Flat wire motor wire plugging method, flat wire motor and vehicle

Abstract

The invention belongs to the technical field of flat wire motors, and discloses a flat wire motor wire plugging method, a flat wire motor and a vehicle. A flat wire motor stator comprises six pole single-layer distribution windings; z rectangular stator grooves are uniformly arranged along the circumferential direction of the flat wire motor stator, and m layers of flat wire conductors are arranged in each rectangular stator groove; the flat wire motor stator comprises three phases of winding structures, and each phase of winding structure is provided with n parallel branches. The Yth stator slot of the Xth layer and the Y-zth / pth stator slot of the (X + 1) th layer are in cross-layer welding through a first coil, and the Y-zth / pth stator slot of the (X + 1) th layer and the Y-2z / pth stator slot of the Xth layer are in cross-layer welding through a second coil; and the Kth stator slot of the (X + 1) th layer and the (K-z / p) th stator slot of the (m-X) th layer are welded in a cross-layer manner through a third coil, and X is an odd number. According to the invention, a wire plugging mode formed by combining three-phase p-pole z-slot m-layer n branches can be satisfied, and the influence of the maximum back electromotive force and the circulating current between the branches is small.

Description

Technical Field

[0001] The invention relates to the technical field of flat wire motors, and in particular to a flat wire motor plugging method, a flat wire motor and a vehicle. Background Art

[0002] With the vigorous development of the new energy vehicle industry, the high power density and high torque density performance indicators of drive motors have received increasing attention. In this technical context, motors using flat wire windings have become a technical solution with great application prospects due to their high power density, torque density and efficiency advantages. However, in the specific implementation of flat wire motors, the application of hairpin flat wire windings (Hair-pin) faces many technical challenges: first, its arrangement in the stator slot is relatively complex, and there are various line types; second, the motor's pole slot matching, the number of winding layers and the combination of winding branches show diverse characteristics. Especially under the combined working conditions of 3-phase p-pole z-slot m-layer n-branch, due to its inherent phase belt distribution characteristics, the traditional plug-in method can no longer simultaneously meet the technical requirements of maximum back electromotive force and avoiding the influence of circulating current. At present, there is no solution that can be generally applied to the stator of 3-phase p-pole z-slot m-layer n-branch flat wire motors, so it is urgent to develop new technical solutions to break through the above technical bottlenecks. Summary of the invention

[0003] In order to solve or partially solve the problems existing in the related art, the purpose of the present invention is to provide a flat wire motor plug-in method, a flat wire motor and a vehicle, which can meet the plug-in method formed by a combination of 3-phase p-pole z-slot m-layer n-branch, and has little influence on the maximum back electromotive force and the circulating current between branches.

[0004] To achieve the above-mentioned object, the present invention provides a flat wire motor plugging method, which is used for plugging the stator of a flat wire motor with 3-phase p-pole z-slot m-layer n-branch, wherein z / p / 3≥2 and is an integer, m / n=2, and the pole pitch is z / p; the flat wire motor stator comprises a 6-pole single-layer distributed winding; the flat wire motor stator is evenly provided with z rectangular stator slots along the circumferential direction, and each rectangular stator slot has m layers of flat wire conductors; the flat wire motor stator comprises a three-phase winding structure, and each phase winding structure has n parallel branches; the Y-th stator slot of the X-th layer and the Yz / p-th stator slot of the X+1-th layer are welded across layers by a first coil, the Yz / p-th stator slot of the X+1-th layer and the Y-2z / p-th stator slot of the X-th layer are welded across layers by a second coil; the K-th stator slot of the X+1-th layer and the Kz / p-th stator slot of the mX-th layer are welded across layers by a third coil, X is an odd number, and K is an arbitrary value.

[0005] In a preferred embodiment of the present invention, two adjacent parallel branches differ in space by 60°.

[0006] In a preferred embodiment of the present invention, the coil is a hairpin coil.

[0007] In a preferred embodiment of the present invention, each phase winding structure comprises a welding end and an insertion end, and the three-phase power lead wire and the neutral wire are arranged at the insertion end or the welding end.

[0008] In a preferred embodiment of the present invention, each phase winding structure is composed of n branches connected in parallel, and each branch is composed of 4 layers of hairpin-type flat copper wires in m layers.

[0009] In a preferred embodiment of the present invention, the three-phase winding structure includes a U-phase winding, a V-phase winding and a W-phase winding.

[0010] In a preferred embodiment of the present invention, each three-phase winding structure occupies 3 stator slots under each pole.

[0011] In a preferred embodiment of the present invention, the first coil and the second coil are arranged in mirror symmetry. The present invention also discloses a flat wire motor, which is manufactured by a flat wire motor plugging method.

[0012] The invention also discloses a vehicle, comprising a flat wire motor.

[0013] The invention has the following advantages: the stator winding arrangement scheme of the flat wire motor provided by the invention has many significant advantages. First, in terms of electromagnetic performance, the scheme cleverly solves the technical difficulties under the specific combination of 6 poles, 54 slots, 8 layers and 4 branches. Through the innovative winding arrangement design, the maximum back electromotive force is successfully generated, while the influence of the circulating current between the branches is effectively suppressed. This optimization not only improves the electromagnetic performance of the motor, but also ensures the stability and reliability of operation.

[0014] Secondly, at the process implementation level, the present invention adopts a highly standardized design concept. By unifying the twist angle design of the welding end, all welding points maintain a consistent twist angle, which greatly simplifies the complexity of the welding process. At the same time, a unified winding span design is adopted at the plug-in end. This standardized design significantly improves the manufacturing processability of the winding and creates favorable conditions for the application of automated production lines. This not only improves production efficiency and reduces labor costs, but also ensures product consistency and quality stability.

[0015] More importantly, the technical solution of the present invention has strong versatility and compatibility. The winding arrangement scheme is not only suitable for specific pole slot combinations, but can also be flexibly extended to other pole slot combinations with similar characteristics. This good scalability enables the present invention to adapt to the production and manufacturing of different electromagnetic performance requirements, providing greater flexibility for motor design. Especially in the increasingly diverse application scenarios of new energy vehicle drive motors, this highly compatible technical solution has important engineering application value, which can effectively reduce design costs and shorten product development cycles. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] In order to more clearly illustrate the technical solutions of the embodiments disclosed in the present invention, the drawings of the embodiments will be briefly introduced below. These drawings are only used for illustrative purposes and are not intended to limit the protection scope of the present invention.

[0017] Figure 1 This is a schematic diagram of the winding method of the first branch of one phase of an 8-layer flat wire hairpin winding;

[0018] Figure 2 This is a schematic diagram of the winding method of the second branch of one phase of an 8-layer flat wire hairpin winding;

[0019] Figure 3 This is a schematic diagram of the winding method of the third branch of one phase of an 8-layer flat wire hairpin winding;

[0020] Figure 4 This is a schematic diagram of the winding method of the fourth branch of one phase of an 8-layer flat wire hairpin winding;

[0021] Figure 5 This is a schematic diagram of the winding method of 4 branches of one phase of an 8-layer flat wire hairpin winding;

[0022] Figure 6 It is a schematic diagram of the winding method of 8-layer flat wire hairpin winding 3 phases;

[0023] Figure 7 This is the development diagram of the winding method of the first branch of one phase of an 8-layer flat wire hairpin winding;

[0024] Figure 8 This is the development diagram of the winding method of the second branch of one phase of the 8-layer flat wire hairpin winding;

[0025] Fig. 9 This is the development diagram of the winding method of the third branch of one phase of the 8-layer flat wire hairpin winding;

[0026] Fig.10 This is the expanded diagram of the winding method of the fourth branch of one phase of an 8-layer flat wire hairpin winding. DETAILED DESCRIPTION

[0027] The technical solution of the present invention (including the preferred technical solution) is further described in detail below by means of the accompanying drawings and by listing some optional embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0028] The present invention provides a flat wire motor plugging method, which significantly improves the safety and stability of the flat wire motor rear seat through innovative design and layout. The specific implementation of the present invention will be described in detail below with reference to the accompanying drawings.

[0029] This implementation case takes a full-pitch single-layer wave winding with a pole pair number P=3, a slot number Z=54, and a conductor number N=24 per slot as an example to further explain the flat wire motor plugging method of the present invention.

[0030] The flat wire hairpin stator of the present invention includes a 6-pole single-layer distributed winding, 54 rectangular stator slots are evenly distributed along the circumference, and each rectangular slot has 8 layers of flat wire conductors. There is a three-phase winding structure, which are U, V, and W phases, each phase has a parallel branch, a is 1, 2, 3, and 4, and each phase occupies 3 stator slots under each pole. The hairpin winding is divided into a welding end and an insertion end. The three-phase power lead wire and the neutral wire can be set at the insertion end or the welding end, and the other coils use coils. Among them, the first branch is distributed on the first and second layers and the seventh and eighth layers, and the two ends of the hairpin coil are placed across the layers and the coil span is consistent. The welding ends are all cross-layer welded, and the welding twist angles are consistent. The second branch is connected in the same way as the first branch, and rotates 2 poles. The third branch is connected in the same way as the fourth branch, and is distributed on the third and fourth layers and the fifth and sixth layers.

[0031] The winding lead-out terminals U1in, U2in, U3in, U4in, V1in, V2in, V3in, V4in, W1in, W2in, W3in, W4in, U1out, U2out, U3out, U4out, V1out, V2out, V3out, V4out, W1out, W2out, W3out, W4out of the present invention have subscript numbers 1, 2, 3, 4 corresponding to the 1st branch, 2nd branch, 3rd branch, and 4th branch of each phase winding respectively, U1in, V1in, W1in are three-phase power supply access terminals, U1out, V1out, W1out are three-phase winding center point terminals, each phase winding is connected in parallel by 4 branches, and each branch is composed of 4 layers of hairpin-type flat copper wires among 1, 2, 3, 4, 5, 6, 7, and 8 layers. The first and second branches of the winding are arranged on the first and second layers and the seventh and eighth layers. The conductors of every two layers (odd and even layers) of the inserted layer are stacked by hairpin flat wire windings with a pitch of Y=9, and the welding sides are formed by twisting and welding the hairpin flat wire windings with a pitch of Y=9.

[0032] The 4 parallel branches of the U-phase winding, the first branch of the U-phase power line enters from terminal U1in and exits from terminal U1out, the second branch enters from terminal U2in and exits from terminal U2out, the third branch enters from terminal U3in and exits from terminal U3out, the fourth branch enters from terminal U4in and exits from terminal U4out, and then all the conductors are connected in series in a wave-wound form according to the direction of the winding current.

[0033] Parallel branch 1: U1 enters from the 1st layer of slot 43 (dashed line), then enters the 2nd layer of slot 34 (solid line) with a pitch of Y=9, then enters the 1st layer of slot 25 (dashed line) with a pitch of Y=9, then enters the 2nd layer of slot 16 (solid line) with a pitch of Y=9, then enters the 1st layer of slot 7 (dashed line) with a pitch of Y=9, then enters the 2nd layer of slot 52 (solid line) with a pitch of Y=9, then enters the 2nd layer of slot 54 (solid line) with a pitch of Y=1= 8 enters the first layer of slot 44 (dashed line), at this time, the first winding of the first and second layers of flat wires of the first branch is completed, and then enters the second layer of slot 35 with a pitch of Y = 9 (solid line), and then enters the first layer of slot 26 with a pitch of Y = 9 (dashed line), and then enters the second layer of slot 17 with a pitch of Y = 9 (solid line), and then enters the first layer of slot 8 with a pitch of Y = 9 (dashed line), and then enters the second layer of slot 53 with a pitch of Y = 9 Layer (solid line), and then enter the 1st layer of slot No. 45 with a pitch of Y1=8 (dashed line). At this time, the second winding of the 1st and 2nd layers of the 1st branch is completed. The third winding rule is the same as the first and second winding rules. When it is connected to the 2nd layer of slot No. 54, it is connected to the 7th layer of slot No. 45 with a pitch of Y=9, and then enters the 8th layer of slot No. 36 with a pitch of Y=9 (solid line), and then enters the 7th layer of slot No. 27 with a pitch of Y=9 (dashed line), and then enters the 8th layer of slot No. 18 with a pitch of Y=9 (solid line), and then enters the 7th layer of slot No. 9 with a pitch of Y=9 (dashed line), and then enters the 2nd layer of slot No. 54 with a pitch of Y=9 (solid line), and then enters the 7th layer of slot No. 45 with a pitch of Y1=8 (dashed line). At this time, the first winding of the 7th and 8th layers of the 1st branch is completed, and the second and third winding rules are consistent with the winding rules of the 1st and 2nd layers.

[0034] Parallel branch 2: Parallel branch 2 follows the same rule as parallel branch 1, with a 60° difference in space. The 8th layer of slot 7 is connected to the three-phase power line, and the 1st layer of slot 52 is connected to the center point.

[0035] Parallel branch 3: U1 enters from the 3rd layer of slot 43 (dashed line), then enters the 4th layer of slot 34 (solid line) with a pitch of Y=9, then enters the 3rd layer of slot 25 (dashed line) with a pitch of Y=9, then enters the 4th layer of slot 16 (solid line) with a pitch of Y=9, then enters the 3rd layer of slot 7 (dashed line) with a pitch of Y=9, then enters the 4th layer of slot 52 (solid line) with a pitch of Y=9, then enters the 4th layer of slot 54 (solid line) with a pitch of Y=9, then enters the 4th layer of slot 52 ... 8 enters the 3rd layer of slot 44 (dashed line), at this time, the first winding of the 1st and 2nd layers of flat wire of the first branch is completed, and then enters the 4th layer of slot 35 with a pitch of Y = 9 (solid line), and then enters the 3rd layer of slot 26 with a pitch of Y = 9 (dashed line), and then enters the 4th layer of slot 17 with a pitch of Y = 9 (solid line), and then enters the 3rd layer of slot 8 with a pitch of Y = 9 (dashed line), and then enters the 4th layer of slot 53 with a pitch of Y = 9 Layer (solid line), and then enter the 3rd layer of slot No. 45 with a pitch of Y1=8 (dashed line). At this time, the second winding of the 3rd and 4th layers of the 3rd branch is completed. The third winding rule is the same as the first and second winding rules. When it is connected to the 4th layer of slot No. 54, it is connected to the 5th layer of slot No. 45 with a pitch of Y=9, and then enters the 6th layer of slot No. 36 with a pitch of Y=9 (solid line), and then enters the 5th layer of slot No. 27 with a pitch of Y=9 (dashed line), and then enters the 6th layer of slot No. 18 with a pitch of Y=9 (solid line), and then enters the 5th layer of slot No. 9 with a pitch of Y=9 (dashed line), and then enters the 6th layer of slot No. 54 with a pitch of Y=9 (solid line), and then enters the 5th layer of slot No. 45 with a pitch of Y1=8 (dashed line). At this time, the first winding of the 5th and 6th layers of the 1st branch is completed, and the second and third winding rules are consistent with the winding rules of the 3rd and 4th layers.

[0036] Parallel branch 4: Parallel branch 4 follows the same rule as parallel branch 3, with a 60° difference in space. The 6th layer of slot 7 is connected to the three-phase power line, and the 3rd layer of slot 52 is connected to the center point.

[0037] Those skilled in the art will readily appreciate that the above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, combinations, replacements, improvements, etc. made within the spirit and principles of the present invention are included within the protection scope of the present invention.

Claims

1. A method for inserting a flat wire motor, characterized in that: The invention is used for inserting wires of a flat-wire motor stator with 3-phase p-pole z-slot m-layer n-branch, wherein z / p / 3≥2 and is an integer, m / n=2, and the pole pitch is z / p; the flat-wire motor stator comprises a 6-pole single-layer distributed winding; the flat-wire motor stator is evenly provided with z rectangular stator slots along the circumferential direction, and each rectangular stator slot has m layers of flat wire conductors; the flat-wire motor stator comprises a three-phase winding structure, and each phase winding structure has n parallel branches; the Y-th stator slot of the X-th layer and the Yz / p-th stator slot of the X+1-th layer are welded across layers by a first coil, the Yz / p-th stator slot of the X+1-th layer and the Y-2z / p-th stator slot of the X-th layer are welded across layers by a second coil; the K-th stator slot of the X+1-th layer and the Kz / p-th stator slot of the mX-th layer are welded across layers by a third coil, and X is an odd number.

2. The flat wire motor plugging method according to claim 1, characterized in that: The two adjacent parallel branches differ by 60° in space.

3. The flat wire motor plugging method according to claim 1, characterized in that: The coil is a hairpin type coil.

4. The flat wire motor plugging method according to claim 3, characterized in that: Each phase winding structure comprises a welding end and an insertion end, and the three-phase power lead wire and the neutral wire are arranged at the insertion end or the welding end.

5. The flat wire motor plugging method according to claim 1, characterized in that: Each phase winding structure is composed of n branches connected in parallel, and each branch is composed of 4 layers of hairpin-type flat copper wires in m layers.

6. The flat wire motor plugging method according to claim 1, characterized in that: The three-phase winding structure includes a U-phase winding, a V-phase winding and a W-phase winding.

7. The flat wire motor plugging method according to claim 1, characterized in that: Each three-phase winding structure occupies 3 stator slots under each pole.

8. The flat wire motor plugging method according to claim 1, characterized in that: The first coil and the second coil are arranged in mirror symmetry.

9. A flat wire motor, characterized in that: The flat wire motor is manufactured by the flat wire motor plugging method as claimed in any one of claims 1 to 8.

10. A vehicle, characterized in that: Comprising the flat wire motor as claimed in claim 9.

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