12-layer long-span hairpin flat wire motor stator
By designing a 12-layer long-span flat-line motor stator, using multi-pole slot fit and I-PIN/U-PIN issuing combination, the problems of flat-line motor stator winding asymmetry, difficult forming and increased end height are solved, and high torque output, low noise and high efficiency motor performance are achieved.
Patent Information
- Application Number
- CN202411603510.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-11-12
- Publication Date
- 2025-03-14
AI Technical Summary
The existing flat wire motor stator windings have asymmetry problems, resulting in high induced electromotive force and AC copper consumption, affecting the performance and service life of the motor. At the same time, the molding process is difficult, the cost of automation mass production is high, and the irregular arrangement method leads to an increase in the end height, affecting the axial assembly length.
A 12-layer long-span flat-line motor stator is designed, using multi-pole groove combination, the stator winding is combined by I-PIN and U-PIN. The three-phase lead wire and terminal terminal are welded to form a whole, and the whole is potted. Insulating paper is used in the stator groove to isolate the winding conductor and the iron core, and there is a welding gap between the conductors between adjacent layers, optimizing the winding structure.
It improves the torque output capability of the motor, reduces the winding magnetic potential harmonics and vibration noise, reduces the risk of phase-in insulation in the stator slot, improves the motor power density and thermal uniformity, reduces material and manufacturing costs, and achieves efficient and reliable motor performance.
Smart Images
Figure CN119628286A_ABST
Abstract
Description
Technical Field
[0001] The invention relates to the field of motors, and in particular to a 12-layer long-span hairpin flat wire motor stator. Background Art
[0002] With the rapid development of new energy vehicle technology, the drive motor, as one of the core components of new energy vehicles, has higher and higher requirements for its electromagnetic performance and response speed. Flat wire motors are gradually being used in the field of new energy passenger car drive motors with their unique advantages.
[0003] Compared with the slot full rate of about 50% of round wire stator winding, the slot full rate of flat wire stator winding can reach more than 70%. At the same time, flat wire stator winding has smaller resistance and copper loss, better electromagnetic performance, and better heat dissipation effect. Therefore, flat wire stator winding has become one of the mainstream forms of stators for new energy vehicle drive motors, and the development trend in the field of flat wire drive motors is high speed, light weight, and high efficiency. To achieve high speed, light weight and high efficiency of flat wire drive motors, we must focus on improving their electromagnetic performance. The design difficulty of improving the performance of flat wire drive motors has always been the stator space winding arrangement and its connection method. The existing stator winding arrangement method generally has the following disadvantages: 1) There is an asymmetric problem in the stator winding arrangement, which is easy to generate induced electromotive force. When the winding is working, it will generate large AC copper loss under the action of high-frequency AC current, causing the local temperature of the motor stator to be too high, affecting the performance of various materials, resulting in performance degradation and reducing the service life of the motor.
[0004] 2) There are many types of flat wire stator winding clips, the molding process is difficult, and the cost and difficulty of achieving automated mass production are high.
[0005] 3) The flat wire stator winding is arranged irregularly, requiring a large number of bus bars or busbars to connect the phase winding branches and star points, which will increase the height of the winding ends and affect the axial assembly length of the motor.
[0006] 4) The existing flat wire motor stators are relatively small, and performance indicators such as power, speed and torque cannot meet the needs of some fields. Summary of the invention
[0007] In order to solve the above technical problems, the present invention provides a 12-layer long-span hairpin flat wire motor stator which is simple in structure, safe and reliable.
[0008] The technical solution of the present invention for solving the above technical problems is: a 12-layer long-span hairpin flat wire motor stator, comprising a stator winding and a stator core, wherein the stator core is provided with stator slots, the stator winding is installed in the stator slots, the winding conductor is isolated from the stator core by insulating paper in the stator slots, the stator winding is composed of a number of I-PIN hairpins and U-PIN hairpins, the three-phase lead wires of the stator winding are welded to the wiring terminals to form a whole, and the whole is potted.
[0009] The above-mentioned 12-layer long-span hairpin flat wire motor stator has positioning pressure plates installed at both ends of the stator core, and an insulating end plate is installed on the inner circle of the positioning pressure plate. The insulating end plate and the positioning pressure plate have the same height to form a plane, and the corresponding positions on the plane are engraved with slot numbers.
[0010] In the above-mentioned 12-layer long-span hairpin flat wire motor stator, the height of the straight end of the stator winding does not exceed the insulating end plate.
[0011] The stator winding of the 12-layer long-span hairpin flat wire motor stator is composed of a plurality of I-PIN hairpins, U-PIN hairpins of different spans and cross-layer U-PIN hairpins inserted together in 72 stator slots, and the stator winding as a whole is 6 branches connected in parallel.
[0012] The above-mentioned 12-layer long-span hairpin flat wire motor stator has space for I-PIN hairpin arrangement in the first and twelfth layers of the stator winding, and multiple I-PIN hairpins are centrally led out from adjacent stator slots. The crown ends of the I-PIN hairpins are welded to the terminal lead wires and used as wiring terminals together, and the welding ends are welded and connected to the hairpins in other stator slots; the crown ends of the stator winding are connected in a triangular shape as a whole.
[0013] In the above-mentioned 12-layer long-span hairpin flat wire motor stator, the adjacent layers of the welding end windings in the stator slots are twisted in opposite directions, that is, if the first layer is twisted clockwise, the second layer is twisted counterclockwise, and so on.
[0014] In the above-mentioned 12-layer long-span hairpin flat wire motor stator, welding gaps are left between conductors welded to each other at different layers at the welding end.
[0015] In the above-mentioned 12-layer long-span hairpin flat wire motor stator, in two adjacent layers in the stator slot, the number of U, V, and W three-phase hairpins is the same, cross-layer winding conductor gaps are left between the even layers and the odd layers, and the non-cross-layer winding conductor gap is smaller than the cross-layer winding conductor gap.
[0016] In the above-mentioned 12-layer long-span hairpin flat wire motor stator, the U-PIN hairpins on the same layer in the stator slot are arranged in pairs, and the spans of the paired U-PIN hairpins are B1 and B2 respectively, where B1=5 and B2=7, and the straight ends of the U-PIN hairpins of the B1 span are distributed on the inner side of the straight ends of the U-PIN hairpins of the B2 span.
[0017] The stator core of the 12-layer long-span hairpin flat wire motor is composed of stacked stator punching sheets.
[0018] The beneficial effects of the present invention are: 1. The present invention adopts a pole-slot combination with a larger number of slots, which improves the torque output capacity of the motor, reduces the magnetic potential harmonics of the winding, reduces the vibration noise generated when the motor is running, can effectively reduce the risk of phase-to-phase insulation in the stator slots, improve the power density of the motor, and can meet the performance requirements of the drive motor of a vehicle with high torque requirements.
[0019] 2. Different from the existing common 8-layer small-diameter winding structure with a span of 4 or 5 slots, the present invention adopts a long-distance winding structure design. The 12-layer large-diameter winding structure has a span of 5 or 7 slots. The span arc length of the same 5-slot span is longer. This long-distance winding structure can be applied to larger motor stators, can effectively break through the power limitation, reduce the iron loss generated by the stator during the operation of the motor, optimize the NVH performance of the motor, improve the efficiency of the motor, effectively improve the thermal uniformity and overall temperature of the motor stator, and ensure the reliability of the motor working for a long time.
[0020] 3. The long-distance winding structure adopted in the present invention is composed of two types of I-PIN hairpins and multiple types of U-PIN hairpins. Compared with the stator hairpins using all-U-Pin hairpin windings, the types are reduced by 5, which reduces the cost of mold investment, improves the manufacturability of processing, can meet the application needs of different occasions, and has broad application prospects.
[0021] 4. The lead-out wire positions of the winding structure adopted by the present invention are concentrated in a smaller range on the stator circumference, and the three-phase incoming and outgoing wire positions are distributed in a similar pattern, with good connectivity, and the end connection structures of each phase are compact, which reduces material and manufacturing costs. BRIEF DESCRIPTION OF THE DRAWINGS
[0022] Figure 1 It is a structural schematic diagram of the present invention.
[0023] Figure 2 for Figure 1 Top view of the .
[0024] Figure 3 This is a schematic diagram of the structure of the first-layer I-PIN card issuance.
[0025] Figure 4 This is a schematic diagram of the structure of the 12th layer I-PIN card issuance.
[0026] Figure 5 This is a schematic diagram of the U-PIN card issuance structure.
[0027] Figure 6This is a top-down view of the U-PIN card issuance structure.
[0028] Figure 7 It is a schematic diagram of the partial structure of the U-phase winding. DETAILED DESCRIPTION
[0029] The present invention will be further described below in conjunction with the accompanying drawings and embodiments.
[0030] like Figure 1 , Figure 2 As shown, a 12-layer long-span hairpin flat wire motor stator includes a stator winding 1 and a stator core 2. The stator core 2 is composed of stacked stator punching sheets. The stator core 2 is provided with stator slots. The stator winding 1 is installed in the stator slots. The winding conductor is isolated from the stator core 2 by insulating paper 5 in the stator slots. The stator winding 1 is composed of a number of I-PIN hairpins and U-PIN hairpins. The three-phase lead wires of the stator winding 1 are welded to the terminal 6 to form a whole, and the whole is potted.
[0031] Positioning plates 3 are installed at both ends of the stator core 2, and insulating end plates 4 are installed on the inner ring of the positioning plates 3. The insulating end plates 4 and the positioning plates 3 have the same height to form a plane, and the corresponding positions on the plane are engraved with slot numbers.
[0032] The straight ends of the stator windings are arranged in the slots of the stator core 2 in the connection mode and sequence shown in the stator system diagram. The height of the straight ends of the stator windings does not exceed the insulating end plate 4, allowing the hairpin bending to compress the insulating paper 5 that exceeds the insulating end plate 4 to deform.
[0033] like Figure 2-Figure 6 As shown, the stator winding 1 is composed of a plurality of I-PIN hairpins, U-PIN hairpins with different spans and cross-layer U-PIN hairpins inserted into 72 stator slots, and the stator winding 1 as a whole is 6 branches connected in parallel.
[0034] In two adjacent layers in the stator slots, the number of U, V, and W three-phase hairpins is the same, cross-layer winding conductor gaps are left between the even and odd layers, and the non-cross-layer winding conductor gap is smaller than the cross-layer winding conductor gap.
[0035] The U-PIN hairpins on the same layer in the stator slot are arranged in pairs, and the spans of the paired U-PIN hairpins are B1 and B2 respectively, where B1=5 and B2=7, and the straight end of the U-PIN hairpin of span B1 is distributed on the inner side of the straight end of the U-PIN hairpin of span B2.
[0036] like Figure 7 As shown, the adjacent layers of the welding end winding in the stator slot are twisted in opposite directions, that is, if the first layer is twisted clockwise, the second layer is twisted counterclockwise, and so on. A welding gap is left between the conductors welded to each other at different layers of the welding end.
[0037] The stator winding has space for arranging I-PIN hairpins in the first and 12th layers. Multiple I-PIN hairpins are led out from adjacent stator slots. The crown end of the I-PIN hairpin is higher than the height of the U-PIN hairpin. The crown end of the I-PIN hairpin is welded with the terminal lead-out wire and used as a terminal. The welded end is welded and connected to the hairpins in other stator slots; the crown end of the stator winding is connected in a triangle as a whole. The first layer of I-PIN hairpins and the 12th layer of I-PIN hairpins are arranged according to the stator system diagram. The two ensure that the bending rotation direction is close, so that the welding position is concentrated in a certain position.
[0038] The stator of the present invention has excellent electromagnetic performance, good temperature uniformity, good environmental and design adaptability, low phase-to-phase insulation risk in the stator slots, and a shorter stator end height. Compared with the common 8-layer flat wire stator, the overall manufacturing cost is reduced by about 30%, and compared with the stator hairpins using full U-Pin hairpin windings, the types of hairpins are reduced by 5, which can effectively control costs, improve processing manufacturability to meet the application needs of different occasions, and has broad application prospects.
Claims
1. A 12-layer long-span hairpin flat wire motor stator, comprising a stator winding and a stator core, characterized in that: The stator core is provided with stator slots, and the stator winding is installed in the stator slots. The winding conductor is isolated from the stator core by insulating paper in the stator slots. The stator winding is composed of a number of I-PIN hairpins and U-PIN hairpins. The three-phase lead wires of the stator winding are welded to the wiring terminals to form a whole, and the whole is potted.
2. The 12-layer long-span hairpin flat wire motor stator according to claim 1 is characterized in that: Positioning plates are installed at both ends of the stator core, and an insulating end plate is installed on the inner ring of the positioning plate. The insulating end plate and the positioning plate have the same height to form a plane, and the corresponding positions on the plane are engraved with slot numbers.
3. The 12-layer long-span hairpin flat wire motor stator according to claim 2 is characterized in that: The height of the straight end of the stator winding does not exceed the insulating end plate.
4. The 12-layer long-span hairpin flat wire motor stator according to claim 2 is characterized in that: The stator winding is composed of a plurality of I-PIN hairpins, U-PIN hairpins with different spans and cross-layer U-PIN hairpins inserted into 72 stator slots, and the stator winding as a whole is 6 branches connected in parallel.
5. The 12-layer long-span hairpin flat wire motor stator according to claim 4 is characterized in that: Space is reserved for arranging I-PIN hairpins in the first and twelfth layers of the stator winding, and multiple I-PIN hairpins are collectively led out from adjacent stator slots. The crown end of the I-PIN hairpin is higher than the height of the U-PIN hairpin. The crown end of the I-PIN hairpin is welded with terminal lead wires and used as a wiring terminal together, and the welded end is welded and connected to the hairpins in other stator slots; the crown end of the stator winding is connected in a triangle as a whole.
6. The 12-layer long-span hairpin flat wire motor stator according to claim 5 is characterized in that: Adjacent layers of the welding end windings in the stator slots are twisted in opposite directions, that is, if the first layer is twisted clockwise, the second layer is twisted counterclockwise, and so on.
7. The 12-layer long-span hairpin flat wire motor stator according to claim 5, characterized in that: A welding gap is left between conductors that are welded to each other at different layers at the welding end.
8. The 12-layer long-span hairpin flat wire motor stator according to claim 5, characterized in that: In two adjacent layers in the stator slots, the number of U, V, and W three-phase hairpins is the same, cross-layer winding conductor gaps are left between the even and odd layers, and the non-cross-layer winding conductor gap is smaller than the cross-layer winding conductor gap.
9. The 12-layer long-span hairpin flat wire motor stator according to claim 5, characterized in that: The U-PIN hairpins on the same layer in the stator slot are arranged in pairs, and the spans of the paired U-PIN hairpins are B1 and B2 respectively, where B1=5 and B2=7, and the straight end of the U-PIN hairpin of span B1 is distributed on the inner side of the straight end of the U-PIN hairpin of span B2.
10. The 12-layer long-span hairpin flat wire motor stator according to claim 1, characterized in that: The stator core is composed of stacked stator punching sheets.