Stator winding of flat wire motor

Abstract

The invention discloses a flat wire motor stator winding, and belongs to the technical field of motor stator winding, the flat wire motor stator winding comprises a stator, a plurality of stator grooves are arranged in the stator, the flat wire motor stator winding also comprises winding pairs formed by first windings and second windings, and the winding pairs are continuously arranged along the circumferential direction of the stator grooves, so that the winding pairs form even number layers in the radial direction in the stator grooves; taking the first layer and the second layer as a first layer pair, taking the third layer and the fourth layer as a second layer pair, and sequentially arranging; two ends of the first winding and the second winding are respectively arranged on an odd-numbered layer and an even-numbered layer of the same layer pair; and the winding pairs of different layer pairs are connected along the circumferential direction of the stator. According to the scheme, the types of line types of the hairpin winding are few, the investment of a production line on hairpin forming equipment and tools can be reduced, and the line types are simple in classification and easy to manage; the motor stator winding is reasonable in structure, and the connection mode and process are simple to realize.

Description

Technical Field

[0001] The present invention relates to a technology of a motor stator, and more particularly to a flat wire motor stator winding. Background Art

[0002] Since the flat wire winding molding process is relatively complex and its structure needs to consider space avoidance, the process implementation of its connection method requires simplicity and efficiency, and multiple different solutions need to be compatible on the same production line. Therefore, the process manufacturability of the winding connection solution and the rationality of the product structure are crucial.

[0003] For example: Chinese patent announcement number CN112436617A, announcement date March 2, 2021, invention name is a motor stator and motor, the application discloses a motor stator winding, including three phase windings installed on the stator core, and forming M layers in the radial direction of the stator core; each phase winding is formed by a plurality of long pitch conductors and a plurality of short pitch conductors along the circumference of the stator core to form X branch windings connected in parallel, the long pitch conductor surrounds the short pitch conductor; the long pitch conductor includes a long pitch conductor one, the two slots of the long pitch conductor one are located in two adjacent layers of the stator core in the radial direction, and the two slots of the short pitch conductor are located in two adjacent layers of the stator core in the radial direction; the long pitch conductor of at least one phase winding also includes a long pitch conductor two, the two slots of the long pitch conductor two are located in the first and Mth layers of the stator core in the radial direction. This solution eliminates the bridge wire, dissipates heat evenly, and improves power and torque, but the process implementation of its connection method is difficult and the production investment cost is high. Summary of the invention

[0004] The present invention overcomes the problem of complex winding process of the existing flat wire motor stator winding, and provides a flat wire motor stator winding. The flat wire motor stator winding of this solution has a reasonable structure and a relatively simple connection process.

[0005] In order to solve the above technical problems, the present invention adopts the following technical solutions: a flat wire motor stator winding, including a stator, a plurality of stator slots are arranged inside the stator, and also includes a winding pair formed by a first winding and a second winding, and the winding pairs are arranged continuously along the circumference of the stator slots, and the winding pairs are radially formed into an even number of layers in the stator slots; the first layer and the second layer are used as a first layer pair, and the third layer and the fourth layer are used as a second layer pair, which are arranged in sequence; the two ends of the first winding and the second winding are respectively arranged in the odd layers and the even layers of the same layer pair; the winding pairs of different layer pairs are connected along the circumference of the stator. In this solution, both the first winding and the second winding are hairpin-type windings, and only two types of windings are needed to complete the winding arrangement. The first winding and the second winding are arranged in the stator slots, and the winding pairs are inserted and arranged in the stator slots in a circumferential direction and cover the stator slots. The winding pairs form multiple layers in the stator slots, wherein one end of the winding pair is arranged in an odd-numbered layer, and the other end is arranged in an even-numbered layer of an adjacent layer, so that all the first windings and the second windings in different layers are finally connected along the circumferential direction of the stator to form a winding loop. The winding scheme of this solution is simple and reasonable, and can achieve continuous winding of the windings.

[0006] Preferably, the span of the first winding is smaller than the span of the second winding, and the first winding is arranged inside the second winding. The sizes of the first winding and the second winding are different to avoid interference between the two windings, wherein the span of the first winding is smaller than the span of the second winding, so that the first winding is arranged inside the second winding, so that the first winding and the second winding form a winding pair.

[0007] Preferably, the winding pair forms a three-phase winding, each phase winding includes N branches, the branch includes a first connection and a second connection, and when N is an odd number, the first connection and the second connection are connected to form an intermediate node. The arrangement of the three-phase winding is exactly the same, namely, the U phase, the V phase and the W phase, and each phase winding has N branches. The branches between each phase winding form an adjacent and continuous arrangement, that is, the first branch of the U phase and the first branch of the V phase and the first branch of the W phase are continuously adjacent to each other. Since the same winding pair is located in the same branch, there are two connections on each branch, namely the first connection and the second connection. When N is an odd number, the first connection and the second connection are connected together to form a complete branch, and when N is an even number, the connection on the branch is directly connected without the need for an intermediate node connection.

[0008] Preferably, each branch is connected in a loop at the innermost layer or the outermost layer or both the innermost and outermost layers of the stator. Since the first winding and the second winding form a winding pair and are on the same branch, a loop connection can be formed from the first layer to the last layer, that is, a loop can be formed at the innermost layer or the outermost layer; of course, a loop connection can also be formed at the innermost layer and the outermost layer.

[0009] Preferably, the winding pairs in different layer pairs are connected to the winding pairs in adjacent layer pairs with two phases in between. The winding pairs on different layer pairs need to be connected at two-phase intervals, U phase, V phase, W phase, U phase, V phase, W phase, etc., so that a circumferentially arranged winding can be formed on the stator.

[0010] Preferably, the first winding and the second winding between different winding pairs are connected interchangeably. In order to form a complete loop between the same winding pair, between different winding pairs, the first winding in the previous winding pair is connected to the second winding in the next winding pair, and the second winding in the previous winding pair is connected to the first winding in the next winding pair, so that a loop can be formed between the winding pairs.

[0011] As a preference, it also includes a busbar, which is fixed to the stator by welding; the busbar includes a neutral copper bar, a wiring copper bar and a three-phase copper bar, the neutral copper bar connects the lead-in wire or lead-out wire of each phase winding, and the wiring copper bar connects the first wiring and the second wiring; the neutral copper bar, the wiring copper bar and the three-phase copper bar are arranged along the circumference of the winding, and the neutral copper bar is arranged above or below the wiring copper bar and the three-phase copper bar. The busbar is fixed to the end of the stator by welding, and the neutral copper bar, the wiring copper bar and the three-phase copper bar in the busbar can be integrated by injection molding, wherein the neutral copper bar is used to connect the lead-out wire or lead-in wire of each phase, the wiring copper bar is used to connect the first wiring and the second wiring, the wiring copper bar and the neutral copper bar are arranged in layers up and down, and the three-phase copper bar can use soft connection to lead out the wiring, and the spatial arrangement is reasonable.

[0012] Preferably, positioning blocks are used to position the copper bars of the busbars during the injection molding process to ensure the gap, and dispensing or secondary injection molding is used for insulation and sealing after the injection molding is completed. A certain gap needs to be ensured between the copper bars of the busbars to prevent the copper bars from contacting each other and causing a short circuit. After the injection molding is completed, dispensing can be used for insulation, or secondary injection molding can be used for insulation and sealing.

[0013] Preferably, the copper bars leading out of the three-phase windings are led out by soft connections, and the copper bars of each phase winding are distributed along the radial direction of the windings. The three-phase windings are all led out by soft connections, and at the same time, the copper bars leading out of each phase winding are arranged in layers along the radial direction of the windings, which can not only utilize the available radial space of the stator, but also greatly reduce the height space of the motor in the axial direction.

[0014] Preferably, before connecting the winding pairs of different layers, the winding pairs are twisted and formed by a twisting tool or equipment, and the winding pairs are connected by welding. Since the first winding and the second winding in this solution are both hairpin-type windings, the first winding and the second winding include a hairpin end and a welding end. Before the first winding and the second winding are inserted into the stator slot, the welding end is straight. After being inserted into the stator slot, the welding end needs to be twisted to achieve the connection between different winding pairs.

[0015] Compared with the prior art, the present invention has the following beneficial effects: (1) The hairpin winding has fewer types of wire types, which can reduce the investment in hairpin forming equipment and tooling for the production line, and the wire type classification is simple and easy to manage; (2) The welding ends are regular and regular, and different winding schemes can be easily switched by the production line turning tooling; (3) The disconnected parts of each branch of the winding are connected by the end bus, which can reduce the structural size of the winding connection and make the process easier to operate; (4) The copper bars in the bus are reasonably arranged, fixed together by tooling and injection molding, and the process assembly operability is high. Moreover, by selecting the injection molding material, the insulation performance between the copper bars can be increased within a smaller gap. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 The figure is a schematic diagram of the assembly structure of the stator winding and busbar of the flat wire motor of the present invention.

[0017] Figure 2 This is a schematic axonometric diagram of the stator structure of the flat wire motor of the present invention.

[0018] Figure 3 It is a schematic structural diagram of the flat wire motor busbar of the present invention.

[0019] Figure 4 Schematic diagram of the winding of the U-phase winding of the present invention.

[0020] Figure 5 Schematic diagram of the winding of the V-phase winding of the present invention.

[0021] Figure 6 Schematic diagram of the winding of the W-phase winding of the present invention.

[0022] Figure 7 It is a schematic diagram of the lead wires of the flat wire motor winding of the present invention.

[0023] In the figure: 1.1. Stator, 2.1. Winding pair, 2.11. First winding, 2.12. Second winding, 3.1. First layer pair, 3.2. Second layer pair, 3.3. Third layer pair, 4.1. First branch, 4.2. Second branch, 4.3. Third branch, 5.1. First connection, 5.2. Second connection, 6.1. Bus, 6.11. Neutral point copper bus, 6.12. Connection copper bus, 7.1. Hairpin end, 7.2. Welding end, 8.1. U phase lead wire, 8.2. V phase lead wire, 8.3. W phase lead wire, 9.1. Three-phase copper bus, 10.1. Soft connecting conductor. DETAILED DESCRIPTION

[0024] The technical solution of the present invention is further described in detail below through specific embodiments in conjunction with the accompanying drawings.

[0025] Example 1: Figures 1 to 4 A flat wire motor stator winding is shown. This solution needs to use a stator 1.1 of a flat wire motor. Specifically, the stator 1.1 includes 48 stator slots. The number of slots in the stator 1.1 can be determined according to actual design requirements. The stator 1.1 used in this solution has 48 slots, and the stator slots are evenly distributed along the inner ring of the stator 1.1. In the stator 1.1, any stator slot is used as the No. 1 stator slot, and then the stator slots are defined as the No. 2 stator slot, the No. 3 stator slot, ..., the No. 48 stator slot in the clockwise direction (or counterclockwise direction).

[0026] The windings are arranged in the stator slots. Specifically, in this solution, only two different types of windings are needed to complete the winding arrangement of the stator slots, namely the first winding 2.11 and the second winding 2.12. The first winding 2.11 and the second winding 2.12 are both flat wire windings. The cross-section of the flat wire winding is rectangular, which can better fill the inside of the stator slots. The stator slot filling rate is higher, so that the flat wire motor can output more power per unit volume or weight. The first winding 2.11 and the second winding 2.12 are hairpin-type windings, such as Figure 4 As shown, the two ends of the stator 1.1 are defined as an upper end and a lower end respectively, the upper end of the stator 1.1 is a welding end 7.2 of the first winding 2.11 and the second winding 2.12, and the lower end of the stator 1.1 is a hairpin end 7.1 of the first winding 2.11 and the second winding 2.12, wherein the hairpin ends 7.1 of the first winding 2.11 and the second winding 2.12 are a V-shaped structure connected together, and the welding ends 7.2 of the first winding 2.11 and the second winding 2.12 are a straight copper wire structure before being inserted into the stator slot, so that the first winding 2.11 and the second winding 2.12 are easily inserted into the stator slot.

[0027] Specifically, the span of the first winding 2.11 is smaller than the span of the second winding 2.12. In the present embodiment, the two welding ends 7.2 of the first winding 2.11 span 6 stator slot pitches in the stator 1.1, and the two welding ends 7.2 of the second winding 2.12 span 8 stator slot pitches in the stator 1.1. The first winding 2.11 is just located at the inner side of the second winding 2.12, so that the first winding 2.11 and the second winding 2.12 form a winding pair 2.1. Then, the above-mentioned winding pairs 2.1 are continuously arranged in the 48 stator slots of the stator 1.1. Specifically, the first winding 2.11 is placed in the middle position of the second winding 2.12, inserted into the stator slots, and occupies four slots. Then, the second winding pair 2.1 is adopted and arranged in the stator slots in the same manner along the stator slots in a clockwise direction (or counterclockwise direction) and moved two stator slots, until all the stator slots are filled with the winding pairs 2.1.

[0028] For example, Figure 4 In the first winding pair, the two hairpin ends 7.1 of the first winding 2.11 are respectively located in the 3rd slot and the 8th slot, and the two hairpin ends 7.1 of the second winding 2.12 are respectively located in the 2nd slot and the 9th slot; the second winding pair is arranged at the right adjacent position of the first winding pair, that is, in the second winding pair ( Figure 4 Not shown, see Figure 6 ), the two hairpin ends of the first winding 2.11 are respectively located in slot No. 5 and slot No. 10, the two hairpin ends of the second winding 2.12 are respectively located in slot No. 4 and slot No. 11, and so on, so that all the stator slots on the stator 1.1 can be covered.

[0029] It should be noted that, in this embodiment, after the stator slots are filled with winding pairs 2.1, six layers of windings are formed. Of course, the number of winding layers can be determined according to actual design requirements. This solution is described with six layers of windings. The two hairpin ends 7.1 of the first winding 2.11 and the second winding 2.12 are respectively located in the first layer and the second layer. Figure 4As shown, taking the first winding pair as an example, the left side hairpin end 7.1 of the first winding 2.11 is located at the first layer position of the 3rd slot, the right side hairpin end 7.1 of the first winding 2.11 is located at the second layer position of the 8th slot, the left side hairpin end 7.1 of the second winding 2.12 is located at the first layer position of the 2nd slot, and the right side hairpin end 7.1 of the second winding 2.12 is located at the second layer position of the 9th slot. The right side hairpin end of the second winding in another winding pair is arranged at the second layer position of the 3rd slot, the right side hairpin end of the first winding in the another winding pair is arranged at the second layer position of the 2nd slot, the left side hairpin end of the second winding in another winding pair is arranged at the first layer position of the 8th slot, and the left side hairpin end of the first winding in the another winding pair is arranged at the first layer position of the 9th slot.

[0030] As can be seen from the above, this winding method arranges the winding pairs in two adjacent layers as a whole. Therefore, this solution regards the first and second layers, the third and fourth layers, and the fifth and sixth layers as three layer pairs. The first layer is the inner diameter side of the stator 1.1, and the sixth layer is the outer diameter side of the stator 1.1. Each winding pair is arranged in the corresponding layer pair. When wiring, it is only necessary to wire the winding pairs 2.1 in different layer pairs. Specifically, in the first layer pair 3.1 of the first and second layers, in the second layer pair 3.2 of the third and fourth layers, and in the third layer pair 3.3 of the fifth and sixth layers, a winding pair 2.1 will be arranged in the same corresponding position, that is, in Figure 4 As shown, in the first and second layers, slot No. 2, slot No. 3, slot No. 8 and slot No. 9 are arranged with a group of winding pairs 2.1, and correspondingly in the third and fourth layers, fifth and sixth layers, slot No. 2, slot No. 3, slot No. 8 and slot No. 9 are also arranged with a group of winding pairs 2.1, and the arrangement of the winding pairs 2.1 in the third and fourth layers, fifth and sixth layers is the same as that in the first and second layers.

[0031] Then the winding pair 2.1 arranged in the stator slot is connected. Specifically, Figure 4 As shown, it is a schematic diagram of the parallel winding of the U-phase winding of this scheme. The U-phase winding includes three branches, namely the first branch 4.1, the second branch 4.2 and the third branch 4.3. The number of branches can also be selected according to actual design needs.

[0032] First is the first branch 4.1, whose connection path is as follows: 14-1→21-2→27-3→32-4→38-5→45-6→3-5→8-6→14-6→9-5→3-6→44-5→38-4→33-3→27-2→20-1→15-1→20-2→26-3→33-4→39-5→44-6→2-5→9-6→15-6→8-5→2-6→45-5→39-4→32-3→26-2→21-1. Among them, 14-1→21-2 means: the first layer of slot 14 is connected to the second layer of slot 21, and this connection belongs to the same winding of the same layer pair; 21-2→27-3 means: the second layer of slot 21 is connected to the third layer of slot 27, and this connection belongs to the connection between different windings in different layer pairs; the rest are similar. Among them, 8-6→14-6 and 9-6→15-6 are the winding connections formed by the first branch 4.1 on the sixth layer; among them, 20-1→15-1 is the connection between the disconnection points of the first wiring 5.1 and the second wiring 5.2 on the first branch 4.1, which are connected through the wiring copper bus 6.12.

[0033] Then comes the second branch 4.2, whose connection path is as follows: 26-1→33-2→39-3→44-4→2-3→9-4→15-5→20-6→26-6→21-5→15-4→8-3→2-4→45-3→39-2→32-1→27-1→32-2→38-3→45-4→3-3→8-4→14-5→21-6→27-6→20-5→14-4→9-3→3-4→44-3→38-2→33-1. Similarly, 26-1→33-2 means: the first layer of slot 26 is connected to the second layer of slot 33, and this connection belongs to the same winding of the same layer pair; 33-2→39-3 means: the second layer of slot 33 is connected to the third layer of slot 39, and this connection belongs to the connection between different windings in different layer pairs; the rest are analogous. Among them, 20-6→26-6 and 21-6→27-6 are the winding connections formed by the second branch 4.2 on the sixth layer; among them, 32-1→27-1 is the connection between the disconnection points of the first connection 5.1 and the second connection 5.2 on the second branch 4.2, which are connected through the connection copper bar 6.12.

[0034] Finally, the third branch 4.3 has the following connection path: 38-1→45-2→3-1→8-2→14-3→21-4→27-5→32-6→38-6→33-5→27-4→20-3→14-2→9-1→3-2→44-1→39-1→44-2→2-1→9-2→15-3→20-4→26-5→33-6→39-6→32-5→26-4→21-3→15-2→8-1→2-2→45-1. Similarly, 38-1→45-2 means: the first layer of slot No. 38 is connected to the second layer of slot No. 45, 45-2→3-1 means: the second layer of slot No. 45 is connected to the first layer of slot No. 3, the above connections all belong to the connection of the same layer pair, but the former belongs to the structure of the same winding, while the latter belongs to the connection between different windings of the same layer pair; 8-2→14-3 means: the second layer of slot No. 8 is connected to the third layer of slot No. 14, this connection belongs to the connection between different windings in different layer pairs; the rest are similar. 32-6→38-6 and 33-6→39-6 are the third branch 4.3 forming a loop connection on the sixth layer. Among them, 44-1→39-1 is the connection between the disconnection points of the first connection 5.1 and the second connection 5.2 on the third branch 4.3, which are connected through the connection copper bus 6.12.

[0035] It can be seen from the upper winding connection method that the two welding ends 7.2 of the first winding 2.11 and the second winding 2.12 in a winding pair 2.1 are respectively located in different layers in the same layer pair. For example, the left end of the first winding 2.11 is located in the first layer of the first layer pair 3.1, the right end of the first winding 2.11 is located in the second layer of the first layer pair 3.1, the left end of the second winding 2.12 is located in the first layer of the first layer pair 3.1, and the right end of the second winding 2.12 is located in the second layer of the first layer pair 3.1. Among them, the first branch 4.1, the second branch 4.2 and the third branch 4.3 all include a first connection 5.1 and a second connection 5.2, that is, each branch is composed of two connecting lines. In the first branch 4.1, the first connection 5.1 is: 14-1→21-2→27-3→32-4→38-5→45-6→3-5→8-6→14-6→9-5→3-6→44-5→38-4→33-3→27-2→20-1, and the second connection 5.2 is: 15-1→20-2→26-3→33-4→39-5→44-6→2-5→9-6→15-6→8-5→2-6→45-5→39-4→32-3→26-2→21-1. The first connection 5.1 and the second connection 5.2 are wound in the same manner and are located in two adjacent stator slots; the first connection 5.1 and the second connection 5.2 are connected between 20-1 and 15-1 to form an intermediate node; the layout of the second branch 4.2 and the third branch 4.3 is similar to that of the first branch 4.1. Specifically, a connection copper bar 6.12 is arranged at the intermediate node position, that is, the intermediate nodes of the first branch 4.1, the second branch 4.2 and the third branch 4.3 of the U-phase winding are all arranged on the connection copper bar 6.12. Specifically, after the winding is arranged, a busbar 6.1 is arranged at the welding end 7.2 of the stator winding, and the busbar 6.1 includes a connection copper bar 6.12 and a neutral point copper bar 6.11. The connection copper bar 6.12 is used to connect the disconnected connection between the first connection 5.1 and the second connection 5.2. The first connection and the second connection are connected at the welding end through the connection copper bar with an unconventional span, and a neutral node is formed, that is, the connection between 20-1 and 15-1, the connection between 27-1 and 32-1, and the connection between 44-1 and 39-1. Then the neutral point copper bar 6.11 is arranged at the upper end or lower end of the above-mentioned connection copper bar 6.12 (3 is arranged at the upper end in the figure), and is used for the connection of the lead-out wires or lead-in wires of each branch of the U phase. Such an arrangement can reduce the axial length of the stator 1.1 to a certain extent and reduce the volume of the motor.

[0036] In this solution, the first branch 4.1, the second branch 4.2 and the third branch 4.3 are all connected from the first layer (innermost layer), and finally connected back to the first layer at the sixth layer (outermost layer), so the lead-out wire and the lead-in wire are both on the first layer. Of course, the overall wiring and winding method can also be reversed, and it is also possible to connect from the outermost layer to the innermost layer. In the actual production process, the arrangement of the winding is to use tooling to insert the pre-arranged winding pair 2.1 into the stator slot together. Therefore, only the layout of the winding pair needs to be designed to form different wiring windings.

[0037] In this solution, in the same phase winding and in the same layer pair, the positions of the winding pairs 2.1 are separated by two phases, that is, the U phase, V phase and W phase are arranged in sequence in the stator slot, so that the winding pairs in the same phase are separated by two phases, that is, four stator slots. The winding connection needs to be connected from the first layer pair 3.1 to the third layer pair 3.3 in sequence, and it is also necessary to form a circumferential arrangement in the stator slot, so that the connection interval between the same phase windings between different layer pairs will be separated by the distance of the two-phase windings. In addition, in order to ensure the circular connection between different winding pairs 2.1, an interchange connection is formed between the first winding 2.11 and the second winding 2.12, that is, for the two interconnected winding pairs 2.1, the first winding of the first winding pair is connected to the second winding of the second winding pair, and the second winding of the first winding pair is connected to the first winding of the second winding pair.

[0038] The busbar 6.1 includes a connection copper busbar 6.12, a neutral point copper busbar 6.11 and a three-phase copper busbar 9.1. The three are formed into an integrated structure by injection molding. In order to prevent direct contact between them, it is necessary to ensure that a certain distance is maintained between the copper buses. Therefore, during the copper busbar injection molding process, a positioning block is required to ensure the gap between them. Finally, dispensing or secondary injection molding is used for insulation and sealing to ensure the performance of the motor.

[0039] like Figure 7 The figure shows the wiring diagram of the flat wire motor winding lead wires.

[0040] Example 2: Figures 1 to 3 and Figure 5 A flat wire motor stator winding is shown. This solution needs to use a stator 1.1 of a flat wire motor. Specifically, the stator 1.1 includes 48 stator slots. The number of slots in the stator 1.1 can be determined according to actual design requirements. The stator 1.1 used in this solution has 48 slots, and the stator slots are evenly distributed along the inner ring of the stator 1.1. In the stator 1.1, any stator slot is used as the No. 1 stator slot, and then the stator slots are defined as the No. 2 stator slot, the No. 3 stator slot, ..., the No. 48 stator slot in the clockwise direction (or counterclockwise direction).

[0041] The windings are arranged in the stator slots. Specifically, in this solution, only two different types of windings are needed to complete the winding arrangement of the stator slots, namely the first winding 2.11 and the second winding 2.12. The first winding 2.11 and the second winding 2.12 are both flat wire windings. The cross-section of the flat wire winding is rectangular, which can better fill the inside of the stator slots. The stator slot filling rate is higher, so that the flat wire motor can output more power per unit volume or weight. The first winding 2.11 and the second winding 2.12 are hairpin-type windings, such as Figure 5 As shown, the two ends of the stator 1.1 are defined as an upper end and a lower end respectively, the upper end of the stator 1.1 is a welding end 7.2 of the first winding 2.11 and the second winding 2.12, and the lower end of the stator 1.1 is a hairpin end 7.1 of the first winding 2.11 and the second winding 2.12, wherein the hairpin ends 7.1 of the first winding 2.11 and the second winding 2.12 are a V-shaped structure connected together, and the welding ends 7.2 of the first winding 2.11 and the second winding 2.12 are a straight copper wire structure before being inserted into the stator slot, so that the first winding 2.11 and the second winding 2.12 are easily inserted into the stator slot.

[0042] Specifically, the span of the first winding 2.11 is smaller than the span of the second winding 2.12. In the present embodiment, the two welding ends 7.2 of the first winding 2.11 span 6 stator slot pitches in the stator 1.1, and the two welding ends 7.2 of the second winding 2.12 span 8 stator slot pitches in the stator 1.1. The first winding 2.11 is just located at the inner side of the second winding 2.12, so that the first winding 2.11 and the second winding 2.12 form a winding pair 2.1. Then, the above-mentioned winding pairs 2.1 are continuously arranged in the 48 stator slots of the stator 1.1. Specifically, the first winding 2.11 is placed in the middle position of the second winding 2.12, inserted into the stator slots, and occupies four slots. Then, the second winding pair 2.1 is adopted and arranged in the stator slots in the same manner along the stator slots in a clockwise direction (or counterclockwise direction) and moved two stator slots, until all the stator slots are filled with the winding pairs 2.1.

[0043] For example, Figure 5 In the first winding pair, the two hairpin ends 7.1 of the first winding 2.11 are respectively located in the No. 1 slot and the No. 6 slot, and the two hairpin ends 7.1 of the second winding 2.12 are respectively located in the No. 48 slot and the No. 7 slot; the second winding pair is arranged at the right adjacent position of the first winding pair, that is, in the second winding pair ( Figure 5 Not shown, see Figure 4), the two hairpin ends of the first winding 2.11 are respectively located in slot No. 3 and slot No. 8, the two hairpin ends of the second winding 2.12 are respectively located in slot No. 2 and slot No. 9, and so on, so that all the stator slots on the stator 1.1 can be covered.

[0044] It should be noted that, in this embodiment, after the stator slots are filled with winding pairs 2.1, six layers of windings are formed. Of course, the number of winding layers can be determined according to actual design requirements. This solution is described with six layers of windings. The two hairpin ends 7.1 of the first winding 2.11 and the second winding 2.12 are located in the first layer and the second layer respectively. Figure 5 As shown, taking the first winding pair as an example, the left hairpin end 7.1 of the first winding 2.11 is located at the first layer position of the No. 1 slot, the right hairpin end 7.1 of the first winding 2.11 is located at the second layer position of the No. 6 slot, the left hairpin end 7.1 of the second winding 2.12 is located at the first layer position of the No. 48 slot, and the right hairpin end 7.1 of the second winding 2.12 is located at the second layer position of the No. 7 slot. The right hairpin end of the second winding in another winding pair is arranged at the second layer position of the No. 1 slot, the right hairpin end of the first winding in the above another winding pair is arranged at the second layer position of the No. 48 slot, the left hairpin end of the second winding in another winding pair is arranged at the first layer position of the No. 6 slot, and the left hairpin end of the first winding in the above another winding pair is arranged at the first layer position of the No. 7 slot.

[0045] As can be seen from the above, this winding method arranges the winding pairs in two adjacent layers as a whole. Therefore, this solution regards the first and second layers, the third and fourth layers, and the fifth and sixth layers as three layer pairs. The first layer is the inner diameter side of the stator 1.1, and the sixth layer is the outer diameter side of the stator 1.1. Each winding pair is arranged in the corresponding layer pair. When wiring, it is only necessary to wire the winding pairs 2.1 in different layer pairs. Specifically, in the first layer pair 3.1 of the first and second layers, in the second layer pair 3.2 of the third and fourth layers, and in the third layer pair 3.3 of the fifth and sixth layers, a winding pair 2.1 will be arranged in the same corresponding position, that is, in Figure 5 As shown, in the first and second layers, slot No. 48, slot No. 1, slot No. 6 and slot No. 7 are arranged with a group of winding pairs 2.1, and correspondingly in the third and fourth layers, fifth and sixth layers, slot No. 48, slot No. 1, slot No. 6 and slot No. 7 are also arranged with a group of winding pairs 2.1, and the arrangement of the winding pairs 2.1 in the third and fourth layers, fifth and sixth layers is the same as that in the first and second layers.

[0046] Then the winding pair 2.1 arranged in the stator slot is connected. Specifically, Figure 5As shown, it is a schematic diagram of the parallel winding of the V-phase winding of this scheme. The V-phase winding includes three branches, namely the first branch 4.1, the second branch 4.2 and the third branch 4.3. The number of branches can also be selected according to actual design needs.

[0047] First is the first branch 4.1, whose connection path is as follows: 18-1→25-2→31-3→36-4→42-5→1-6→7-5→12-6→18-6→13-5→7-6→48-5→42-4→37-3→31-2→24-1→19-1→24-2→30-3→37-4→43-5→48-6→6-5→13-6→19-6→12-5→6-6→1-5→43-4→36-3→30-2→25-1. Among them, 18-1→25-2 means: the first layer of slot 18 is connected to the second layer of slot 25, and this connection belongs to the same winding in the same layer pair; 25-2→31-3 means: the second layer of slot 25 is connected to the third layer of slot 31, and this connection belongs to the connection between different windings in different layer pairs; the rest are similar. 12-6→18-6 and 13-6→19-6 are the winding connections formed by the first branch 4.1 on the sixth layer. Among them, 24-1→19-1 is the connection between the disconnection points of the first wiring 5.1 and the second wiring 5.2 on the first branch 4.1, which are connected through the wiring copper bus 6.12.

[0048] Then comes the second branch 4.2, whose connection path is as follows: 30-1→37-2→43-3→48-4→6-3→13-4→19-5→24-6→30-6→25-5→19-4→12-3→6-4→1-3→43-2→36-1→31-1→36-2→42-3→1-4→7-3→12-4→18-5→25-6→31-6→24-5→18-4→13-3→7-4→48-3→42-2→37-1. Similarly, 30-1→37-2 means: the first layer of slot 30 is connected to the second layer of slot 37, and this connection belongs to the same winding of the same layer pair; 37-2→43-3 means: the second layer of slot 37 is connected to the third layer of slot 43, and this connection belongs to the connection between different windings in different layer pairs; the rest are similar. 24-6→30-6 and 25-6→31-6 are the second branch 4.2 forming a loop connection on the sixth layer. Among them, 36-1→31-1 is the connection between the disconnection points of the first connection 5.1 and the second connection 5.2 on the second branch 4.2, which are connected through the connection copper bar 6.12.

[0049] Finally, the third branch 4.3 has the following connection path: 42-1→1-2→7-1→12-2→18-3→25-4→31-5→36-6→42-6→37-5→31-4→24-3→18-2→13-1→7-2→48-1→43-1→48-2→6-1→13-2→19-3→24-4→30-5→37-6→43-6→36-5→30-4→25-3→19-2→12-1→6-2→1-1. Similarly, 42-1→1-2 means: the first layer of slot No. 42 is connected to the second layer of slot No. 1, 1-2→7-1 means: the second layer of slot No. 1 is connected to the first layer of slot No. 7, the above connections all belong to the connection of the same layer pair, but the former belongs to the structure of the same winding, while the latter belongs to the connection between different windings of the same layer pair; 12-2→18-3 means: the second layer of slot No. 12 is connected to the third layer of slot No. 18, this connection belongs to the connection between different windings in different layer pairs; the rest are similar. 36-6→42-6 and 37-6→43-6 are the third branch 4.3 forming a loop connection on the sixth layer. Among them, 48-1→43-1 is the connection between the disconnection points of the first connection 5.1 and the second connection 5.2 on the third branch 4.3, which are connected through the connection copper bus 6.12.

[0050] It can be seen from the upper winding connection method that the two welding ends 7.2 of the first winding 2.11 and the second winding 2.12 in a winding pair 2.1 are respectively located in different layers in the same layer pair. For example, the left end of the first winding 2.11 is located in the first layer of the first layer pair 3.1, the right end of the first winding 2.11 is located in the second layer of the first layer pair 3.1, the left end of the second winding 2.12 is located in the first layer of the first layer pair 3.1, and the right end of the second winding 2.12 is located in the second layer of the first layer pair 3.1. Among them, the first branch 4.1, the second branch 4.2 and the third branch 4.3 all include a first connection 5.1 and a second connection 5.2, that is, each branch is composed of two connecting lines. In the first branch 4.1, the first connection 5.1 is: 18-1→25-2→31-3→36-4→42-5→1-6→7-5→12-6→18-6→13-5→7-6→48-5→42-4→37-3→31-2→24-1, and the second connection 5.2 is: 19-1→24-2→30-3→37-4→43-5→48-6→6-5→13-6→19-6→12-5→6-6→1-5→43-4→36-3→30-2→25-1. The first connection 5.1 and the second connection 5.2 are wound in the same manner and are located in two adjacent stator slots; the first connection 5.1 and the second connection 5.2 are connected between 24-1 and 19-1 to form an intermediate node; the layout of the second branch 4.2 and the third branch 4.3 is similar to that of the first branch 4.1. Specifically, a connection copper bar 6.12 is arranged at the intermediate node position, that is, the intermediate nodes of the first branch 4.1, the second branch 4.2 and the third branch 4.3 of the V-phase winding are all arranged on the connection copper bar 6.12. Specifically, after the winding is arranged, a busbar 6.1 is arranged at the welding end 7.2 of the stator winding, and the busbar 6.1 includes a connection copper bar 6.12 and a neutral point copper bar 6.11. The connection copper bar 6.12 is used to connect the disconnected connection between the first connection 5.1 and the second connection 5.2. The first connection 5.1 and the second connection 5.2 are connected at the welding end 7.2 through the connection copper bar 6.12 with an unconventional span, and form a neutral node, that is, the connection between 24-1→19-1, the connection between 31-1 and 36-1, and the connection between 48-1 and 43-1. Then the neutral point copper bar 6.11 is arranged at the upper end or lower end of the above connection copper bar 6.12 (3 is arranged at the upper end in the figure), and is used for connecting the lead-out wires or lead-in wires of each branch of the V phase. Such an arrangement can reduce the axial length of the stator 1.1 to a certain extent and reduce the volume of the motor.

[0051] In this solution, the first branch 4.1, the second branch 4.2 and the third branch 4.3 are all connected from the first layer (innermost layer), and finally connected back to the first layer at the sixth layer (outermost layer), so the lead-out wire and the lead-in wire are both on the first layer. Of course, the overall wiring and winding method can also be reversed, and it is also possible to connect from the outermost layer to the innermost layer. In the actual production process, the arrangement of the winding is to use tooling to insert the pre-arranged winding pair 2.1 into the stator slot together. Therefore, only the layout of the winding pair needs to be designed to form different wiring windings.

[0052] In this solution, in the same phase winding and in the same layer pair, the positions of the winding pairs 2.1 are separated by two phases, that is, the U phase, V phase and W phase are arranged in sequence in the stator slot, so that the winding pairs in the same phase are separated by two phases, that is, four stator slots. The winding connection needs to be connected from the first layer pair 3.1 to the third layer pair 3.3 in sequence, and it is also necessary to form a circumferential arrangement in the stator slot, so that the connection interval between the same phase windings between different layer pairs will be separated by the distance of the two-phase windings. In addition, in order to ensure the circular connection between different winding pairs 2.1, an interchange connection is formed between the first winding 2.11 and the second winding 2.12, that is, for the two interconnected winding pairs 2.1, the first winding of the first winding pair is connected to the second winding of the second winding pair, and the second winding of the first winding pair is connected to the first winding of the second winding pair.

[0053] The busbar 6.1 includes a connection copper busbar 6.12, a neutral point copper busbar 6.11 and a three-phase copper busbar 9.1. The three are formed into an integrated structure by injection molding. In order to prevent direct contact between them, it is necessary to ensure that a certain distance is maintained between the copper buses. Therefore, during the copper busbar injection molding process, a positioning block is required to ensure the gap between them. Finally, dispensing or secondary injection molding is used for insulation and sealing to ensure the performance of the motor.

[0054] Example 3: Figures 1 to 3 as well as Figure 6 A flat wire motor stator winding is shown. This solution needs to use a stator 1.1 of a flat wire motor. Specifically, the stator 1.1 includes 48 stator slots. The number of slots in the stator 1.1 can be determined according to actual design requirements. The stator 1.1 used in this solution has 48 slots, and the stator slots are evenly distributed along the inner ring of the stator 1.1. In the stator 1.1, any stator slot is used as the No. 1 stator slot, and then the stator slots are defined as the No. 2 stator slot, the No. 3 stator slot, ..., the No. 48 stator slot in the clockwise direction (or counterclockwise direction).

[0055] The windings are arranged in the stator slots. Specifically, in this solution, only two different types of windings are needed to complete the winding arrangement of the stator slots, namely the first winding 2.11 and the second winding 2.12. The first winding 2.11 and the second winding 2.12 are both flat wire windings. The cross-section of the flat wire winding is rectangular, which can better fill the inside of the stator slots. The stator slot filling rate is higher, so that the flat wire motor can output more power per unit volume or weight. The first winding 2.11 and the second winding 2.12 are hairpin-type windings, such as Figure 6 As shown, the two ends of the stator 1.1 are defined as an upper end and a lower end respectively, the upper end of the stator 1.1 is a welding end 7.2 of the first winding 2.11 and the second winding 2.12, and the lower end of the stator 1.1 is a hairpin end 7.1 of the first winding 2.11 and the second winding 2.12, wherein the hairpin ends 7.1 of the first winding 2.11 and the second winding 2.12 are a V-shaped structure connected together, and the welding ends 7.2 of the first winding 2.11 and the second winding 2.12 are a straight copper wire structure before being inserted into the stator slot, so that the first winding 2.11 and the second winding 2.12 are easily inserted into the stator slot.

[0056] Specifically, the span of the first winding 2.11 is smaller than the span of the second winding 2.12. In the present embodiment, the two welding ends 7.2 of the first winding 2.11 span 6 stator slot pitches in the stator 1.1, and the two welding ends 7.2 of the second winding 2.12 span 8 stator slot pitches in the stator 1.1. The first winding 2.11 is just located at the inner side of the second winding 2.12, so that the first winding 2.11 and the second winding 2.12 form a winding pair 2.1. Then, the above-mentioned winding pairs 2.1 are continuously arranged in the 48 stator slots of the stator 1.1. Specifically, the first winding 2.11 is placed in the middle position of the second winding 2.12, inserted into the stator slots, and occupies four slots. Then, the second winding pair 2.1 is adopted and arranged in the stator slots in the same manner along the stator slots in a clockwise direction (or counterclockwise direction) and moved two stator slots, until all the stator slots are filled with the winding pairs 2.1.

[0057] For example, Figure 6 In the first winding pair, the two hairpin ends 7.1 of the first winding 2.11 are respectively located in the 5th slot and the 10th slot, and the two hairpin ends 7.1 of the second winding 2.12 are respectively located in the 4th slot and the 11th slot; the second winding pair is arranged at the right adjacent position of the first winding pair, that is, in the second winding pair ( Figure 6 Not shown, see Figure 5), the two hairpin ends of the first winding 2.11 are respectively located in slot No. 7 and slot No. 12, the two hairpin ends of the second winding 2.12 are respectively located in slot No. 6 and slot No. 13, and so on, so as to cover all the stator slots on the stator 1.1.

[0058] It should be noted that, in this embodiment, after the stator slots are filled with winding pairs 2.1, six layers of windings are formed. Of course, the number of winding layers can be determined according to actual design requirements. This solution is described with six layers of windings. The two hairpin ends 7.1 of the first winding 2.11 and the second winding 2.12 are respectively located in the first layer and the second layer. Figure 6 As shown, taking the first winding pair as an example, the left side hairpin end 7.1 of the first winding 2.11 is located at the first layer position of the 5th slot, the right side hairpin end 7.1 of the first winding 2.11 is located at the second layer position of the 10th slot, the left side hairpin end 7.1 of the second winding 2.12 is located at the first layer position of the 4th slot, and the right side hairpin end 7.1 of the second winding 2.12 is located at the second layer position of the 11th slot. The right side hairpin end of the second winding in another winding pair is arranged at the second layer position of the 5th slot, the right side hairpin end of the first winding in the above another winding pair is arranged at the second layer position of the 4th slot, the left side hairpin end of the second winding in another winding pair is arranged at the first layer position of the 10th slot, and the left side hairpin end of the first winding in the above another winding pair is arranged at the first layer position of the 11th slot.

[0059] As can be seen from the above, this winding method arranges the winding pairs in two adjacent layers as a whole. Therefore, this solution regards the first and second layers, the third and fourth layers, and the fifth and sixth layers as three layer pairs. The first layer is the inner diameter side of the stator 1.1, and the sixth layer is the outer diameter side of the stator 1.1. Each winding pair is arranged in the corresponding layer pair. When wiring, it is only necessary to wire the winding pairs 2.1 in different layer pairs. Specifically, in the first layer pair 3.1 of the first and second layers, in the second layer pair 3.2 of the third and fourth layers, and in the third layer pair 3.3 of the fifth and sixth layers, a winding pair 2.1 will be arranged in the same corresponding position, that is, in Figure 6 As shown, in the first and second layers, slot No. 4, slot No. 5, slot No. 10 and slot No. 11 are arranged with a group of winding pairs 2.1, and correspondingly in the third and fourth layers, fifth and sixth layers, slot No. 4, slot No. 5, slot No. 10 and slot No. 11 are also arranged with a group of winding pairs 2.1. The arrangement of the winding pairs 2.1 in the third and fourth layers, fifth and sixth layers is the same as that of the winding pairs 2.1 in the first and second layers.

[0060] Then the winding pair 2.1 arranged in the stator slot is connected. Specifically, Figure 6As shown, it is a schematic diagram of the parallel winding of the W-phase winding of this scheme. The W-phase winding includes three branches, namely the first branch 4.1, the second branch 4.2 and the third branch 4.3. The number of branches can also be selected according to actual design needs.

[0061] First is the first branch 4.1, whose connection path is as follows: 22-1→29-2→35-3→40-4→46-5→5-6→11-5→16-6→22-6→17-5→11-6→4-5→46-4→41-3→35-2→28-1→23-1→28-2→24-3→41-4→47-5→4-6→10-5→17-6→23-6→16-5→10-6→5-5→47-4→40-3→34-2→29-1. Among them, 22-1→29-2 means: the first layer of slot No. 22 is connected to the second layer of slot No. 29, and this connection belongs to the same winding in the same layer pair; 29-2→35-3 means: the second layer of slot No. 29 is connected to the third layer of slot No. 35, and this connection belongs to the connection between different windings in different layer pairs; the rest are similar. 16-6→22-6 and 17-6→23-6 are the winding connections formed by the first branch 4.1 on the sixth layer. Among them, 28-1→23-1 is the connection between the disconnection points of the first wiring 5.1 and the second wiring 5.2 on the first branch 4.1, which are connected through the wiring copper bus 6.12.

[0062] Then comes the second branch 4.2, whose connection path is as follows: 34-1→41-2→47-3→4-4→10-3→17-4→23-5→28-6→34-6→29-5→23-4→16-3→10-4→5-3→47-2→40-1→35-1→40-2→46-3→5-4→11-3→16-4→22-5→29-6→35-6→28-5→22-4→17-3→11-4→4-3→46-2→41-1. Similarly, 34-1→41-2 means: the first layer of slot 34 is connected to the second layer of slot 41, and this connection belongs to the same winding of the same layer pair; 41-2→47-3 means: the second layer of slot 41 is connected to the third layer of slot 47, and this connection belongs to the connection between different windings in different layer pairs; the rest are similar. 28-6→34-6 and 29-6→35-6 are the second branch 4.2 forming a loop connection on the sixth layer. Among them, 40-1→35-1 is the connection between the disconnection points of the first connection 5.1 and the second connection 5.2 on the second branch 4.2, which are connected through the connection copper bar 6.12.

[0063] Finally, the third branch 4.3 has the following connection path: 46-1→5-2→11-1→16-2→22-3→29-4→35-5→40-6→46-6→41-5→35-4→28-3→22-2→17-1→11-2→4-1→47-1→4-2→10-1→17-2→23-3→28-4→34-5→41-6→47-6→40-5→34-4→29-3→232→16-1→10-2→5-1. Similarly, 46-1→5-2 means: the first layer of slot No. 46 is connected to the second layer of slot No. 5, 5-2→11-1 means: the second layer of slot No. 5 is connected to the first layer of slot No. 11, the above connections all belong to the connection of the same layer pair, but the former belongs to the structure of the same winding, while the latter belongs to the connection between different winding pairs of the same layer pair; 16-2→22-3 means: the second layer of slot No. 16 is connected to the third layer of slot No. 22, this connection belongs to the connection between different windings in different layer pairs; the rest are similar. 40-6→46-6 and 41-6→47-6 are the third branch 4.3 forming a loop connection on the sixth layer. Among them, 4-1→47-1 is the connection between the disconnection points of the first connection 5.1 and the second connection 5.2 on the third branch 4.3, which are connected through the connection copper bus 6.12.

[0064] It can be seen from the upper winding connection method that the two welding ends 7.2 of the first winding 2.11 and the second winding 2.12 in a winding pair 2.1 are respectively located in different layers in the same layer pair. For example, the left end of the first winding 2.11 is located in the first layer of the first layer pair 3.1, the right end of the first winding 2.11 is located in the second layer of the first layer pair 3.1, the left end of the second winding 2.12 is located in the first layer of the first layer pair 3.1, and the right end of the second winding 2.12 is located in the second layer of the first layer pair 3.1. Among them, the first branch 4.1, the second branch 4.2 and the third branch 4.3 all include a first connection 5.1 and a second connection 5.2, that is, each branch is composed of two connecting lines. In the first branch 4.1, the first connection 5.1 is: 22-1→29-2→35-3→40-4→46-5→5-6→11-5→16-6→22-6→17-5→11-6→4-5→46-4→41-3→35-2→28-1, and the second connection 5.2 is: 23-1→28-2→24-3→41-4→47-5→4-6→10-5→17-6→23-6→16-5→10-6→5-5→47-4→40-3→34-2→29-1. The first connection 5.1 and the second connection 5.2 are wound in the same manner and are located in two adjacent stator slots; the first connection 5.1 and the second connection 5.2 are connected between 28-1 and 23-1 to form an intermediate node; the layout of the second branch 4.2 and the third branch 4.3 is similar to that of the first branch 4.1. Specifically, a connection copper bar 6.12 is arranged at the intermediate node position, that is, the intermediate nodes of the first branch 4.1, the second branch 4.2 and the third branch 4.3 of the W-phase winding are all arranged on the connection copper bar 6.12. Specifically, after the winding is arranged, a busbar 6.1 is arranged at the welding end 7.2 of the stator winding, and the busbar 6.1 includes a connection copper bar 6.12 and a neutral point copper bar 6.11. The connection copper bar 6.12 is used to connect the disconnected connection between the first connection 5.1 and the second connection 5.2. The first connection 5.1 and the second connection 5.2 are connected at the welding end 7.2 through the connection copper bar 6.12 with an unconventional span, and form a neutral node, that is, the connection between 28-1→23-1, the connection between 35-1 and 40-1, and the connection between 4-1 and 47-1. Then the neutral point copper bar 6.11 is arranged at the upper end or lower end of the above connection copper bar 6.12 (3 is arranged at the upper end in the figure), and is used for connecting the lead-out wires or lead-in wires of each branch of the W phase. Such an arrangement can reduce the axial length of the stator 1.1 to a certain extent and reduce the volume of the motor.

[0065] In this solution, the first branch 4.1, the second branch 4.2 and the third branch 4.3 are all connected from the first layer (innermost layer), and finally connected back to the first layer at the sixth layer (outermost layer), so the lead-out wire and the lead-in wire are both on the first layer. Of course, the overall wiring and winding method can also be reversed, and it is also possible to connect from the outermost layer to the innermost layer. In the actual production process, the arrangement of the winding is to use tooling to insert the pre-arranged winding pair 2.1 into the stator slot together. Therefore, only the layout of the winding pair needs to be designed to form different wiring windings.

[0066] In this solution, in the same phase winding and in the same layer pair, the positions of the winding pairs 2.1 are separated by two phases, that is, the U phase, V phase and W phase are arranged in sequence in the stator slot, so that the winding pairs in the same phase are separated by two phases, that is, four stator slots. The winding connection needs to be connected from the first layer pair 3.1 to the third layer pair 3.3 in sequence, and it is also necessary to form a circumferential arrangement in the stator slot, so that the connection interval between the same phase windings between different layer pairs will be separated by the distance of the two-phase windings. In addition, in order to ensure the circular connection between different winding pairs 2.1, an interchange connection is formed between the first winding 2.11 and the second winding 2.12, that is, for the two interconnected winding pairs 2.1, the first winding of the first winding pair is connected to the second winding of the second winding pair, and the second winding of the first winding pair is connected to the first winding of the second winding pair.

[0067] The busbar 6.1 includes a connection copper busbar 6.12, a neutral point copper busbar 6.11 and a three-phase copper busbar 9.1. The three are formed into an integrated structure by injection molding. In order to prevent direct contact between them, it is necessary to ensure that a certain distance is maintained between the copper buses. Therefore, during the copper busbar injection molding process, a positioning block is required to ensure the gap between them. Finally, dispensing or secondary injection molding is used for insulation and sealing to ensure the performance of the motor.

[0068] Embodiment 4: The three-phase windings of the U phase, V phase and W phase in Embodiment 1, Embodiment 2 and Embodiment 3 are arranged in the stator slots to complete the winding arrangement of the stator winding of the flat wire motor, wherein the neutral point copper bar 6.11 of the three-phase windings of the U phase, V phase and W phase is arranged along the circumference of the winding on one side of the welding end 7.2 of the stator winding, and the busbar 6.1 and the stator 1.1 are fixed by welding. A three-phase copper bar 9.1 is also arranged on the busbar 6.1, and the three-phase copper bar, the wiring copper bar and the neutral point copper bar are injection molded as one, and are the wiring leads of the U phase, the V phase and the W phase respectively. The three-phase copper bar 9.1 is arranged on the third layer, the fourth layer and the fifth layer of the stator winding respectively; a soft connecting conductor 10.1 is also connected to the three-phase copper bar 9.1, and the other end of the soft connecting conductor 10.1 is provided with a copper sheet with a round hole to meet the assembly requirements of other subsequent parts.

[0069] After the three-phase windings of the U phase, V phase and W phase are designed and laid out, the windings are inserted into the stator slots at the same time using a tool or equipment, and then the windings are twisted and formed using a twisting tool or equipment so that the first winding 2.11 and the second winding 2.12 on the corresponding winding pair can be close to each other, which is conducive to the welding connection between different winding pairs 2.1.

[0070] In this scheme, fewer types of hairpin winding wires are used, which can reduce the investment in hairpin forming equipment and tooling for the production line. The wire type classification is simple and easy to manage; the welding ends are regular and regular, and different winding schemes can be easily switched by the production line turning tooling; the disconnected parts of each branch of the winding are connected by the end bus, which can reduce the structural size of the winding connection and is easier to operate on the process end; the copper busbars in the busbar 6.1 are reasonably arranged, fixed together by tooling and injection molding, and the process assembly operability is high. Through the selection of injection molding materials, the insulation performance between the copper busbars can be increased in a smaller gap.

Claims

1. A flat wire motor stator winding, comprising a stator, wherein a plurality of stator slots are provided inside the stator, characterized in that: The invention comprises a winding pair formed by a first winding and a second winding, and the winding pair is continuously arranged along the circumference of the stator slot, and the winding pair is radially formed into an even number of layers in the stator slot; The first layer and the second layer are arranged as a first layer pair, and the third layer and the fourth layer are arranged as a second layer pair in sequence; the two ends of the first winding and the second winding are arranged in the odd-numbered layers and the even-numbered layers of the same layer pair respectively; The winding pairs of different layers are connected along the circumferential direction of the stator.

2. A flat wire motor stator winding according to claim 1, characterized in that: The span of the first winding is smaller than the span of the second winding, and the first winding is arranged inside the second winding.

3. A flat wire motor stator winding according to claim 1 or 2, characterized in that: The winding pair forms a three-phase winding, each phase winding includes N branches, the branches include a first connection and a second connection, and when N is an odd number, the first connection and the second connection are connected to form an intermediate node.

4. A flat wire motor stator winding according to claim 3, characterized in that: Each branch is connected in a winding manner at the innermost layer or the outermost layer or the innermost and outermost layers of the stator.

5. A flat wire motor stator winding according to claim 1 or 2, characterized in that: The winding pairs in different layer pairs are connected to the winding pairs in adjacent layer pairs with an interval of two phases.

6. A flat wire motor stator winding according to claim 5, characterized in that: The first winding and the second winding between different winding pairs are connected interchangeably.

7. The flat wire motor stator winding according to claim 3, characterized in that: It also includes a busbar, which is fixed to the stator by welding; the busbar includes a neutral point copper bar, a wiring copper bar and a three-phase copper bar, the neutral point copper bar is connected to the lead-in wire or the lead-out wire of each phase winding, and the wiring copper bar is connected to the first wiring and the second wiring; the neutral point copper bar, the wiring copper bar and the three-phase copper bar are arranged along the circumference of the winding, and the neutral point copper bar is arranged above or below the wiring copper bar and the three-phase copper bar.

8. A flat wire motor stator winding according to claim 7, characterized in that: During the injection molding process, positioning blocks are used to position the copper bars of the busbars to ensure the gap. After the injection molding is completed, dispensing or secondary injection molding is used for insulation and sealing.

9. The flat wire motor stator winding according to claim 3, characterized in that: The copper bars leading out the three-phase windings are led out using soft connections, and the copper bars of each phase winding are distributed along the radial direction of the winding.

10. The flat wire motor stator winding according to claim 1, characterized in that: Before connecting the winding pairs of different layers, the winding pairs are twisted and formed by using a twisting tool or equipment, and the winding pairs are connected by welding.

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