Hybrid winding structure, stator assembly and motor

Abstract

This application relates to a hybrid layer winding structure, a stator assembly, and a motor. The stator assembly has 2p poles, and the core has Z stator slots evenly spaced circumferentially, where Z = 18p. Every three stator slots form a group. The two stator slots on either side are sequentially arranged with slot layers 1, 2, ..., (m+1), and the stator slot in the middle is sequentially arranged with slot layers 1, 2, ..., m, where m is an even number not less than 4. Each phase winding circuit includes n parallel winding branches, and each winding branch includes several lapped coils. The lapped coils are arranged in m / 2+1 cross-layer configurations. The hybrid layer winding structure provided by this application can improve the peak power of the motor at high speeds, increase the area of ​​the motor's high-efficiency range, and significantly reduce the proportion of back EMF harmonics, thereby effectively improving the problem of low power density or low torque density in the motor.

Description

Technical Field

[0001] This application relates to the field of motor technology, and in particular to a hybrid layer winding structure, stator assembly, and motor. Background Technology

[0002] Flat-wire motors are an important component of the power system for new energy vehicles. Their stator assembly typically includes a core and windings wound around it. The winding structure of flat-wire motors usually employs an even-number layer winding design, with several stator slots on the core typically having identical slot shapes and accommodating the same number of conductor layers. When current flows through the conductors, this often generates significant harmonics and results in poor power matching, leading to low power density or torque density in the motor, necessitating improvements. Summary of the Invention

[0003] Based on this, this application provides a hybrid layer winding structure, stator assembly, and motor to improve the problem that the power density or torque density of the motor is low due to the use of an even number of winding layers and the identical slot shape of several stator slots in the prior art.

[0004] In a first aspect, this application provides a hybrid layer winding structure for a stator assembly. The stator assembly has 2p poles and includes a core component with Z stator slots evenly spaced circumferentially, where Z = 18p. In the Z stator slots, every three slots form a group. Within the same group, the two slots on either side are sequentially provided with slot layers 1, 2, ..., (m+1), and the middle slot is sequentially provided with slot layers 1, 2, ..., m, where m is an even number not less than 4. The hybrid layer winding structure includes three phases of winding lines: U, V, and W. The winding lines of phases V and W are sequentially shifted Z / 3p from the winding branch of phase U. The winding circuit of each phase is completely wound in the three stator slots that constitute the same group, and is evenly spaced by six stator slots. The winding circuit of each phase includes n parallel winding branches, and each winding branch includes several lapped coils. The lapped coil includes two spaced lapped effective edges, which are located in one of the slot layers of the stator slot. The lapped coil is provided with m / 2+1 cross-layer arrangements: the two lapped effective edges cross the first slot layer and the second slot layer, the two lapped effective edges cross the third slot layer and the fourth slot layer, ... the two lapped effective edges cross the (m-1)th slot layer and the mth slot layer, and the two lapped effective edges cross the (m+1)th slot layer and the (m+1)th slot layer.

[0005] In one embodiment, the lapped coil further includes a lapped welding end and a lapped hairpin end. Two lapped welding ends are provided, which are located at the same end of the two effective lapped sides and extend in a direction that approaches each other. The lapped hairpin end is connected to the other end of the two effective lapped sides.

[0006] In one embodiment, each winding branch further includes a bridging line that connects two of the lapped coils. The two lapped coils connected by the bridging line cross layers in a manner where two effective lapped edges cross the (m+1)th slot layer and the (m+1)th slot layer.

[0007] In one embodiment, the lapped coils of the same cross-layer method all have the same pitch.

[0008] In one embodiment, Z = 54, p = 3, m = 6, n = 2 or 3, and the pitch of the three types of lapped coils with two effective lapped edges spanning the 1st and 2nd slot layers, two effective lapped edges spanning the 3rd and 4th slot layers, and two effective lapped edges spanning the 5th and 6th slot layers are all 9 slots, and the pitch of the lapped coils with two effective lapped edges spanning the (m+1)th and (m+1)th slot layers is 7 slots.

[0009] In one embodiment, when n=2, the entry position of the first winding branch of the U phase and the entry position of the second winding branch of the U phase are respectively the first slot layer and the seventh slot layer of the same stator slot.

[0010] In one embodiment, when n=2, the first winding branch of the U phase is:

[0011] 1.1-10.2-2.1-11.2-3.1-12.2-1.3-10.4-2.3-11.4-3.3-12.4-1.5-10.6-2.5-11.6-3.5-12.6-3.7-10.7-19.7-12.7-21.6-12.5-20.6-11.5-19.6-10.5-21.4-12.3-20.4- 11.3-19.4-10.3-21.2-12.1-20.2-11.1-19.2-10.1-19.1-28.2-20.1-29.2-21.1-30.2-19.3-28.4-20.3-29.4-21.3-30.4-19.5-28.6-20.5-29.6-21.5-30.6-21.7-28.7;

[0012] The second winding branch of the U phase is:

[0013] 1.7-48.7-3.6-48.5-2.6-47.5-1.6-46.5-3.4-48.3-2.4-47.3-1.4-46.3-3.2-48.1-2.2-47.1-1.2-46.1-37.1-46.2-38.1-47.2-39.1-48.2-37.3-46.4-38.3-47.4-39.3- 48.4-37.5-46.6-38.5-47.6-39.5-48.6-39.7-46.7-37.7-30.7-39.6-30.5-38.6-29.5-37.6-28.5-39.4-30.3-38.4-29.3-37.4-28.3-39.2-30.1-38.2-29.1-37.2-28.1.

[0014] In one embodiment, when n=3, the first winding branch of the U phase is:

[0015] 1.1-10.2-2.1-11.2-3.1-12.2-1.3-10.4-2.3-11.4-3.3-12.4-1.5-10.6-2.5-11.6-3.5-12.6-3.7-10.7-19.7-12.7-21.6-12.5-20.6-11.5-19.6-10.5-21.4-12.3-20.4-11.3-19.4-10.3-21.2-12.1-20.2-11.1-19.2-10.1;

[0016] The second winding branch of the U phase is:

[0017] 19.1-28.2-20.1-29.2-21.1-30.2-19.3-28.4-20.3-29.4-21.3-30.4-19.5-28.6-20.5-29.6-21.5-30.6-21.7-28.7-37.7-30.7-39.6-30.5-38.6-29.5-37.6-28.5-39.4-30.3-38.4-29.3-37.4-28.3-39.2-30.1-38.2-29.1-37.2-28.1;

[0018] The third winding branch of the U phase is:

[0019] 37.1-46.2-38.1-47.2-39.1-48.2-37.3-46.4-38.3-47.4-39.3-48.4-37.5-46.6-38.5-47.6-39.5-48.6-39.7-46.7-1.7-48.7-3.6-48.5-2.6-47.5-1.6-46.5-3.4-48.3-2.4-47.3-1.4-46.3-3.2-48.1-2.2-47.1-1.2-46.1

[0020] Secondly, this application provides a stator assembly, which includes any of the hybrid layer winding structures provided in this application.

[0021] Thirdly, this application provides an electric motor, which includes any of the stator components provided in this application.

[0022] The hybrid layer winding structure provided in this application can improve the peak power of the motor at high speeds, increase the area of ​​the motor's high-efficiency zone, and significantly reduce the proportion of back EMF harmonics, thereby effectively improving the problem of low power density or low torque density of the motor. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the mixed-layer winding structure provided in Embodiment 1 of this application wound on an iron core.

[0024] Figure 2 A schematic diagram of the winding structure of the mixed layer winding provided in Embodiment 1 of this application, which is a 54-slot, 6-pole, parallel 2-branch winding;

[0025] Figure 3 A schematic diagram of the winding of the U phase when the mixed layer winding structure provided in Embodiment 1 of this application is 54 slots, 6 poles, and 2 parallel branches;

[0026] Figure 4 This is a schematic diagram of the structure of the lapped coil with a mixed-layer winding structure provided in Embodiment 1 of this application;

[0027] Figure 5 This is a schematic diagram of the bridge wire structure of the hybrid layer winding structure provided in Embodiment 1 of this application;

[0028] Figure 6 A schematic diagram of the winding of phase U when the mixed layer winding structure provided in Embodiment 1 of this application is 54 slots, 6 poles, and 3 branches in parallel;

[0029] Figure 7 A comparison chart of the output performance of Example 1 and the comparative example provided for the application of Example 1 of this application;

[0030] Figure 8 The opposite potential spectrum diagram of Embodiment 1 provided for Application Embodiment 2 of this application;

[0031] Figure 9 The opposite potential spectrum diagram of the comparative example provided in Embodiment 2 of this application;

[0032] Figure 10 A comparison diagram of the back potential of Embodiment 1 and the comparative example provided for the application embodiment 3 of this application;

[0033] Figure 11 A comparison chart of stator transient temperature curves of Example 1 and the comparative example provided for Application Example 4 of this application.

[0034] Reference numerals: 100, lapped coil; 110, effective lapped edge; 120, lapped welding end; 130, lapped hairpin end; 200, bridge wire; 210, bridge arc segment; 220, bridge welding end; 300, core component; 310, stator slot. Detailed Implementation

[0035] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0036] It should be noted that the illustrations provided in this embodiment are only schematic representations of the basic concept of the present invention.

[0037] The structures, proportions, sizes, etc., shown in the accompanying drawings of this specification are only for the purpose of assisting those skilled in the art in understanding and reading the content disclosed in the specification, and are not intended to limit the conditions under which the present invention can be implemented. Any modifications to the structure, changes in the proportions, or adjustments to the size, without affecting the effects and objectives that the present invention can produce, should still fall within the scope of the technical content disclosed in the present invention.

[0038] The orientations or positional relationships indicated by terms such as "upper," "lower," "left," "right," "middle," "longitudinal," "lateral," "horizontal," "inner," "outer," "radial," and "circumferential" used in this specification are based on the orientations or positional relationships shown in the accompanying drawings and are only for the purpose of simplifying the description. They do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as limiting the present invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0039] Example 1

[0040] Embodiment 1 of this application provides a hybrid layer winding structure, such as... Figures 1 to 11 As shown, the hybrid layer winding structure is used for the stator assembly, which has 2p poles. The stator assembly also includes a core 300, which has Z stator slots 310 evenly spaced circumferentially, where Z = 18p. In the Z stator slots 310, every three consecutive slots form a group. In the same group, the two slots on either side are sequentially provided with slot layers 1, 2, ..., (m+1), and the middle slot is sequentially provided with slot layers 1, 2, ..., m, where m is an even number not less than 4. The hybrid layer winding structure includes winding lines for three phases: U, V, and W. The winding lines for phases V and W are obtained by sequentially shifting the U-phase line by Z / 3p and 2Z / 3p stator slots 310, respectively. The winding lines for each phase... All are completely wound within the three stator slots 310 that form the same group, and are evenly spaced by six stator slots 310. The winding circuit of each phase includes n parallel winding branches, where n is a natural number not less than 2. Each winding branch includes several lapped coils 100. The lapped coil 100 includes two spaced lapped effective edges 110, which are located in one of the slot layers of the stator slot 310. The lapped coil 100 has m / 2+1 cross-layer configurations: the two lapped effective edges 110 cross the first and second slot layers, the two lapped effective edges 110 cross the third and fourth slot layers, ... the two lapped effective edges 110 cross the (m-1)th and mth slot layers, and the two lapped effective edges 110 cross the (m+1)th and (m+1)th slot layers.

[0041] like Figure 1As shown in this embodiment, the stator assembly may include a core 300 and a winding structure wound on the core 300. The core 300 may include a plurality of stator laminations, which may be manufactured by stacking. The core 300 may be cylindrical and hollow, with Z stator slots 310 evenly spaced along its circumference on its inner side. At least part of the winding structure is wound within the stator slots 310; where Z = 18p, and p is the number of pole pairs in the stator assembly, i.e., the number of poles in the stator assembly is 2p. Based on the distribution of the winding structure within the stator slots 310, the stator slots 310 can be divided into several slot layers along the radial direction of the core 300. In this embodiment, the stator slots 310 have two numbers of slot layers: m layers and m+1 layers, where m is an even number not less than 4. Along the radial direction of the core component 300, from the inside out, the first slot layer, the second slot layer... the mth or m+1th slot layer can be set sequentially. In the Z stator slots 310, every three consecutive stator slots 310 can be set as a group. Within the same group of stator slots 310, the two stator slots located on either side have m+1 slot layers each, while the stator slot 310 located in the middle has m slot layers.

[0042] like Figure 2 and Figure 3 As shown, the stator assembly can be applied to a three-phase motor. The three phases of the stator assembly can be U-phase, V-phase, and W-phase, respectively. The designations "U", "V", and "W" are only for the convenience of describing the three phases of the stator assembly and are not intended to limit them. In some embodiments, other designations may also be used to represent the three phases of the stator assembly. Correspondingly, the winding structure includes winding lines for three phases, namely, winding lines for the U-phase, V-phase, and W-phase. For any phase, its winding lines are completely arranged within the three stator slots 310 forming the same group, that is, the winding lines of any phase fill all slot layers of the three consecutive stator slots 310 during winding; at the same time, its winding lines are evenly spaced by 6 stator slots 310. To ensure three-phase balance, the winding lines of the V-phase and W-phase can be obtained by sequentially shifting the winding lines of the U-phase by Z / 3p and 2Z / 3p stator slots 310, respectively. Since Z = 18p, the winding branches of phase V and phase W can be obtained by sequentially shifting the winding branch of phase U by 6 and 12 stator slots 310, respectively. It is easy to see that under this winding rule, 9 consecutive stator slots 310 can form three groups, and the winding lines of the three phases can sequentially fill all the slot layers of the three groups of stator slots 310.

[0043] like Figure 3 and Figure 4As shown, in this embodiment, the winding circuit of each phase can include n parallel winding branches, where n is a natural number not less than 2. Each winding branch includes several lapped coils 100. The lapped coil 100 has a U-shaped shape and can therefore be called an up-in line. It includes two spaced-apart effective lapped edges 110, which are respectively disposed in two stator slots 310, and the effective lapped edges 110 are located in one of the slot layers of the stator slot 310.

[0044] In this embodiment, the two effective edges 110 of the lapped coil 100 are interlayered in a specified manner. Specifically, the interlayering method of the lapped coil 100 is m / 2+1, including the two effective edges 110 crossing the first slot layer and the second slot layer, the two effective edges 110 crossing the third slot layer and the fourth slot layer, ..., the two effective edges 110 crossing the (m-1)th slot layer and the mth slot layer, and the two effective edges 110 crossing the (m+1)th slot layer and the (m+1)th slot layer. For example, if m = 6, the interlayering method of the lapped coil 100 is 4: crossing the first slot layer and the second slot layer, crossing the third slot layer and the fourth slot layer, crossing the fifth slot layer and the sixth slot layer, and crossing the seventh slot layer and the seventh slot layer.

[0045] It is easy to understand that, since stator slot 310 has a mixed number of m and m+1 layers, when the winding structure of this application is completed, it forms a mixed layer winding structure with both odd and even numbers of layers, and the number of layers is not less than 4. Verification has shown that, compared to an even-numbered layer winding structure with identical slot shapes for stator slot 310, the mixed-layer winding structure provided by this application can improve the peak power of the motor at high speeds, increase the area of ​​the motor's high-efficiency range, and significantly reduce the proportion of back EMF harmonics, thereby effectively improving the problem of low power density or low torque density in the motor.

[0046] Specifically, the lapped coil 100 also includes a lapped welding end 120 and a lapped hairpin end 130. There are two lapped welding ends 120, which are located at the same end of the two lapped effective edges 110 and extend in a direction that is close to each other. The lapped hairpin end 130 is connected to the other end of the two lapped effective edges 110.

[0047] like Figure 4As shown in this embodiment, the lapped coil 100 can be manufactured using an integral molding method. It can be made of a flat conductor, specifically enameled wire, and the conductor material inside the enameled wire can be copper wire. In addition to two effective lapped sides 110, the lapped coil 100 also includes two lapped welding ends 120 and one lapped hairpin end 130. The two lapped welding ends 120 can be respectively located at the same end of the two effective lapped sides 110, and the two lapped welding ends 120 can extend obliquely in a direction approaching each other to form a convergent shape. One lapped hairpin end 130 can be located between the other ends of the two effective lapped sides 110, and it can be specifically configured as a "V" shape, with the tip of the "V" pointing away from the stator core. When the two lapped coils 100 are connected, the two lapped coils 100 are connected through one of their lapped welding ends 120, and the two lapped welding ends 120 can be connected by welding.

[0048] It is understood that this embodiment, by reasonably setting the structure of the lapped coil 100, facilitates the lapping of several lapped coils 100 to obtain the required winding structure with the required number of mixed layers.

[0049] More specifically, each winding branch also includes a bridge line 200, which connects two lapped coils 100. The two lapped coils 100 connected by the bridge line 200 are connected by two effective lapped edges 110 that span the (m+1)th slot layer and the (m+1)th slot layer.

[0050] like Figure 3 and Figure 5 As shown in this embodiment, by way of example, the bridging wire 200 can be used to connect two lapped coils 100 across several stator slots 310 as needed. It can include a bridging arc segment 210 and a bridging welding end 220, wherein there can be two bridging welding ends 220, and the bridging arc segment 210 connects the two bridging welding ends 220. Similarly, the bridging wire 200 can also be integrally formed, and its material can be the same as that of the lapped coil 100. The bridging wire 200 can be positioned close to the lapped welding end 120 of the lapped coil 100. When connecting two lapped coils 100, its two bridging welding ends 220 can be connected to one lapped welding end 120 of one lapped coil 100 respectively, and the connection method can still be welding fixation. When m is an even number, the bridge line 200 can be used to connect two lapped coils 100 with two effective lapped edges 110 spanning the (m+1)th slot layer and the (m+1)th slot layer.

[0051] It is understood that, by setting the bridge line 200, the two cross-layer methods in each winding branch are to connect the two effective edges 110 of the (m+1)th slot layer and the (m+1)th slot layer of the lapped coil 100 across several stator slots 310 as needed, so as to wind a winding structure with the required number of mixed layers.

[0052] More specifically, all 100 coils with the same cross-layer winding method have the same pitch.

[0053] like Figure 3 As shown in this embodiment, the number of stator slots 310 between the two effective sides of the lapped coil 100 is exemplarily illustrated, which is the pitch of the lapped coil 100. Lapped coils 100 using the same layering method can all use the same pitch, which can be defined as having the same line type. For example, when m=6, the pitch of the lapped coil 100 spanning the first and second slot layers can all be set to 9 slots, which is the first line type of the lapped coil 100; the pitch of the lapped coil 100 spanning the third and fourth slot layers can all be set to 9 slots, which is the second line type of the lapped coil 100; the pitch of the lapped coil 100 spanning the fifth and sixth slot layers can all be set to 9 slots, which is the third line type of the lapped coil 100; and the pitch of the lapped coil 100 spanning the seventh and seventh slot layers can all be set to 7 slots, which is the fourth line type of the lapped coil 100. It should be noted that when the layering method or pitch of the two lapped coils 100 are different, they should be different wire types. It is easy to understand that by adopting the aforementioned arrangement in this embodiment, the types of wire types of the lapped coils 100 can be simplified, thereby making the winding structure less prone to errors during the winding process and improving the winding efficiency of the winding structure.

[0054] More specifically, the pitch of the three types of coils 100 with Z=54, p=3, m=6, n=2 or 3, with two effective sides 110 spanning the 1st and 2nd slot layers, two effective sides 110 spanning the 3rd and 4th slot layers, and two effective sides 110 spanning the 5th and 6th slot layers, is 9 slots. The pitch of the coil 100 with two effective sides 110 spanning the (m+1)th and (m+1)th slot layers is 7 slots.

[0055] like Figure 3As shown in this embodiment, exemplarily, this embodiment uses a three-phase winding structure with 54 slots, 6 poles, and 2 parallel branches, or a three-phase winding structure with 54 slots, 6 poles, and 3 parallel branches as examples. In both winding structures, the lapped coil 100 is provided with four types of wire profiles. The first type is the lapped coil 100 with a pitch of 9 slots and two effective lapped edges 110 spanning the 1st and 2nd slot layers; the second type is the lapped coil 100 with a pitch of 9 slots and two effective lapped edges 110 spanning the 3rd and 4th slot layers; the third type is the lapped coil 100 with a pitch of 9 slots and two effective lapped edges 110 spanning the 5th and 6th slot layers; and the fourth type is the lapped coil 100 with a pitch of 7 slots and two effective lapped edges 110 spanning the 7th and 8th slot layers.

[0056] It is understandable that this embodiment, by reasonably setting the pitch and layering method of the lapped coil 100, facilitates the winding of a three-phase winding structure with 54 slots, 6 poles, and multiple branches in parallel.

[0057] More specifically, when n=2, the entry position of the first winding branch of phase U and the entry position of the second winding branch of phase U are the first and seventh slot layers of the same stator slot 310, respectively, and the entry position of the first winding branch of phase U and the exit position of the second winding branch of phase U are the first and seventh slot layers of another stator slot 310, respectively.

[0058] like Figure 2 and Figure 3 As shown in this embodiment, exemplarily illustrating that when the winding structure is a 54-slot, 6-pole, parallel 2-branch configuration, both winding branches can be wired into the same stator slot 310, with the wire entry positions being the innermost and outermost layers of the stator slot 310, i.e., the first and seventh slot layers of the stator slot 310, respectively. It is easy to understand that under this structure, the winding structure also has the characteristic of centralized wire entry and exit, which makes it more convenient to subsequently introduce and exit the winding lines of the three phases, i.e., to prepare the busbar assembly composed of phase copper busbars and / or star-point copper busbars.

[0059] More specifically, when n=2, the first winding branch of phase U is:

[0060] 1.1-10.2-2.1-11.2-3.1-12.2-1.3-10.4-2.3-11.4-3.3-12.4-1.5-10.6-2.5-11.6-3.5-12.6-3.7-10.7-19.7-12.7-21.6-12.5-20.6-11.5-19.6-10.5-21.4-12.3-20.4- 11.3-19.4-10.3-21.2-12.1-20.2-11.1-19.2-10.1-19.1-28.2-20.1-29.2-21.1-30.2-19.3-28.4-20.3-29.4-21.3-30.4-19.5-28.6-20.5-29.6-21.5-30.6-21.7-28.7;

[0061] The second winding branch of phase U is:

[0062] 1.7-48.7-3.6-48.5-2.6-47.5-1.6-46.5-3.4-48.3-2.4-47.3-1.4-46.3-3.2-48.1-2.2-47.1-1.2-46.1-37.1-46.2-38.1-47.2-39.1-48.2-37.3-46.4-38.3-47.4-39.3- 48.4-37.5-46.6-38.5-47.6-39.5-48.6-39.7-46.7-37.7-30.7-39.6-30.5-38.6-29.5-37.6-28.5-39.4-30.3-38.4-29.3-37.4-28.3-39.2-30.1-38.2-29.1-37.2-28.1.

[0063] like Figure 2 and Figure 3 As shown in this embodiment, by way of example, the 54 conductor slots can be represented by serial numbers "1" to "54". The serial numbers "1" to "54" are only for the convenience of describing the 54 conductor slots and are not intended to limit them.

[0064] Taking the first winding branch of phase U as an example. The line corresponding to "1.1-10.2" is the first lapped coil 100, whose two effective lapped edges 110 are wound on the first slot layer of stator slot 310 (number "1") and the second slot layer of stator slot 310 (number "10"), respectively, with a pitch of 9 slots. Simultaneously, it represents the first winding branch of phase U entering from the first slot layer of stator slot 310 (number "1"), as shown in the example below. Figure 2 and Figure 3U1 in the middle. The subsequent winding circuits are similar, where the circuits corresponding to "3.7-10.7" and "19.7-12.7" are both lapped coils 100 that cross the 7th slot layer and the 7th slot layer. The pitch of the two lapped coils 100 is 7 slots, and they are connected by a bridge line 200. The two bridge welding sections of the bridge line 200 are connected between the 7th slot layer of stator slot 310 with serial number "10" and the 7th slot layer of stator slot 310 with serial number "12". The line corresponding to "21.7-28.7" is the last lapped coil 100, whose two effective lapped edges 110 are wound on the 7th layer of stator slot 310 with serial number "21" and the 7th layer of stator slot 310 with serial number "28", respectively, with a pitch of 7 slots; at the same time, it represents the first winding branch of phase U, which is the output line from the 7th layer of stator slot 310 with serial number "28", as shown in the figure. Figure 2 and Figure 3 X1 in the middle.

[0065] The second winding branch of phase U is similar. The line corresponding to "1.7-48.7" is the first lapped coil 100, with a pitch of 9 slots. Simultaneously, it represents the second winding branch of phase U, which is the 7th slot layer entry line of stator slot 310, numbered "1". See the figure below. Figure 2 and Figure 3 In U2, the line corresponding to “37.2-28.1” is the last lapped coil 100, with a pitch of 7 slots; simultaneously, it represents the second winding branch of phase U, the first layer output of stator slot 310 with sequence number “28”, as shown in the figure. Figure 2 and Figure 3 X2 in the diagram. It is not difficult to see that the entry position of the first winding branch of phase U and the entry position of the second winding branch of phase U are the first and seventh slot layers of stator slot 310 with serial number "1", respectively; the entry position of the first winding branch of phase U and the exit position of the second winding branch of phase U are the seventh and first slot layers of stator slot 310 with serial number "28", respectively.

[0066] The winding lines of phases V and W can be shifted sequentially by 6 and 12 stator slots 310 respectively from the winding lines of phase U along the direction of increasing stator slot number 310. Based on this, the entry positions of the two winding branches of phase V are 7.1 and 7.7 respectively, referring to... Figure 2 V1 and V2; the outgoing lines of the two winding branches of phase V are at 34.7 and 34.1 respectively, refer to Figure 2 Y1 and Y2 in the diagram. The entry points of the two winding branches of phase W are 13.1 and 13.7 respectively, referring to... Figure 2 The outgoing lines of the two winding branches of phase W1 and W2 are located at 40.7 and 40.1 respectively, referring to... Figure 2 Z1 and Z2 in the example.

[0067] In this embodiment, the hybrid layer winding structure may further include phase copper busbars and star copper busbars. The phase copper busbars correspond one-to-one with the three phases of the stator assembly, i.e., there are three phases. Each phase copper busbar is connected to the input positions of all n winding branches of its corresponding phase. For example, in the aforementioned embodiment, the phase copper busbar corresponding to U is connected to U1 and U2. The star copper busbar can be configured as a single unit, connected to the output positions of all 3n winding branches of the three phases, i.e., the star copper busbar connects to X1, X2, Y1, Y2, Z1, and Z2.

[0068] Of course, in some embodiments, the star-point copper busbar can also correspond to the number of parallel winding branches of any phase, i.e., set to n. Each star-point copper busbar is connected to the outgoing positions of the corresponding winding branches of the three phases. For example, in the aforementioned embodiment, the star-point copper busbar corresponding to the first winding branch is connected to U1, V1, and W1.

[0069] More specifically, when n=3, the first winding branch of phase U is:

[0070] 1.1-10.2-2.1-11.2-3.1-12.2-1.3-10.4-2.3-11.4-3.3-12.4-1.5-10.6-2.5-11.6-3.5-12.6-3.7-10.7-19.7-12.7-21.6-12.5-20.6-11.5-19.6-10.5-21.4-12.3-20.4-11.3-19.4-10.3-21.2-12.1-20.2-11.1-19.2-10.1;

[0071] The second winding branch of phase U is:

[0072] 19.1-28.2-20.1-29.2-21.1-30.2-19.3-28.4-20.3-29.4-21.3-30.4-19.5-28.6-20.5-29.6-21.5-30.6-21.7-28.7-37.7-30.7-39.6-30.5-38.6-29.5-37.6-28.5-39.4-30.3-38.4-29.3-37.4-28.3-39.2-30.1-38.2-29.1-37.2-28.1;

[0073] The third winding branch of phase U is:

[0074] 37.1-46.2-38.1-47.2-39.1-48.2-37.3-46.4-38.3-47.4-39.3-48.4-37.5-46.6-38.5-47.6-39.5-48.6-39.7-46.7-1.7-48.7-3.6-48.5-2.6-47.5-1.6-46.5-3.4-48.3-2.4-47.3-1.4-46.3-3.2-48.1-2.2-47.1-1.2-46.1.

[0075] like Figure 6 As shown in this embodiment, it is illustrated by example. Similarly, in the first winding branch of phase U, the line corresponding to "1.1-10.2" is the first lapped coil 100, with a pitch of 9 slots; at the same time, it represents the first winding branch of phase U as the first slot layer entry line of stator slot 310 with sequence number "1", referring to... Figure 6 U1 in the diagram. The lines corresponding to "3.7-10.7" and "19.7-12.7" are both lapped coils 100 spanning the 7th slot layer and the 7th slot layer respectively. Both lapped coils 100 have a pitch of 7 slots and are connected by a bridge line 200. The two bridge welded sections of the bridge line 200 connect the 7th slot layer of stator slot 310 (number "10") and the 7th slot layer of stator slot 310 (number "12"). The line corresponding to "19.2-10.1" is the last lapped coil 100 with a pitch of 9 slots; simultaneously, it represents the first winding branch of phase U, originating from the 1st slot layer of stator slot 310 (number "10"). (Refer to...) Figure 6 X1 in the middle.

[0076] In the second winding branch of phase U, the line corresponding to "19.1-28.2" is the first lapped coil 100, with a pitch of 9 slots. Simultaneously, it represents the second winding branch of phase U as the first slot layer entry line of stator slot 310, numbered "19". (Refer to...) Figure 6 In U2, the line corresponding to “37.2-28.1” is the last lapped coil 100, with a pitch of 9 slots; simultaneously, it represents the second winding branch of phase U, the first layer output of stator slot 310 with sequence number “28”, as shown in the reference. Figure 6 X2 in the middle.

[0077] In the third winding branch of phase U, the line corresponding to "37.1-46.2" is the first lapped coil 100, with a pitch of 9 slots. Simultaneously, it represents the second winding branch of phase U, which is the first slot layer entry line of stator slot 310 with sequence number "37". (Refer to...) Figure 6In U3, “1.2-46.1” corresponds to the last lapped coil 100, with a pitch of 9 slots; simultaneously, it represents the third winding branch of phase U, the first layer output of stator slot 310 with sequence number “46”, refer to… Figure 6 X3 in the middle.

[0078] The winding lines of phases V and W can be shifted sequentially by 6 and 12 stator slots 310 respectively, from the winding lines of phase U along the direction of increasing stator slot number 310. Based on this, the input positions of the two winding branches of phase V are 7.1, 25.1, and 43.1, respectively; the output positions of the two winding branches of phase V are 16.1, 34.1, and 52.1, respectively. Similarly, the input positions of the two winding branches of phase W are 13.1, 31.1, and 49.1, respectively; the output positions of the two winding branches of phase W are 22.1, 40.1, and 2.1, respectively.

[0079] In some embodiments, n can be other parameters. For example, the aforementioned three-phase winding structure with 54 slots, 6 poles, and 3 parallel branches can be adjusted to a three-phase winding structure with 54 slots, 6 poles, and 6 parallel branches. For instance, any winding branch is broken into two winding branches at the bridge line 200. In this case, the three parallel winding branches of any phase are adjusted to six parallel winding branches, i.e., n = 6. It should be noted that in this embodiment, the design of the bridge line 200 can be omitted.

[0080] Of course, in other embodiments, Z, p, and m can also be other parameters. For example, Z = 72, p = 4, m = 4. In this embodiment, the layer-crossing method of the plurality of lapped coils 100 includes: two lapped effective edges 110 crossing the first slot layer and the second slot layer, two lapped effective edges 110 crossing the third slot layer and the fourth slot layer, and two lapped effective edges 110 crossing the fifth slot layer and the fifth slot layer. Another example is Z = 108, p = 6, m = 8. In this embodiment, the layer-crossing method of the plurality of lapped coils 100 includes: two lapped effective edges 110 crossing the first slot layer and the second slot layer, two lapped effective edges 110 crossing the third slot layer and the fourth slot layer, two lapped effective edges 110 crossing the fifth slot layer and the sixth slot layer, two lapped effective edges 110 crossing the seventh slot layer and the eighth slot layer, and two lapped effective edges 110 crossing the ninth slot layer and the ninth slot layer.

[0081] The implementation principle of the hybrid layer winding structure provided in Embodiment 1 of this application is as follows:

[0082] Stator laminations are stacked to form a core 300, and then several lapped coils 100 are wound on the core 300 to form 3n winding branches. The lapped coils 100 are configured with m / 2+1 different layer crossing methods: two effective lapped edges 110 spanning the 1st and 2nd slot layers, two effective lapped edges 110 spanning the 3rd and 4th slot layers, ... two effective lapped edges 110 spanning the (m-1)th and mth slot layers, and two effective lapped edges 110 spanning the (m+1)th and (m+1)th slot layers. Subsequently, phase busbars and star busbars are connected to designated positions in the 3n winding branches.

[0083] The hybrid layer winding structure provided in this application can improve the peak power of the motor at high speeds, increase the area of ​​the motor's high-efficiency zone, and significantly reduce the proportion of back EMF harmonics, thereby effectively improving the problem of low power density or low torque density of the motor.

[0084] Example 2

[0085] Embodiment 2 of this application provides a stator assembly, which includes any of the hybrid layer winding structures provided in this application.

[0086] Example 3

[0087] Embodiment 2 of this application provides an electric motor, which includes any of the stator components provided in this application.

[0088] Comparative Example

[0089] This application provides a comparative example of a 54-slot, 6-pole, 6-layer, parallel 2-branch winding structure with identical stator slot 310 slot type, which is used for comparison with the 54-slot, 6-pole, mixed-layer, parallel 2-branch winding structure in Embodiment 1 of this application.

[0090] Application Example 1

[0091] This application compares the output performance of motors suitable for the two winding structures provided in Embodiment 1 and the comparative example. Under the premise that other parameters such as motor size / material usage are the same, the results are as follows: Figure 7 The comparison diagrams shown indicate that the solid lines represent the data for the motor to which the winding structure provided in Embodiment 1 is suitable, while the solid lines represent the data for the motor to which the winding structure provided in the comparative example is suitable. It is readily apparent that Embodiment 1 of this application can optimize the motor inductance, thereby increasing the motor's output power at high speeds by 15%; simultaneously, the area of ​​the motor's high-efficiency region can be increased by 5%-10%.

[0092] Application Example 2

[0093] This application uses Example 2 to obtain the opposite potential spectrum of the motors suitable for the two winding structures provided in Example 1 and the comparative example. Under the premise that other parameters such as motor size / material usage are the same, the following can be obtained: Figure 8 and Figure 9 The bar chart shown, in which Figure 8 This indicates the data for the motor to which the winding structure provided in Embodiment 1 is applicable. Figure 9 This indicates the data for the motor to which the winding structure provided by the proportional converter is applicable. Figure 8 and Figure 9 In the diagram, the horizontal axis represents the harmonic order, and the vertical axis represents the voltage, with the unit being V. It is easy to see that Embodiment 1 of this application can reduce the proportion of the 3rd / 5th / 7th harmonics, thereby improving the NVH performance of the motor.

[0094] Application Example 3

[0095] This application uses Example 3 to compare the back EMF of the two winding structures provided in Example 1 and the comparative example for motors. Under the premise that other parameters such as motor size / material usage are the same, the results are as follows: Figure 10 The comparison diagram shows that the red line represents the data for the motor to which the winding structure provided in Embodiment 1 is suitable, and the blue line represents the data for the motor to which the winding structure provided in the comparative example is suitable. It is easy to see that Embodiment 1 of this application can optimize the inductance of the motor, thereby improving the sinusoidal nature of the back EMF waveform.

[0096] Application Example 4

[0097] This application uses Example 4 to compare the stator transient temperature curves of motors suitable for the two winding structures provided in Example 1 and the comparative example. Under the premise that other parameters such as motor size / material usage are the same, the results are as follows: Figure 11 The comparison diagram shows that the dashed line represents the data for the motor to which the winding structure provided in Embodiment 1 is suitable, and the solid line represents the data for the motor to which the winding structure provided in the comparative example is suitable. It is easy to see that Embodiment 1 of this application requires lower electrical density / line load and lower copper loss heating while outputting the same peak power. Specifically, the peak temperature of the stator winding is reduced by approximately 30°C, and the peak temperature of the stator core can be reduced by approximately 15°C.

[0098] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0099] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

Claims

1. A hybrid layer winding structure, characterized in that, The hybrid layer winding structure is used for a stator assembly, the stator assembly has 2p poles, and the stator assembly also includes a core (300), the core (300) having Z stator slots (310) evenly spaced along the circumference, where Z = 18p; in the Z stator slots (310), every 3 stator slots (310) form a group, and in the same group of stator slots (310), the two stator slots (310) located on both sides are... 0) Each stator slot (310) is sequentially provided with slot layers 1, 2...(m+1), and the middle stator slot (310) is sequentially provided with slot layers 1, 2...m, where m is an even number not less than 4; the mixed-layer winding structure includes winding lines for three phases: U, V, and W. The winding lines for phase V and phase W are obtained by sequentially shifting the winding branch of phase U by Z / 3p and 2Z / 3p stator slots (310), respectively. The winding lines are all completely wound within the three stator slots (310) forming the same group, and are evenly spaced by six stator slots (310). The winding lines of each phase include n parallel winding branches, and each winding branch includes several lapped coils (100). The lapped coils (100) include two spaced-apart effective lapped edges (110), and the effective lapped edges (110) are arranged in the stator slots (310). Within one of the slot layers; wherein the lapped coil (100) is provided with m / 2+1 cross-layer arrangements: two lapped effective edges (110) cross the 1st and 2nd slot layers, two lapped effective edges (110) cross the 3rd and 4th slot layers... two lapped effective edges (110) cross the (m-1)th and mth slot layers, and two lapped effective edges (110) cross the (m+1)th and (m+1)th slot layers.

2. The hybrid layer winding structure according to claim 1, characterized in that, The lapped coil (100) further includes a lapped welding end (120) and a lapped hairpin end (130). There are two lapped welding ends (120), which are located at the same end of the two lapped effective sides (110) and extend in a direction that is close to each other. The lapped hairpin end (130) is connected to the other end of the two lapped effective sides (110).

3. The hybrid layer winding structure according to claim 2, characterized in that, Each winding branch also includes a bridge line (200), which connects two of the lapped coils (100). The two lapped coils (100) connected by the bridge line (200) are connected by two effective lapped edges (110) that span the (m+1)th slot layer and the (m+1)th slot layer.

4. The hybrid layer winding structure according to claim 2 or 3, characterized in that, All the lapped coils (100) of the same cross-layer method have the same pitch.

5. The hybrid layer winding structure according to claim 4, characterized in that, Z=54, p=3, m=6, n=2 or 3, the pitch of the three types of overlapping coils (100) with two overlapping effective edges (110) spanning the 1st and 2nd slot layers, two overlapping effective edges (110) spanning the 3rd and 4th slot layers, and two overlapping effective edges (110) spanning the 5th and 6th slot layers are all 9 slots, and the pitch of the overlapping coil (100) with two overlapping effective edges (110) spanning the (m+1)th and (m+1)th slot layers is 7 slots.

6. The hybrid layer winding structure according to claim 5, characterized in that, When n=2, the entry position of the first winding branch of the U phase and the entry position of the second winding branch of the U phase are the first and seventh slot layers of the same stator slot (310), respectively.

7. The hybrid layer winding structure according to claim 6, characterized in that, When n=2, the first winding branch of the U phase is: 1.1-10.2-2.1-11.2-3.1-12.2-1.3-10.4-2.3-11.4-3.3-12.4-1.5-10.6-2.5-11.6-3.5-12.6-3.7-10.7-19.7-12.7-21.6-12.5-20.6-11.5-19.6-10.5-21.4-12.3-20.4-11.3-19.4-10.3-21.2-12.1-20.2-11.1-19.2-10.1-19.1-28.2-20.1-29.2-21.1-30.2-19.3-28.4-20.3-29.4-21.3-30.4-19.5-28.6-20.5-29.6-21.5-30.6-21.7-28.7； The second winding branch of the U phase is: 1.7-48.7-3.6-48.5-2.6-47.5-1.6-46.5-3.4-48.3-2.4-47.3-1.4-46.3-3.2-48.1-2.2-47.1-1.2-46.1-37.1-46.2-38.1-47.2-39.1-48.2-37.3-46.4-38.3-47.4-39.3-48.4-37.5-46.6-38.5-47.6-39.5-48.6-39.7-46.7-37.7-30.7-39.6-30.5-38.6-29.5-37.6-28.5-39.4-30.3-38.4-29.3-37.4-28.3-39.2-30.1-38.2-29.1-37.2-28.1。 8. The hybrid layer winding structure according to claim 5, characterized in that, When n=3, the first winding branch of the U phase is: 1.1-10.2-2.1-11.2-3.1-12.2-1.3-10.4-2.3-11.4-3.3-12.4-1.5-10.6-2.5-11.6-3.5-12.6-3.7-10.7-19.7-12.7-21.6-12.5-20.6-11.5-19.6-10.5-21.4-12.3-20.4-11.3-19.4-10.3-21.2-12.1-20.2-11.1-19.2-10.1； The second winding branch of the U phase is: 19.1-28.2-20.1-29.2-21.1-30.2-19.3-28.4-20.3-29.4-21.3-30.4-19.5-28.6-20.5-29.6-21.5-30.6-21.7-28.7-37.7-30.7-39.6-30.5-38.6-29.5-37.6-28.5-39.4-30.3-38.4-29.3-37.4-28.3-39.2-30.1-38.2-29.1-37.2-28.1； The third winding branch of the U phase is: 37.1-46.2-38.1-47.2-39.1-48.2-37.3-46.4-38.3-47.4-39.3-48.4-37.5-46.6-38.5-47.6-39.5-48.6-39.7-46.7-1.7-48.7-3.6-48.5-2.6-47.5-1.6-46.5-3.4-48.3-2.4-47.3-1.4-46.3-3.2-48.1-2.2-47.1-1.2-46.1。 9. A stator assembly, characterized in that, The stator assembly includes a hybrid layer winding structure as described in any one of claims 1-8.

10. An electric motor, characterized in that, The motor includes the stator assembly as described in claim 9.

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