Flat wire winding motor stator, flat wire motor and vehicle

Abstract

The invention discloses a flat wire winding motor stator, a flat wire motor and a vehicle. The flat wire winding motor stator comprises a stator iron core and three phases of flat wire windings, the stator iron core is provided with a plurality of stator grooves, multiple layers of flat wire windings are wound in the stator grooves, and each phase of flat wire winding comprises at least one parallel branch; each parallel branch in each phase of the flat wire winding is wound from the innermost layer of the slot opening of the stator slot to the outermost layer of the slot bottom, so that the innermost layer and the secondary inner layer in each phase of the flat wire winding form adjacent layer overlines; the innermost layer and the secondary inner layer in each phase of flat wire winding adopt a first flat copper wire except the adjacent layer of overline, the other layers in each phase of flat wire winding adopt a second flat copper wire, and the thickness of the first flat copper wire is greater than that of the second flat copper wire. According to the invention, the copper wire slot fullness rate is improved, the efficiency of the motor is improved, and the production and manufacturing cost is reduced.

Description

Technical Field

[0001] The present invention relates to the field of new energy electric drive technology, and in particular to a flat wire winding motor stator, a flat wire motor and a vehicle. Background Art

[0002] For new energy vehicle drive motors, the motors are all powered by inverters, that is, the inverter converts the DC power of the power battery into three-phase AC power and outputs it to the motor windings. At present, the inverter uses PWM modulation technology, which approximates sinusoidal AC power through duty cycle modulation. Due to the high-speed switching of the inverter power devices, the fast dv / dt and di / dt will generate overshoot voltage spikes on the AC output side and apply them to the motor stator coil. The electric field formed by the overshoot voltage spike will produce corona discharge, which will slowly erode the insulation layer of the copper wire and cause insulation failure. Therefore, new energy drive motors must be corona resistant.

[0003] For the currently commonly used commercial vehicle 650Vdc platform voltage (520~750Vdc) and the higher 800Vdc platform, the overshoot voltage will be further increased compared to the original 400V platform. At the same time, the high-voltage platform uses a large number of SIC power devices. Higher switching frequency means higher overshoot voltage, which further increases the corona resistance requirements for motor copper wire. The conventional design is to thicken the insulation and corona-resistant insulation layer, which will increase the overall cost and reduce the slot fill rate. Summary of the invention

[0004] The present invention provides a flat wire winding motor stator, a flat wire motor and a vehicle, so as to solve the problem that improving the corona resistance of the motor will lead to a reduction in the slot fill rate, thereby affecting the power density and efficiency of the motor.

[0005] According to one aspect of the present invention, a flat wire winding motor stator is provided, the flat wire winding motor stator comprising a stator core and a three-phase flat wire winding, the stator core having a plurality of stator slots, multiple layers of the flat wire winding being wound in the stator slots, and each phase of the flat wire winding comprising at least one parallel branch;

[0006] Each of the parallel branches in the flat wire winding of each phase is wound from the innermost layer of the slot opening of the stator slot to the outermost layer of the slot bottom, so that the innermost layer and the second innermost layer of the flat wire winding of each phase form adjacent layer cross-wires;

[0007] The innermost and second innermost layers of the flat wire winding of each phase use first flat copper wires except the adjacent layer cross-wires, and the remaining layers of the flat wire winding of each phase use second flat copper wires, and the thickness of the first flat copper wire is thicker than that of the second flat copper wire.

[0008] Optionally, the first flat copper wire adopts a thick paint film, wherein the total thickness of the double-sided paint film of the thick paint film ranges from 0.25 mm to 0.40 mm, and the thickness of the corona-resistant coating of the thick paint film accounts for 40% to 60%;

[0009] The second flat copper wire adopts a thin paint film, wherein the total thickness of the double-sided paint film of the thin paint film ranges from 0.15 mm to 0.25 mm, and the thickness of the corona-resistant coating of the thin paint film accounts for 30% to 50%.

[0010] Optionally, both the first flat copper wire and the second flat copper wire are made of a polyimide material containing a corona-resistant coating.

[0011] Optionally, six layers of flat copper wire are wound in each of the stator slots and each phase of the flat wire winding includes one parallel branch, or six layers of flat copper wire are wound in each of the stator slots and each phase of the flat wire winding includes two parallel branches, or eight layers of flat copper wire are wound in each of the stator slots and each phase of the flat wire winding includes one parallel branch, or eight layers of flat copper wire are wound in each of the stator slots and each phase of the flat wire winding includes two parallel branches;

[0012] The innermost layer and the second innermost layer of the flat wire winding of each phase constitute a group of U-Pin cross-wires.

[0013] Optionally, 8 layers of flat copper wire are wound in each of the stator slots and each phase of the flat wire winding includes four parallel branches;

[0014] The innermost layer and the second innermost layer in the flat wire winding of each phase constitute a group of U-Pin cross-wires, and the outermost layer and the second outermost layer in the flat wire winding of each phase constitute a group of U-Pin cross-wires.

[0015] Optionally, the outermost layer and the second outermost layer of the flat wire winding of each phase are made of the first flat copper wire except the adjacent layer cross-wires.

[0016] According to another aspect of the present invention, a flat wire motor is provided. The flat wire motor comprises the flat wire winding motor stator according to any one of the embodiments of the present invention.

[0017] According to another aspect of the present invention, a vehicle is provided, the vehicle comprising the flat wire motor according to any embodiment of the present invention.

[0018] The technical solution of the embodiment of the present invention is that the stator of the flat wire winding motor includes a stator core and a three-phase flat wire winding, the stator core has a plurality of stator slots, multiple layers of the flat wire winding are wound in the stator slots, and each phase of the flat wire winding includes at least one parallel branch; each of the parallel branches in the flat wire winding of each phase is wound from the innermost layer of the slot opening of the stator slot to the outermost layer of the slot bottom, so that the innermost layer and the second innermost layer of the flat wire winding of each phase form adjacent layer crossover wires; the innermost layer and the second innermost layer of the flat wire winding of each phase except the adjacent layer crossover wire adopt the first flat copper wire, and the remaining layers in the flat wire winding of each phase adopt the second flat copper wire, and the thickness of the first flat copper wire is thicker than the thickness of the second flat copper wire. The present invention solves the problem that improving the corona resistance of the motor will lead to a decrease in the slot fill rate, thereby affecting the power density and efficiency of the motor, and realizes the improvement of the copper wire slot fill rate, the improvement of the motor efficiency, and the reduction of the production cost.

[0019] It should be understood that the contents described in this section are not intended to identify the key or important features of the embodiments of the present invention, nor are they intended to limit the scope of the present invention. Other features of the present invention will become easily understood through the following description. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the following briefly introduces the drawings required for use in the description of the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0021] Figure 1 is a cross-sectional view of a stator of a flat wire winding motor provided by an embodiment of the present invention, in which six layers of flat wire windings are wound in stator slots;

[0022] Figure 2 According to an embodiment of the present invention, Figure 1 The schematic diagram of the arrangement of the flat copper wires of the stator of the flat wire winding motor is shown;

[0023] Figure 3 is a cross-sectional view of a flat wire winding motor stator in which 8 layers of flat wire windings are wound in stator slots according to an embodiment of the present invention;

[0024] Figure 4 According to an embodiment of the present invention, Figure 3 The schematic diagram of the arrangement of the flat copper wires of the stator of the flat wire winding motor is shown;

[0025] Figure 5 is a schematic diagram of the arrangement of flat copper wires of a parallel branch a=1 and a parallel branch a=2 of a 6-layer flat wire winding provided by an embodiment of the present invention;

[0026] Figure 6 is a schematic diagram of the arrangement of flat copper wires of parallel branches a=1 and a=2 of an 8-layer flat wire winding provided by an embodiment of the present invention;

[0027] Figure 7 It is a schematic diagram of the arrangement of flat copper wires with 8-layer flat wire winding parallel branches a=4 provided according to an embodiment of the present invention. DETAILED DESCRIPTION

[0028] In order to enable those skilled in the art to better understand the scheme of the present invention, the technical scheme in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the 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 should fall within the scope of protection of the present invention.

[0029] It should be noted that the terms "first", "second", etc. in the specification and claims of the present invention and the above-mentioned drawings are used to distinguish similar objects, and are not necessarily used to describe a specific order or sequence. It should be understood that the data used in this way can be interchanged where appropriate, so that the embodiments of the present invention described herein can be implemented in an order other than those illustrated or described herein. In addition, the terms "including" and "having" and any variations thereof are intended to cover non-exclusive inclusions, for example, a process, method, system, product or device that includes a series of steps or units is not necessarily limited to those steps or units that are clearly listed, but may include other steps or units that are not clearly listed or inherent to these processes, methods, products or devices.

[0030] Figure 1 A cross-sectional view of a stator of a flat wire winding motor provided by an embodiment of the present invention, in which six layers of flat wire windings are wound in stator slots. Figure 2 The embodiment of the present invention provides Figure 1 The schematic diagram of the flat copper wire arrangement of the flat wire winding motor stator is shown. Figure 3 A cross-sectional view of a flat wire winding motor stator in which eight layers of flat wire windings are wound in stator slots according to an embodiment of the present invention, Figure 4 The embodiment of the present invention provides Figure 3 The flat copper wire arrangement schematic diagram of the flat wire winding motor stator is shown. This embodiment can be applied to improving the corona resistance performance of the inverter-powered flat wire motor.

[0031] like Figures 1 to 4 As shown, the flat wire winding motor stator 1 includes a stator core 2 and a three-phase flat wire winding, the stator core 2 has a plurality of stator slots 3, a plurality of layers of flat wire windings are wound in the stator slots 3, and each phase of the flat wire winding includes at least one parallel branch;

[0032] Each of the parallel branches in the flat wire winding of each phase is wound from the innermost layer of the slot opening of the stator slot 3 to the outermost layer of the slot bottom, so that the innermost layer and the second innermost layer of the flat wire winding of each phase form adjacent layer cross-wires;

[0033] The innermost and second innermost layers of each phase flat wire winding use first flat copper wires except for the adjacent layer cross-wires, and the remaining layers of each phase flat wire winding use second flat copper wires. The thickness of the first flat copper wire is thicker than that of the second flat copper wire.

[0034] Among them, Figure 1 and Figure 3 The flat wire winding motor stator 1 is shown, Figure 1 and Figure 3 There are 48 slots evenly distributed in the circumferential direction. The flat wire winding motor stator 1 may also have other numbers of slots, for example, 54 slots, 72 slots or 96 slots evenly distributed in the circumferential direction of the flat wire winding motor stator 1. The present invention only describes the 48-slot configuration as an example, and does not impose any limitation on the flat wire winding motor stator 1.

[0035] like Figure 2 and Figure 4 The flat copper wire arrangement of the flat wire winding motor stator is shown. The flat wire winding motor stator is designed with 6-layer and 8-layer flat wire windings wound in the stator slots 3. Each conductor in the stator slot 3 can be named and defined. For example, the third conductor from the inner layer of the stator slot 3 No. 20 is defined as 20c.

[0036] The bare copper and paint film sizes of each wire in the current conventional 6-layer and 8-layer flat wire windings are consistent. Thin paint films are uniformly used for low voltage platforms, while thick paint films and ultra-thick paint films (0.3mm to 0.4mm thickness) are uniformly used for 700V to 800V voltage platforms. For a single-phase winding, it can be regarded as a coil with multiple turns. A coil with N turns can be simplified as a series connection of N small coils. The peak corona generated by the inverter overshoot voltage is applied to the motor winding. Due to the effect of the coil inductance, the overshoot voltage spike will be filtered out in stages in the N coils, that is, the voltage spike is mainly borne by the first turn and the first few turns of the coil, so the first few turns of the coil are also the most likely place for corona discharge.

[0037] Based on the above problems, continue to see Figure 2 and Figure 4In the present invention, the innermost layer (i.e., layer a) and the second innermost layer (i.e., layer b) of each phase flat wire winding adopt the first flat copper wire except the adjacent layer cross-wire, and the remaining layers in each phase flat wire winding adopt the second flat copper wire, and the thickness of the first flat copper wire is thicker than that of the second flat copper wire, so as to realize the directional improvement of the weak link of the corona resistance of the winding, and adjust the original large-scale flooding type improvement to the drip irrigation type to supplement the weak link. Compared with the prior art, the difference is that the slot adjacent to the lead-out wire (i.e., the innermost layer 3.2 and the second innermost layer in the flat wire winding) adopts the flat wire with thick paint film, and the remaining turns (i.e., the remaining layers in the flat wire winding) adopt the flat copper wire with thin paint film.

[0038] On the one hand, for the existing flat wire motor production lines, for different types of motors, the multi-line parameters and quantity of the flat wire of each flat wire winding motor are stored in the production system in a modular manner. If N A motors need to be produced, the production system will automatically allocate the required quantity of each line type. According to the required number of lines, the production system will prompt to replace the raw material of the flat copper wire to ensure that the stator of the flat wire winding motor will not have errors due to the replacement of the raw material of the flat copper wire. In order to take into account the production process, the present invention uses the same forming mold and process parameters for the U-Pin cross-wires between the same layers. For the winding form with both the first turn and the last turn between the same layers, the last turn coil also uses a flat copper wire of the same specification as the first turn, reducing the mold change and production line equipment process parameter adjustment cycle.

[0039] On the other hand, for the case where there are many parallel branches of the flat wire winding and the first turns cannot be placed in the innermost winding, for example, the first turns of some parallel branches are arranged in the outermost layer close to the outer circle of the stator (i.e. the outermost layer of the bottom of the stator slot), and some first turns are arranged in the innermost layer close to the inner circle of the stator (i.e. the innermost layer of the slot mouth of the stator slot). At this time, the first flat copper wire with thick paint film is arranged in the outermost and innermost layers. Due to the use of flat copper wire with thin paint film, the process requirements for flat copper wire production will be reduced to a certain extent, and the cost will be reduced, thereby reducing the overall material cost. For flat copper wire with thin paint film of the same outer size, the cross-sectional area of ​​bare copper is larger and the current conducting capacity is stronger. At the same time, the reduction of paint film also reduces thermal resistance. The combined effect of the two phases will improve the efficiency of the motor and reduce the temperature rise. Under the same conditions, the bare copper slot fill rate in the slot will be improved, the overall resistance of the winding will be reduced, and the efficiency will be improved.

[0040] In addition, the arrangement of the flat wire winding of the present invention must ensure symmetry, that is, the resistance and inductance of the coils between different phases and between different winding branches of the same phase are consistent, thereby eliminating the existence of circulating currents between branches from a basic principle.

[0041] In summary, the flat wire winding motor stator provided by the present invention is relatively simple to implement, does not require the addition of additional process equipment such as potting paint, thermoforming resin, etc., does not require the modification of existing production lines, and is compatible with existing processes to ensure the flexibility of product production. Especially for the 800V platform, considering the difficulty and cost of forming an ultra-thick paint film is a key condition. Compared with the uniform paint film thickness, the present invention reduces the difficulty of forming and also reduces the production cost.

[0042] Based on the above embodiment, for example, in one embodiment, in order to save the integrated space of the stator bank, the starting end of the three-phase lead wire is arranged from the innermost conductor in each phase flat wire winding, and 6 layers of flat copper wire are wound in each stator slot and each phase flat wire winding includes two parallel branches, and further see Figure 1 As shown, taking phase A as an example, the first branch can be 14a→8b→2a→44b→38a→32b→26a→20b→14c→8d→2c→44d→38c→32d→26c→20d→14e→8f→2e→44f→38e→32f→26e→20f→25f→31e→37f→43e→1f→7e→13f→19e→25d→31c→37d→43c→1d→7c→13d→19c→25b→31a→37b→43a→1b→7a→13b→19a; the second branch It can be 13a→7b→1a→43b→37a→31b→25a→19b→13c→7d→1c→43d→37c→31d→25c→19d→13e→7f→1e→43f→37e→31f→25e→19f→14f→20e→26f→32e→38f→44e→2f→8e→14d→20c→26d→32c→38d→44c→2d→8c→14b→20a→26b→32a→38b→44a→2b→8a; the winding method of phase B and phase C is periodically symmetrical with phase A.

[0043] Similarly, for each stator slot wound with 6 layers of flat copper wire and each phase of the flat wire winding includes a parallel branch, continue to refer to Figure 1As shown, taking phase A as an example, the number of turns of 6 layers in series is 14a→8b→2a→44b→38a→32b→26a→20b→14c→8d→2c→44d→38c→32d→26c→20d→14e→8f→2e→44f→38e→32f→26e→20f→25f→31e→37f→43e→1f→7e→13f→19e→25d→31c→37d→43c→1d→7c→13d→19c→25b→31a→37b→43a→1b→7a→13b→19a→1 3a→7b→1a→43b→37a→31b→25a→19b→13c→7d→1c→43d→37c→31d→25c→19d→13e→7f→1e→43f→37e→31f→25e→19f→14f→20e→26f→32e→38f→44e→2f→8e→14d→20c→26d→32c→38d→44c→2d→8c→14b→20a→26b→32a→38b→44a→2b→8a; The winding method of phase B and phase C is periodically symmetrical with phase A.

[0044] Similarly, for each stator slot wound with 8 layers of flat copper wire and each phase of the flat wire winding includes a parallel branch, continue to refer to Figure 3 As shown, taking phase A as an example, 14a→8b→2a→44b→38a→32b→26a→20b→14c→8d→2c→44d→38c→32d→26c→20d→14e→8f→2e→44f→38e→32f→26e→20f→14g→8h→2g→44h→38g→32h→26g→2 0h→25h→31g→37h→43g→1h→7g→13h→19g→25f→31e→37f→43e→1f→7e→13f→19e→25d→31c→37d→43c→1d→7c→13d→19c→25b→31a→37b→43a→1b→7a→13b→19a→13a→ 7b→1a→43b→37a→31b→25a→19b→13c→7d→1c→43d→37c→31d→25c→19d→13e→7f→1e→43f→37e→31f→25e→19f→13g→7h→1g→43h→37g→31h→25g→19h→14h→20g→26h →32g→38h→44g→2h→8g→14f→20e→26f→32e→38f→44e→2f→8e→14d→20c→26d→32c→38d→44c→2d→8c→14b→20a→26b→32a→38b→44a→2b→8a; The winding method of phase B and phase C is periodically symmetrical with that of phase A.

[0045] Similarly, for each stator slot wound with 8 layers of flat copper wire and each phase of the flat wire winding includes two parallel branches, continue to refer to Figure 3 As shown, taking phase A as an example, the first branch can be 14a→8b→2a→44b→38a→32b→26a→20b→14c→8d→2c→44d→38c→32d→26c→20d→14e→8f→2e→44f→38e→32f→26e→20f→14g→8h→2g→44h→38g→32h→26 g→20h→25h→31g→37h→43g→1h→7g→13h→19g→25f→31e→37f→43e→1f→7e→13f→19e→25d→31c→37d→43c→1d→7c→13d→19c→25b→31a→37b→43a→1b→7a→13b→19a; Second branch It can be 13a→7b→1a→43b→37a→31b→25a→19b→13c→7d→1c→43d→37c→31d→25c→19d→13e→7f→1e→43f→37e→31f→25e→19f→13g→7h→1g→43h→37g→31h→25g→19h→14h→20g →26h→32g→38h→44g→2h→8g→14f→20e→26f→32e→38f→44e→2f→8e→14d→20c→26d→32c→38d→44c→2d→8c→14b→20a→26b→32a→38b→44a→2b→8a; The winding method of phase B and phase C is periodically symmetrical with phase A.

[0046] It can be seen that for the above four winding forms, the innermost layer and the second innermost layer of each phase flat wire winding constitute a set of U-Pin cross-wires, and the curvature and span of the Pin wires are consistent. Using the same molding die and process parameters, the distribution of the same type of Pins in layer a and layer b is as follows: Figure 5 and Figure 6 For the dark part, taking phase A as an example, all the a-layers are of the same specification, and all the b-layers except for the 4 cross-wires are of this specification.

[0047] Continue to see Figure 5 and Figure 6 The first flat copper wire corresponding to the dark part adopts thick paint film. For the high voltage platform, the total thickness of the double-sided paint film of the thick paint film ranges from 0.25mm to 0.40mm, and the thickness of the corona-resistant coating of the thick paint film accounts for 40% to 60%; Figure 5 and Figure 6The second flat copper wire corresponding to the light-colored part adopts a thin paint film, the total thickness of the thin paint film on both sides ranges from 0.15mm to 0.25mm, and the thickness of the corona-resistant coating of the thin paint film accounts for 30% to 50%. As a result, the width and thickness of the bare copper increase by 0.1mm to 0.15mm respectively compared with the thick paint film when the outer dimensions of the flat copper wire are consistent, which greatly reduces the three-phase resistance, reduces the Joule loss of the copper wire, and improves the copper wire slot full rate.

[0048] Optionally, the first flat copper wire and the second flat copper wire both use a polyimide material containing a corona-resistant coating, and the corona-resistant coating of the thick paint film and the corona-resistant coating of the thin paint film both use a polyimide material containing a corona-resistant coating.

[0049] It can be understood that the first flat copper wire with thick paint film near the above-mentioned first turn has a total of 4 turns of coils. With the commonly used a=2 winding configuration, the first flat copper wire coil on the lead-out side accounts for one-sixth and one-eighth of the 6-layer and 8-layer windings respectively, both of which are above 10%. The flat wire winding motor stator provided by the present invention can effectively filter out overshoot voltage, improve the corona resistance of the whole machine, while reducing the difficulty of process manufacturing and improving efficiency.

[0050] On the basis of the above embodiment, for example, in another embodiment, taking the example that 8 layers of flat copper wires are wound in each stator slot and each phase flat wire winding includes four parallel branches, the outermost layer (i.e., h layer) and the second outermost layer (i.e., g layer) of each phase flat wire winding use the first flat copper wire except for the adjacent layer cross-over wire, that is, the starting end of the three-phase lead wire is arranged with two branches starting from the innermost conductor and the other two branches starting from the outermost winding, and continue to refer to Figure 3As shown, taking phase A as an example, the first branch can be 14a→8b→2a→44b→38a→32b→26a→20b→14c→8d→2c→44d→38c→32d→26c→20d→14e→8f→2e→44f→38e→32f→26e→20f→14g→8h→2g→44h→38g→32h→26g→20 h; the second branch can be 25h→31g→37h→43g→1h→7g→13h→19g→25f→31e→37f→43e→1f→7e→13f→19e→25d→31c→37d→43c→1d→7c→13d→19c→25b→31a→37b→43a→1b→7a→13b→19a; the third branch It can be 13a→7b→1a→43b→37a→31b→25a→19b→13c→7d→1c→43d→37c→31d→25c→19d→13e→7f→1e→43f→37e→31f→25e→19f→13g→7h→1g→43h→37g→31h→25g→19h; the fourth branch can be 14h →20g→26h→32g→38h→44g→2h→8g→14f→20e→26f→32e→38f→44e→2f→8e→14d→20c→26d→32c→38d→44c→2d→8c→14b→20a→26b→32a→38b→44a→2b→8a; The winding method of phase B and phase C is periodically symmetrical with phase A.

[0051] It can be seen that the innermost and second innermost layers of each phase flat wire winding constitute a set of U-Pin crossovers, the curvature and span of the Pin lines are consistent, and the same molding die and process parameters are used. The outermost and second outermost layers of each phase flat wire winding constitute a set of U-Pin crossovers, the curvature and span of the Pin lines are consistent, and the same molding die and process parameters are used. The distribution of the same type of Pins in layers a and b, and the same type of Pins in layers g and h is shown in the figure below. Figure 7 For the dark part, taking phase A as an example, the a-layer and h-layer are all of the same specification, and the b-layer and g-layer are of this specification except for 4 cross-wires.

[0052] Continue to see Figure 7 It can be seen that the outermost layer 3.1 and the second outer layer also use the first flat copper wire with thick paint film. Figure 7 The first flat copper wire corresponding to the dark part adopts thick paint film. For the high voltage platform, the total thickness of the double-sided paint film of the thick paint film ranges from 0.25mm to 0.40mm, and the thickness of the corona-resistant coating of the thick paint film accounts for 40% to 60%; Figure 7The second flat copper wire corresponding to the light-colored part adopts a thin paint film, the total thickness of the thin paint film on both sides ranges from 0.15mm to 0.25mm, and the thickness of the corona-resistant coating of the thin paint film accounts for 30% to 50%. As a result, the width and thickness of the bare copper increase by 0.1mm to 0.15mm respectively compared with the thick paint film when the outer dimensions of the flat copper wire are consistent, which greatly reduces the three-phase resistance, reduces the Joule loss of the copper wire, and improves the copper wire slot full rate.

[0053] It can be understood that the first flat copper wire with thick paint film near the first turn has a total of 4 turns of coils, and the first flat copper wire coil on the lead-out side accounts for a quarter of the 8-layer winding, which is much higher than the proportion in one embodiment. Similarly, the flat wire winding motor stator provided by the present invention can effectively filter out overshoot voltage, improve the corona resistance of the whole machine, reduce process manufacturing difficulty and improve efficiency.

[0054] It should also be noted that the first turn of each parallel branch in the above embodiment can be selected according to actual conditions, that is, the first turn 14a of the first branch and the first turn 13a of the second branch can be arbitrarily selected by technical personnel in this field, and the winding method of phase A can be adjusted accordingly. This embodiment does not impose any restrictions on this.

[0055] In summary, compared with the conventional all-thick paint film solution, the motor performance parameters of the flat wire winding motor stator of the present invention are improved as shown in Table 1. At the same time, in the above two technical solutions, even if the bare copper wire diameter changes, from the analysis of the winding principle path, whether between different phases or between different winding branches of the same phase, the resistance and inductance of the coil are consistent, and the existence of circulating current between branches is excluded from the basic principle.

[0056] Table 1 The flat wire winding motor stator provided by the present invention has improved performance compared with conventional solutions

[0057]

[0058] Based on the same inventive concept, an embodiment of the present invention further provides a flat wire motor, which includes the flat wire winding motor stator provided by an embodiment of the present invention.

[0059] The flat wire motor provided by the embodiment of the present invention includes a flat wire winding motor stator. The flat motor can be oriented to the electric drive 800V platform. With the increase of the voltage platform and the increase of the inverter power switching speed, the corona generated by the overshoot voltage poses an increasing threat to the insulation life and safety of the motor winding. The conventional method of dealing with corona adopts the form of filling glue in the winding slot, winding with mica bandages, and adopting ultra-thick paint film, which faces a series of manufacturing difficulties such as raw material preparation, Pin wire forming, and Pin wire bending, and also greatly increases the cost of raw materials and processes. Based on the corona mechanism, through the reasonable design of the three-phase winding of the flat wire winding motor stator winding, only the first turn and the first few turns of the coil are subjected to corona resistance key protection, which can greatly improve the one-time forming pass rate and production rhythm of the ultra-thick paint film flat copper wire U-Pin bending and twisting, and has high practical significance. At the same time, compared with the uniform paint film thickness, due to the key protection, the overall copper wire slot full rate is improved, the resistance value is reduced, the efficiency of the motor is improved, and the temperature rise is reduced.

[0060] Based on the same inventive concept, an embodiment of the present invention further provides a vehicle, and the vehicle includes the flat wire motor provided by an embodiment of the present invention.

[0061] The vehicle provided by the embodiment of the present invention includes a flat wire motor, which can be oriented to the electric drive 800V platform. With the increase of the voltage platform and the increase of the inverter power switching speed, the corona generated by the overshoot voltage poses an increasing threat to the insulation life and safety of the motor winding. The conventional way to deal with corona is to use glue filling in the winding slot, mica bandage winding, and ultra-thick paint film. It faces a series of manufacturing difficulties such as raw material preparation, Pin wire forming, and Pin wire bending, and also greatly increases the cost of raw materials and processes. Based on the corona mechanism, through the reasonable design of the three-phase winding of the stator winding of the flat wire winding motor, only the first turn and the first few turns of the coil are subjected to key corona resistance protection, which can greatly improve the one-time forming pass rate and production rhythm of the ultra-thick paint film flat copper wire U-Pin bending and twisting, and has high practical significance. At the same time, compared with the uniform paint film thickness, due to the key protection, the overall copper wire slot full rate is improved, the resistance value is reduced, the efficiency of the motor is improved, and the temperature rise is reduced.

[0062] It should be understood that the various forms of processes shown above can be used to reorder, add or delete steps. For example, the steps described in the present invention can be executed in parallel, sequentially or in different orders, as long as the desired results of the technical solution of the present invention can be achieved, and this document does not limit this.

[0063] The above specific implementations do not constitute a limitation on the protection scope of the present invention. It should be understood by those skilled in the art that various modifications, combinations, sub-combinations and substitutions can be made according to design requirements and other factors. Any modification, equivalent substitution and improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.

Claims

1. A flat wire winding motor stator, characterized in that: The flat wire winding motor stator comprises a stator core and a three-phase flat wire winding, wherein the stator core has a plurality of stator slots, multiple layers of the flat wire winding are wound in the stator slots, and each phase of the flat wire winding comprises at least one parallel branch; Each of the parallel branches in the flat wire winding of each phase is wound from the innermost layer of the slot opening of the stator slot to the outermost layer of the slot bottom, so that the innermost layer and the second innermost layer of the flat wire winding of each phase form adjacent layer cross-wires; The innermost and second innermost layers of the flat wire winding of each phase use first flat copper wires except the adjacent layer cross-wires, and the remaining layers of the flat wire winding of each phase use second flat copper wires, and the thickness of the first flat copper wire is thicker than that of the second flat copper wire.

2. The flat wire winding motor stator according to claim 1, characterized in that: The first flat copper wire adopts a thick paint film, wherein the total thickness of the double-sided paint film of the thick paint film ranges from 0.25 mm to 0.40 mm, and the thickness of the corona-resistant coating of the thick paint film accounts for 40% to 60%; The second flat copper wire adopts a thin paint film, wherein the total thickness of the double-sided paint film of the thin paint film ranges from 0.15 mm to 0.25 mm, and the thickness of the corona-resistant coating of the thin paint film accounts for 30% to 50%.

3. The flat wire winding motor stator according to claim 1, characterized in that: The first flat copper wire and the second flat copper wire are both made of polyimide material containing a corona-resistant coating.

4. The flat wire winding motor stator according to claim 1, characterized in that: Six layers of flat copper wire are wound in each of the stator slots and each phase of the flat wire winding includes one parallel branch, or six layers of flat copper wire are wound in each of the stator slots and each phase of the flat wire winding includes two parallel branches, or eight layers of flat copper wire are wound in each of the stator slots and each phase of the flat wire winding includes one parallel branch, or eight layers of flat copper wire are wound in each of the stator slots and each phase of the flat wire winding includes two parallel branches; The innermost layer and the second innermost layer of the flat wire winding of each phase constitute a group of U-Pin cross-wires.

5. The flat wire winding motor stator according to claim 1, characterized in that: Each of the stator slots is wound with 8 layers of flat copper wire and each phase of the flat wire winding includes four parallel branches; The innermost layer and the second innermost layer in the flat wire winding of each phase constitute a group of U-Pin cross-wires, and the outermost layer and the second outermost layer in the flat wire winding of each phase constitute a group of U-Pin cross-wires.

6. The flat wire winding motor stator according to claim 5, characterized in that: The outermost layer and the second outermost layer of the flat wire winding of each phase adopt the first flat copper wire except the adjacent layer cross-wire.

7. A flat wire motor, characterized in that: The flat wire motor comprises the flat wire winding motor stator according to any one of claims 1 to 6.

8. A vehicle, characterized in that: The vehicle includes the flat wire motor according to claim 7.

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