it directly leads to the increase of its torque density. Torque density refers to the torque that the motor can generate in a unit volume, which is a key indicator to measure the dynamic performance of the motor. In practical applications, a larger torque density means that the motor can output more torque in the same volume, which has great advantages for many application scenarios. For example, in the field of electric vehicles, the motor required to drive the vehicle forward or backward needs to have a high torque density, so that it can quickly provide sufficient torque to make the vehicle run smoothly in situations that require more power, such as starting and climbing. The flat wire motor of the present application can better meet these application scenarios with high power requirements, improving the applicability and practicality of the motor.

[0027] 7. Compared with the prior art document CN118659564A cited in the background art, the flat wire winding structure of the present application has significant advantages and characteristics in many key technical points.

[0028] Firstly, the prior art can only adapt to the full-pitch winding with 2 slots per level per phase, while the application sets the number of slots per level per phase to 1, which makes the application more autonomous and flexible in the structure planning and electromagnetic performance matching of the winding, and can be more accurately optimized according to different application requirements.

[0029] Secondly, for the number of hairpins of the flat wire, when facing N layers of flat wires, the prior art requires as many as 2N-1 types of hairpins, which undoubtedly brings heavy burden to the entire manufacturing process, including increasing the processing difficulty, prolonging the production cycle, and increasing the manufacturing cost and many other adverse effects. Unlike the prior art, the application only needs N / 2+1 types of hairpins, and the sharp reduction in the number of hairpins greatly reduces the manufacturing burden, simplifies the production process, and thus improves the production efficiency, and also achieves good results in cost control.

[0030] Thirdly, from the perspective of welding process, the welding end of the prior art exists in every adjacent layer, and this frequent welding arrangement makes the welding process extremely complicated, not only that, but also leads to a high end height of the welding end, which has a certain negative impact on the overall structural compactness and performance stability of the product. The application adopts the mode of adjacent welding of welding ends every two layers, and keeps the welding direction consistent, through this optimization design, the welding process becomes simple and easy to operate, and at the same time, the end height of the welding end is effectively reduced, thereby improving the comprehensive performance and process aesthetics of the product.

[0031] Fourthly, in the application scope of branch winding, the prior art shows strong limitations, and can only be used for single-branch winding. Once double-branch winding is used, busbars must be additionally increased, which undoubtedly brings additional burden in terms of system complexity and cost. On the contrary, the application has wide applicability and can be used for any k-branch winding (k is a divisor of p), and does not need to increase the busbar, providing a more convenient, flexible and economical solution for the design and application of the motor in different application scenarios. BRIEF DESCRIPTION OF DRAWINGS

[0032] Figure 1 is a schematic diagram of a stator structure of an example of the application;

[0033] Figure 2 is a schematic diagram of the distribution of a certain phase winding stator slot of the integer-slot concentrated full-pitch flat wire winding structure of the application;

[0034] Figure 3 is a schematic diagram of the flat wire hairpin structure of the integer-slot concentrated full-pitch flat wire winding structure of the application;

[0035] Figure 4Connection plan view of a coil unit of the concentrated integer-slot distributed-flat- wire winding structure of the application;

[0036] Figure 5 Plan view of all branches of a phase winding of the application;

[0037] Figure 6 Schematic diagram of connection structure of 60-slot 20-pole 10-layer flat wire 1-branch winding;

[0038] Figure 7 Schematic diagram of connection structure of 60-slot 20-pole 10-layer flat wire 5-branch winding;

[0039] Figure 8 Schematic diagram of connection structure of 48-slot 16-pole 8-layer flat wire 4-branch winding;

[0040] Figure 9 Schematic diagram of connection structure of 60-slot 20-pole 10-layer flat wire A-phase winding in the example of the application;

[0041] Figure 10 Schematic diagram of connection structure of 60-slot 20-pole 10-layer flat wire B-phase winding in the example of the application;

[0042] Figure 11 Schematic diagram of connection structure of 60-slot 20-pole 10-layer flat wire C-phase winding in the example of the application;

[0043] Figure 12 Schematic diagram of distribution of 6 kinds of hairpin structures of 10-layer flat wire in the application;

[0044] Figure 13 Schematic diagram of distribution of 6 kinds of hairpin structures of 10-layer flat wire in the application; Figure 12

[0045] The drawings show that: 1, stator core, 2, stator slot, 201, first layer of flat wire, 202, second layer of flat wire, 203, third layer of flat wire, 204, fourth layer of flat wire, 205, fifth layer of flat wire, 206, sixth layer of flat wire, 207, seventh layer of flat wire, 208, eighth layer of flat wire, 209, ninth layer of flat wire, 210, tenth layer of flat wire, 3, inner edge of stator core, 4, outer edge of stator core, 5, hairpin, 501, effective conductor, 502, end of hairpin, 503, welding end, 504, first kind of hairpin, 505, second kind of hairpin, 506, third kind of hairpin, 507, fourth kind of hairpin, 508, fifth kind of hairpin, 509, sixth kind of hairpin, 6, coil unit, 601, first coil group, 602, second coil group, 603, third coil group, 604, fourth coil group. DETAILED DESCRIPTION

[0046] ​The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the specification of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by a person of ordinary skill in the art without creative effort belong to the scope of protection of the present application.

[0047] Embodiment 1

[0048] As a preferred embodiment of the present application, the embodiment discloses an integer-slot concentrated pitch-flat wire winding structure, referring to the drawings in the specification Figure 1 As shown in the drawings, it comprises a stator core 1, the upper and lower sides of the stator core 1 are respectively the connection side and the insertion side of the flat wire, the stator core 1 is an integer-slot stator core, and the number of slots per phase per level of the flat wire winding structure is 1.

[0049] All stator windings under a single rotor pole of a phase are in the same stator slot 2, and there are N layers of flat wires in each stator slot 2, N is an even number, and N≥4. The flat wires under different rotor poles of the same phase are connected by hairpins 5 to form. Each branch of each phase contains one or more coil units 6, and each coil unit 6 is composed of four coil groups, namely a first coil group 601, a second coil group 602, a third coil group 603, and a fourth coil group 604. The welding end portions 503 of the two adjacent hairpins 5 along the circumferential direction are sequentially connected in order between adjacent coil groups.

[0050] Among them, the first coil group 601 and the third coil group 603 each contain a same-layer hairpin, and the two effective conductors 501 of the same-layer hairpin are located in the same layer of flat wires in different slots, which are the first layer of flat wires 201 or the Nth layer of flat wires (here, for example, the tenth layer of flat wires 210). The second coil group 602 and the fourth coil group 604 are both diagonal span areas, each containing N / 2-1 span-layer hairpins (which can be different types such as the second type of hairpin 505, the third type of hairpin 506, etc. depending on the span-layer situation), and the two effective conductors 501 of the span-layer hairpin are located in adjacent layers of flat wires in different slots, and are sequentially connected in order between each span-layer hairpin. The fourth coil group 604 is rotated by m stator slots 2 along the circumferential direction of the stator core 1 from the second coil group 602, and m is the number of winding phases. The same-layer hairpin and the span-layer hairpin are both pitch hairpins. The span of the two effective conductors 501 of all the welding portions of the four coil groups is the same, which is an integer pitch, which means that they can better meet the requirements of electromagnetic performance of the motor in design, so that the magnetic field distribution generated when the current passes through is more uniform, which is conducive to improving the performance indicators such as the operating efficiency and torque output of the motor.

[0051] As an example, referring to the drawings in the specification Figure 1 As shown in the drawings, the flat wire winding is distributed along the radial direction in the stator slot 2 of the stator core 1, and theFigure 1 The 10 layers of flat wires are shown, from the inner edge 3 of the stator core to the outer edge 4 of the stator core, in the radial direction, in order, the first layer of flat wires 201, the second layer of flat wires 202, the third layer of flat wires 203, the fourth layer of flat wires 204, the fifth layer of flat wires 205, the sixth layer of flat wires 206, the seventh layer of flat wires 207, the eighth layer of flat wires 208, the ninth layer of flat wires 209, and the tenth layer of flat wires 210.

[0052] The stator core 1 is uniformly distributed with Q stator slots 2 along the circumference, and for an m-phase winding, the number of slots per phase per level in the stator core 1 is 1, that is, q = Q / (2mp) = 1, where q is the number of slots per phase per level, Q is the number of stator slots, m is the number of winding phases, and p is the number of motor pole pairs. Referring to the drawings in the specification Figure 2 As shown, a distribution diagram of a certain phase stator slot is shown, the stator core 1 is 60 slots, and if the flat wire winding is a 3-phase winding, the number of motor pole pairs is 10 and the number of motor levels is 20 poles. In the drawings Figure 2 In the 60-slot stator core 1 shown in the drawings, taking a certain phase winding as an example, all the stator windings under the single rotor pole of the phase winding are assembled in the same stator slot 2, and there are 10 layers of flat wires in each stator slot 2. The flat wires under different rotor poles of the same phase are connected by hairpins 5, and referring to the drawings in the specification Figure 4 As shown, the phase winding includes one or more coil units 6, and each coil unit 6 is composed of four coil groups, namely a first coil group 601, a second coil group 602, a third coil group 603, and a fourth coil group 604. Adjacent coil groups are connected in order from the beginning to the end through the welded end portions 503 of the two adjacent hairpins 5 along the circumferential direction of the stator core 1. The first coil group 601 and the third coil group 603 include a same-layer hairpin, and the two effective conductors 501 of the same-layer hairpin are located in the same layer of flat wires in different slots, respectively belonging to the first layer of flat wires 201 and the tenth layer of flat wires 210. The second coil group 602 and the fourth coil group 604 are both diagonal span areas and include N / 2-1 span-layer hairpins. The two effective conductors 501 of the span-layer hairpin are located in adjacent layers of flat wires in different slots, and are connected in order from the beginning to the end between each span-layer hairpin. The fourth coil group 604 is rotated by m stator slots 2 along the circumferential direction of the stator core 1 from the second coil group 602, and m is the number of winding phases. The same-layer hairpin and the span-layer hairpin are both integral hairpins. The span of the two effective conductors 501 of all the welded portions of the four coil groups is the same, that is, integral, and in this example, the span is the number of winding phases, that is, span 3 stator slots 2. This uniform integral arrangement further ensures the consistency and stability of the electromagnetic performance of the motor winding, so that the entire flat wire winding structure can play a more coordinated role in the running process.

[0053] In this embodiment, referring to the drawings in the specification Figure 4 As shown, the drawings Figure 4The middle solid line represents the card end 502, and the dashed line represents the welding end 503. Specifically, the first coil group 601 is a same-layer card, which is a tenth-layer flat wire 210. The two effective conductors 501 of the same-layer card are located in the tenth-layer third slot (indicated as 10-3) and the tenth-layer sixth slot (indicated as 10-6). The connection structure of one coil unit 6 is specifically indicated as follows: 10-3 is the first end of the coil, 10-3 to 10-6 is a same-layer card located in the tenth-layer flat wire 210, that is, the first coil group 601; the welding end 503 of 10-6 is connected to 9-9, 9-9 is connected to 8-12, 9-9 to 8-12 is a cross-layer card, 8-12 is connected to 7-15, 7-15 to 6-18 is a cross-layer card, 6-18 is connected to 5-21, 5-21 to 4-24 is a cross-layer card, 4-24 is connected to 3-27, 3-27 to 2-30 is a cross-layer card, 2-30 is connected to 1-33, and the above 9-9 to 2-30 are the second coil group 602, 1-33 to 1-36 is a same-layer card, that is, the third coil group 603. Referring to the connection mode of the second coil group 602, rotating 3 stator slots 2 along the circumference of the stator core 1 is the fourth coil group 604, that is, 1-36 is connected to 2-33, 2-33 to 3-30 is a cross-layer card, 3-30 is connected to 4-27, 4-27 to 5-24 is a cross-layer card, 5-24 is connected to 6-21, 6-21 to 7-18 is a cross-layer card, 7-18 is connected to 8-15, 8-15 to 9-12 is a cross-layer card, and 9-12 is the end of the coil unit 6. The end of the coil unit 6 is connected in series with the first end of the coil unit 6 of the same-phase winding belonging to the same adjacent coil unit 6, so that the connection structure of the 60-slot 20-pole 10-layer flat wire 1 branch winding shown in the description is obtained. Figure 6

[0054] Embodiment 2

[0055] As another preferred embodiment of the present application, the embodiment is further detailed and supplemented to the technical solution of the present application on the basis of the above-mentioned embodiment 1.

[0056] In the embodiment, further operations are performed on the coil unit 6 to construct a complete winding structure. The coil unit 6 is rotated m stator slots 2 in the circumferential direction of the stator core 1 clockwise or counterclockwise, where m is the number of winding phases. Through such a rotating operation, p coil units 6 can be formed, where p is the number of pole pairs.

[0057] For example, a specific case is described as follows. Referring to the description Figure 6 ​As shown, for a three-phase winding (m=3 at this time), we rotate the coil unit 6 clockwise or counterclockwise along the circumference of the stator core 1 by 3 stator slots 2, thus forming 10 coil units 6 (assuming the number of pole pairs p=10 at this time, according to the rule of forming p coil units 6 mentioned above).

[0058] Then, according to the slot number sequence of stator slot 2, the outlet of the lead-out segment of the previous coil unit 6 in adjacent coil units 6 is connected to the inlet of the next coil unit 6. This connection method forms one branch of a phase winding. Furthermore, it is important to note that the beginning and end of the windings should be spaced a full pitch between adjacent layers. This full pitch plays a crucial role in ensuring the electromagnetic performance of the motor windings. It allows for a more uniform distribution of the magnetic field generated when current flows through the windings, thereby improving the motor's operating efficiency and torque output performance indicators.

[0059] Just like in the appendix Figure 6 The example of the 60-slot, 20-pole, 10-layer flat wire, 1-branch winding connection structure clearly demonstrates the specific situation of one branch of a phase winding formed under this connection method. The coil units 6 are connected in an orderly manner according to the above rules, forming a complete current path, which provides a foundation for the normal operation of the motor.

[0060] A further preferred solution is that we can disconnect the corresponding welding end 503 according to different outgoing line positions and busbars to realize the series and parallel connection between multiple coil units 6, thereby forming k branches, where k is a divisor of the number of pole pairs p.

[0061] Specifically, by disconnecting any one of the welded ends 503 in coil unit 6, this disconnected welded end 503 can serve as both the inlet and outlet of the coil unit 6's output wire. In this way, one coil unit 6 can function as a branch. This method allows us to flexibly adjust the number of branches in the motor, better meeting the performance requirements of the motor in different application scenarios.

[0062] Refer to the instruction manual appendix Figure 5 As shown, this is a plan view of all branches of a certain phase winding. In this diagram, we can clearly see how each coil unit 6 achieves different series and parallel connection methods by disconnecting different welding terminals 503, ultimately forming 10 branches. Different connection methods will affect the current distribution and electromagnetic performance of the motor, so in actual design and application, it is necessary to select and adjust them reasonably according to specific requirements.

[0063] As an example, refer to the instruction manual appendix. Figure 7 As shown, based on the above scheme, the following can be obtained: Figure 7A connection structure diagram of a 60-slot 20-pole 10-layer flat wire 5-branch winding is shown.

[0064] As another example, referring to the drawings Figure 8 As shown, according to the above scheme, a 48-slot 16-pole 8-layer flat wire 4-branch winding connection structure diagram can be obtained as shown in the drawings Figure 8 A connection structure diagram of a 60-slot 20-pole 10-layer flat wire 5-branch winding is shown.

[0065] Further, there is a preferred scheme that all branches of a phase winding are rotated by 1 to m-1 stator slots 2 in sequence clockwise or counterclockwise to obtain the connection mode of other m-1 phase windings.

[0066] For example, for a three-phase winding (m=3), in combination with Figure 5 and Figure 6 A 60-slot stator core 1 structure is shown. Figure 9 As shown, if the A-phase winding is rotated by 2 stator slots 2 in sequence clockwise or counterclockwise, the B-phase winding can be obtained (see the drawings Figure 10 As shown), and then, after rotating it by 1 stator slot 2, the C-phase winding can be obtained (see the drawings Figure 11 As shown).

[0067] Through such a rotation operation, the reasonable distribution in space and the balance of electromagnetic performance between the three-phase windings can be ensured. Because the three-phase windings need to work together during the operation of the motor, the magnetic fields generated by them are superimposed and interact with each other to form a stable rotating magnetic field, thereby driving the rotor of the motor to rotate. Therefore, ensuring that the connection mode and distribution rule between the three-phase windings meet the requirements is crucial for the normal operation and performance of the motor.

[0068] As an example of this embodiment, the high-layer effective conductors of the same-layer hairpins are all located in the clockwise direction of the low-layer effective conductors, and the high-layer effective conductors of the cross-layer hairpins are all located in the clockwise direction of the low-layer effective conductors.

[0069] As another example of this embodiment, the high-layer effective conductors of the same-layer hairpins are all located in the counterclockwise direction of the low-layer effective conductors, and the high-layer effective conductors of the cross-layer hairpins are all located in the counterclockwise direction of the low-layer effective conductors.

[0070] As another example of this embodiment, the first and last ends of each cross-layer hairpin are connected in sequence, and the first layer flat wire near the inner side of the stator is inserted into the Nth layer flat wire on the outer side of the stator along the radial direction of the stator core, or the Nth layer flat wire near the outer side of the stator is inserted into the first layer flat wire on the inner side of the stator along the radial direction of the stator core. Figure 5The connection mode is shown clockwise, when the connection mode is counterclockwise, that is, the connection mode of the second coil group and the fourth coil group can be replaced, the positions of the first coil group and the third coil group can be replaced, that is, the flat wire of the first layer is taken as the same layer hairpin, that is, the first coil group, the flat wire of the tenth layer is taken as the third coil group, and the oblique span direction of the second coil group and the fourth coil group is counterclockwise.

[0071] In the embodiment, the integer slot concentrated pitch concentrated winding structure of the application is further enriched and improved through the above series of operations on the coil unit 6 and different connection modes, so that it can more flexibly adapt to different application scenarios and meet diversified motor performance requirements.

[0072] Embodiment 3

[0073] As another preferred embodiment of the application, the embodiment is a further detailed supplement and elaboration of the technical solution of the application on the basis of the above-mentioned embodiment 1 or embodiment 2.

[0074] In the embodiment, referring to the drawings in the specification Figure 3 As shown in the drawings in the specification

[0075] According to the number of layers of flat wires in the stator slot 2, the required types of hairpins 5 in the coil unit 6 are N / 2+1. Referring to the drawings in the specification Figure 13 As shown in the drawings in the specification Figure 13 As shown in the drawings in the specification Figure 13 In the drawings in the specification Figure 12 In the drawings in the specification

[0076] The first type of hairpin 504 is a same layer hairpin, that is, the third coil group, and the two effective conductors 501 of the first type of hairpin 504 are located in 1-33 and 1-36 stator slots 2 respectively;

[0077] —The two effective conductors 501 of the second type of hairpin 505 are located in stator slots 2-30 and 3-27 respectively in the second coil group 602, and the two effective conductors 501 of the second type of hairpin 505 are located in stator slots 2-33 and 3-30 respectively in the fourth coil group 604;

[0078] —The two effective conductors 501 of the third type of hairpin 506 are located in stator slots 4-24 and 5-21 respectively in the second coil group 602, and the two effective conductors 501 of the third type of hairpin 506 are located in stator slots 4-27 and 5-24 respectively in the fourth coil group 604;

[0079] —The two effective conductors 501 of the fourth type of hairpin 507 are located in stator slots 6-18 and 7-15 respectively in the second coil group 602, and the two effective conductors 501 of the fourth type of hairpin 507 are located in stator slots 6-21 and 7-18 respectively in the fourth coil group 604;

[0080] —The two effective conductors 501 of the fifth type of hairpin 508 are located in stator slots 8-12 and 9-9 respectively in the second coil group 602, and the two effective conductors 501 of the fifth type of hairpin 508 are located in stator slots 9-12 and 8-15 respectively in the fourth coil group 604;

[0081] —The sixth type of hairpin 509 is a same-layer hairpin, namely the first coil group. The two effective conductors 501 of the sixth type of hairpin 509 are located in stator slots 10-3 and 10-6 respectively.

[0082] Example 4

[0083] As another preferred embodiment of the present invention, this embodiment discloses an integer slot concentrated full-pitch flat wire motor (not shown in the figure). The flat wire motor includes the integer slot concentrated full-pitch flat wire winding structure shown in Embodiment 1, Embodiment 2 or Embodiment 3 above and a rotor. The rotor is coaxially disposed in the stator core of the flat wire winding structure.

[0084] The above embodiments are only for illustrating the technical concept and features of the present invention, and are intended to enable those skilled in the art to understand the content of the present invention and implement it accordingly. They should not be construed as limiting the scope of protection of the present invention. All equivalent changes or modifications made in accordance with the spirit and essence of the present invention should be covered within the scope of protection of the present invention.

Claims

1. A concentrated integer-slot fractional-pitch flat conductor winding structure, comprising a stator core (1), the upper and lower sides of the stator core (1) being respectively a connection side and an insertion side of a flat conductor, characterized in that: The stator core (1) is an integral-slot stator core, and the slot number of each phase of each level of the flat wire winding structure is 1; All stator windings under a single rotor pole of a phase are in the same stator slot (2), and there are N layers of flat wires in each stator slot (2), N is an even number, and N is greater than or equal to 4; the flat wires under different rotor poles of the same phase are connected by hairpins (5) to form; each phase each branch contains one or more coil units (6), each coil unit (6) is composed of four coil groups, which are first coil group (601), second coil group (602), third coil group (603) and fourth coil group (604), and the adjacent coil groups are sequentially connected through the welding ends (503) of the two adjacent hairpins (5) in the circumferential direction; wherein the first coil group (601) and the third coil group (603) each contain a same layer hairpin, the two effective conductors (501) of the same layer hairpin are located in the same layer flat wire in different slots, and belong to the first layer or the Nth layer flat wire respectively; the second coil group (602) and the fourth coil group (604) are both diagonal span areas, and each contains N / 2-1 span layer hairpins, the two effective conductors (501) of the span layer hairpin are located in adjacent layer flat wires in different slots, and are sequentially connected between each span layer hairpin; the fourth coil group (604) is rotated by m stator slots (2) along the circumferential direction of the stator core (1) from the second coil group (602), and m is the number of winding phases; the same layer hairpin and the span layer hairpin are integral hairpins; the span of the two effective conductors (501) of all welding parts of the four coil groups is the same, and is integral.

2. The concentrated integer-slot fractional pitch flat conductor winding structure of claim 1, wherein: The coil unit (6) is sequentially rotated by m stator slots (2) in the clockwise or counterclockwise direction along the circumferential direction of the stator core (1), and m is the number of winding phases; p coil units (6) are formed, and p is the number of pole pairs; according to the slot number sequence of the stator slot (2), the outlet of the outgoing segment of the previous coil unit (6) in the adjacent coil unit (6) is connected with the inlet of the next coil unit (6) to form a phase winding 1 branch; the head and tail are separated by an integral distance between adjacent layers.

3. The concentrated integer slot fractional pitch flat conductor winding structure of claim 2, wherein: According to the different outgoing positions and bus breaks, the corresponding welding ends (503) are disconnected, and a plurality of coil units (6) are connected in series and parallel to form k branches, and k is a divisor of the number of pole pairs p.

4. A concentrated integer-slot fractional-slot flat wire winding structure according to any one of claims 1-3, characterized in that: All branches of a phase winding are sequentially rotated by 1-m-1 stator slots (2) in the clockwise or counterclockwise direction to obtain the connection mode of the other m-1 phase windings.

5. A concentrated integer slot fractional pitch flat conductor winding structure as claimed in any one of claims 1 to 3, characterized in that: The same layer hairpin and the span layer hairpin each include two in-slot effective conductors (501), hairpin end portions (502) for connection, and two welding end portions (503) for welding.

6. The integer slot concentrated full-pitch flat wire winding structure as described in claim 5, characterized in that: The two effective conductors (501) on the hairpin (5) are arranged in different slots of the same phase winding, and the difference in the number of stator slots crossed by the hairpin (5) is the span of the hairpin (5), which is integral.

7. The integer slot concentrated full-pitch flat wire winding structure as described in any one of claims 1-3, characterized in that: The effective conductors (501) of the same layer hairpin located in the higher layer are located in the clockwise direction of the effective conductors (501) of the lower layer, and the effective conductors (501) of the span layer hairpin located in the higher layer are located in the clockwise direction of the effective conductors (501) of the lower layer.

8. The integer slot concentrated full-pitch flat wire winding structure as described in any one of claims 1-3, characterized in that: The same layer hairpins are located in the counterclockwise direction of the effective conductors (501) of the low layer, and the cross-layer hairpins are located in the counterclockwise direction of the effective conductors (501) of the low layer.

9. The integer slot concentrated full-pitch flat wire winding structure as described in any one of claims 1-3, characterized in that: The first layer flat wire (201) close to the inner side of the stator is radially inserted into the Nth layer flat wire close to the outer side of the stator, or the Nth layer flat wire close to the outer side of the stator is radially inserted into the first layer flat wire (201) close to the inner side of the stator.

10. A concentrated integer-slot fractional-slot flat wire machine, characterized by: The flat wire motor comprises the integer slot concentrated integer pitch flat wire winding structure and the rotor, the rotor is coaxially arranged in the stator core (1) of the flat wire winding structure.

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