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 a slot opening of a stator slot to the outermost layer of the slot bottom, the first turn of each parallel branch adopts a first flat copper wire, the other turns of each parallel branch 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 (520Vdc to 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, and the corona resistance requirements for motor copper wire are further increased. 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 performance 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] After each of the parallel branches in the flat wire winding of each phase is wound from the innermost layer of the stator slot opening to the outermost layer of the slot bottom, the first turn of each of the parallel branches uses the first flat copper wire, and the remaining turns of each of the parallel branches use 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.

[0007] 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%;

[0008] 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 0.20 mm, and the thickness of the corona-resistant coating of the thin paint film accounts for 30% to 50%.

[0009] Optionally, both the first flat copper wire and the second flat copper wire are made of a polyimide material containing a corona-resistant coating.

[0010] Optionally, if the three-phase lead wires of the flat wire winding are located on the crown side of the stator of the flat wire winding motor, 6 layers of flat copper wire are wound in each stator slot and each phase of the flat wire winding includes two parallel branches, or 8 layers of flat copper wire are wound in each stator slot and each phase of the flat wire winding includes two parallel branches;

[0011] And, if the three-phase lead wires of the flat wire winding are located on the crown side of the stator of the flat wire winding motor, 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;

[0012] The first turn of each parallel branch uses the first flat copper wire as an I-Pin line type.

[0013] Optionally, if the three-phase lead wires of the flat wire winding are located on the welding side of the stator of the flat wire winding motor, 6 layers of flat copper wires are wound in each stator slot and each phase of the flat wire winding includes two parallel branches, or 8 layers of flat copper wires are wound in each stator slot and each phase of the flat wire winding includes two parallel branches;

[0014] And, if the three-phase lead wires of the flat wire winding are located on the welding side of the stator of the flat wire winding motor, 8 layers of flat copper wire are wound in each stator slot and each phase of the flat wire winding includes four parallel branches;

[0015] The first turn of each parallel branch uses a first flat copper wire of U-Pin line type.

[0016] Optionally, the first flat copper wire is obtained by winding a corona-resistant film after the first turn of each parallel branch is formed, and the second flat copper wire is obtained by forming the other turns of each parallel branch by a normal flat wire.

[0017] Optionally, the thickness of the corona resistant film ranges from 0.1 mm to 0.2 mm.

[0018] Optionally, the corona-resistant film is wound in a single layer after the first turn of each parallel branch is formed to obtain the first flat copper wire, the angle between the winding direction of the corona-resistant film and the extension direction of the three-phase lead-out wire of the flat wire winding is in the range of 40° to 50°, and the overlap of the corona-resistant film in the width direction between turns during winding is in the range of 52% to 55%.

[0019] 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.

[0020] 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.

[0021] 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 parallel branch 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 first turn of each parallel branch uses the first flat copper wire, and the remaining turns of each parallel branch use 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 current 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 improves the copper wire slot fill rate, improves the efficiency of the motor, and reduces the production cost at the same time.

[0022] 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

[0023] 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.

[0024] 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;

[0025] 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;

[0026] 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;

[0027] 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;

[0028] Figure 5 is a three-dimensional schematic diagram of a flat wire winding motor stator provided according to an embodiment of the present invention;

[0029] Figure 6 It is a schematic diagram of a structure type in which a three-phase lead-out wire of a flat wire winding provided by an embodiment of the present invention is located at the crown side of a stator of a flat wire winding motor and a first turn adopts a first flat copper wire;

[0030] Figure 7 It is a schematic diagram of a structure type in which a three-phase lead-out wire of a flat wire winding provided by an embodiment of the present invention is located at the first turn of a welding side of a stator of a flat wire winding motor and adopts a first flat copper wire;

[0031] Figure 8 is a schematic diagram of the arrangement of flat copper wires with a=2 parallel branches of a 6-layer flat wire winding provided in an embodiment of the present invention;

[0032] Fig. 9 is a schematic diagram of the arrangement of flat copper wires with 8-layer flat wire winding parallel branches a=2 provided in an embodiment of the present invention;

[0033] Fig.10 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

[0034] 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.

[0035] 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.

[0036] Figure 1A 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 in the figure. 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.

[0037] like Figures 1 to 4 As shown, the stator 1 of the flat wire winding motor includes a stator core 2 and a three-phase flat wire winding, the stator core has a plurality of stator slots 3, the multi-layer flat wire winding is wound in the stator slots 3, and each phase of the flat wire winding includes at least one parallel branch;

[0038] After each parallel branch in each phase flat wire winding is wound from the innermost layer of the stator slot opening to the outermost layer of the slot bottom, the first turn of each parallel branch uses the first flat copper wire, and the remaining turns of each parallel branch use the second flat copper wire, and the thickness of the first flat copper wire is thicker than that of the second flat copper wire.

[0039] 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.

[0040] 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.

[0041] 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. The first turn coil of the winding is the first to bear the brunt. The first turn coil is equivalent to the vanguard and is most affected by the impact of corona. Since corona is generated near the uneven conductor and the electric field concentration, the bend where the stator winding is led out of the stator core slot has both uneven conductors and electric field concentration. At the same time, for the first turn coil of the single-phase winding, this is at the starting position of the coil and is directly connected to the inverter power supply. The overshoot voltage spike has not been weakened by the inductor, and it is the most likely location for corona discharge.

[0042] Based on the above problems, continue to see Figure 2 and Figure 4 The present invention makes the first turn of each parallel branch adopt the first flat copper wire, and the remaining turns of each parallel branch adopt the second flat copper wire. The thickness of the first flat copper wire is thicker than that of the second flat copper wire, that is, only the first turn is focused on protection, achieving an effect similar to that of fully selecting a thick paint film.

[0043] 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 are consistent between different phases and between different winding branches of the same phase, thereby eliminating the existence of circulating currents between branches from a basic principle and preventing the flat wire motor from generating additional losses.

[0044] In summary, the flat wire winding motor stator provided by the present invention is relatively simple to implement, and 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 ultra-thick paint films is a key condition. Compared with the uniform thickness of the paint film, the present invention is equivalent to putting the focus of protection on the most critical part, reducing the difficulty of forming while also reducing the production cost.

[0045] Based on the above embodiments, for example, in one embodiment, see Figure 5 and Figure 6 As shown, if the three-phase lead wires of the flat wire winding are located on the crown side 4.2 of the flat wire winding motor stator, 6 layers of flat copper wires are wound in each stator slot and each phase of the flat wire winding includes two parallel branches, or 8 layers of flat copper wires are wound in each stator slot and each phase of the flat wire winding includes two parallel branches, continue to refer to Figure 5 , Figure 6 , Figure 8 and Fig. 9As shown, the first turn of the first branch of phase A is located at 14a and adopts the first flat copper wire, the first turn of the second branch of phase A is located at 13a and adopts the first flat copper wire, the winding methods of phases B and C are periodically symmetrical with phase A, the first turn of the first branch of phase B is located at 10a and adopts the first flat copper wire, the first turn of the second branch of phase B is located at 9a and adopts the first flat copper wire, the first turn of the first branch of phase C is located at 18a and adopts the first flat copper wire, the first turn of the second branch of phase C is located at 17a and adopts the first flat copper wire, and the first turn 4.1 of each parallel branch adopts the first flat copper wire as I-Pin line type 5.

[0046] Similarly, continue to see Figure 5 and Figure 6 As shown, if the three-phase lead wires of the flat wire winding are located on the crown side 4.2 of the flat wire winding motor stator, 8 layers of flat copper wires are wound in each stator slot and each phase of the flat wire winding includes four parallel branches, continue to refer to Figure 5 , Figure 6 and Fig.10 As shown, the first turn of the first branch of phase A is located at 14a and adopts the first flat copper wire, the first turn of the second branch of phase A is located at 25h and adopts the first flat copper wire, the first turn of the third branch of phase A is located at 13a and adopts the first flat copper wire, the first turn of the fourth branch of phase A is located at 14h and adopts the first flat copper wire, the winding method of phase B and phase C is periodically symmetrical with that of phase A, the first turn of the first branch of phase B is located at 10a and adopts the first flat copper wire, the first turn of the second branch of phase B is located at 29h and adopts the first flat copper wire, the first turn of phase B ... The first turn of the three branches is located at 9a and uses the first flat copper wire, the first turn of the fourth branch of phase B is located at 10h and uses the first flat copper wire, the first turn of the first branch of phase C is located at 18a and uses the first flat copper wire, the first turn of the second branch of phase C is located at 29h and uses the first flat copper wire, the first turn of the third branch of phase C is located at 17a and uses the first flat copper wire, the first turn of the fourth branch of phase C is located at 18h and uses the first flat copper wire, and the first turn 4.1 of each parallel branch uses the first flat copper wire as I-Pin line type 5.

[0047] It should be noted that for the winding configuration where the three-phase lead wire of the flat wire winding is located on the crown side of the stator of the flat wire winding motor, the shape of the first turn is an I-Pin line type, that is, one end is welded to the busbar on the crown side, and one end is welded in series with the next turn of the coil on the welding side. At this time, the I-Pin line type itself is a special-shaped line, and the number is small. The production site is generally assisted by simple CNC forming, which will not affect the normal linear production rhythm of the production line.

[0048] Similarly, continue to see Figure 5 and Figure 7As shown, if the three-phase lead wires of the flat wire winding are located on the welding side 4.3 of the flat wire winding motor stator, 6 layers of flat copper wires are wound in each stator slot and each phase of the flat wire winding includes two parallel branches, or 8 layers of flat copper wires are wound in each stator slot and each phase of the flat wire winding includes two parallel branches, continue to refer to Figure 5 , Figure 7 , Figure 8 and Fig. 9 As shown, the first turn of the first branch of phase A is located at 14a and 8b and uses the first flat copper wire, the first turn of the second branch of phase A is located at 13a and 7b and uses the first flat copper wire, the winding method of phase B and phase C is periodically symmetrical with phase A, the first turn of the first branch of phase B is located at 10a and 4b and uses the first flat copper wire, the first turn of the second branch of phase B is located at 9a and 3b and uses the first flat copper wire, the first turn of the first branch of phase C is located at 18a and 12b and uses the first flat copper wire, the first turn of the second branch of phase C is located at 17a and 11b and uses the first flat copper wire, and the first turn 4.1 of each parallel branch uses the first flat copper wire as U-Pin line type 6.

[0049] Similarly, continue to see Figure 5 and Figure 7 As shown, if the three-phase lead wires of the flat wire winding are located on the welding side 4.3 of the flat wire winding motor stator, 8 layers of flat copper wires are wound in each stator slot and each phase of the flat wire winding includes four parallel branches, continue to refer to Figure 5 , Figure 7 and Fig.10 As shown, the first turn of the first branch of phase A is located at 14a and 8b and uses the first flat copper wire, the first turn of the second branch of phase A is located at 25h and 31g and uses the first flat copper wire, the first turn of the third branch of phase A is located at 13a and 7b and uses the first flat copper wire, the first turn of the fourth branch of phase A is located at 14h and 20g and uses the first flat copper wire, the winding method of phase B and phase C is periodically symmetrical with that of phase A, the first turn of the first branch of phase B is located at 10a and 4b and uses the first flat copper wire, the first turn of the second branch of phase B is located at 21h and 27g and uses the first flat copper wire, the third branch of phase B is located at 14h and 20g and uses the first flat copper wire, The first turn of the branch is located at 9a and 3b and uses the first flat copper wire, the first turn of the fourth branch of phase B is located at 10h and 16g and uses the first flat copper wire, the first turn of the first branch of phase C is located at 18a and 12b and uses the first flat copper wire, the first turn of the second branch of phase C is located at 29h and 35g and uses the first flat copper wire, the first turn of the third branch of phase C is located at 17a and 11b and uses the first flat copper wire, the first turn of the fourth branch of phase C is located at 18h and 24g and uses the first flat copper wire, and the first turn 4.1 of each parallel branch uses the first flat copper wire as U-Pin line type 6.

[0050] It should also be noted that for the winding configuration in which the three-phase lead-out wires of the flat wire winding are located on the welding side of the stator of the flat wire winding motor, the shape of the first turn is a U-Pin line type, that is, it needs to be folded back from the crown side, and both ends need to be welded on the welding side. This U-Pin line type itself is similar to the size parameters of other U-Pins on the same layer, and requires two sets of CNC forming parameters. At the same time, in the storage area after the Pin wire is formed, the Pin wires should be distinguished in the preparation stage of the next process for plugging in the wires to prevent misinstallation.

[0051] Continue to see Figures 8 to 10 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%; Figures 8 to 10 The 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 0.20mm, 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 0.2mm 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.

[0052] Optionally, both the first flat copper wire and the second flat copper wire are made of a polyimide material containing a corona-resistant coating, that is, both the corona-resistant coating of the thick paint film and the corona-resistant coating of the thin paint film are made of a polyimide material.

[0053] It is understandable that for the 800V platform, the difficulty and cost of forming ultra-thick paint film is a key condition. The flat wire winding motor stator provided by the present invention greatly improves the one-time forming pass rate of ultra-thick paint film flat copper wire pin bending and twisting, which has high practical significance.

[0054] On the basis of the above embodiments, illustratively, in another embodiment, the first turn of the flat wire of the three-phase lead-out wire of the flat wire winding adopts conventional painted flat copper wire, and the other positions remain unchanged, that is, each parallel branch is first formed with conventional painted flat copper wire, and after forming, the first turn is then wrapped with corona-resistant film, so that the first turn of each parallel branch adopts the first flat copper wire, and the remaining turns of each parallel branch adopt the second flat copper wire for forming.

[0055] Conventional lacquered flat copper wire (ie, normal flat wire) can be selected and set by those skilled in the art according to actual needs, and this embodiment does not impose any limitation on this.

[0056] It can be seen that in this solution, for the 6-layer or 8-layer flat wire winding, and the parallel branch a=2 or the parallel branch a=4, the distribution of the first turns is consistent with the above, and will not be repeated here.

[0057] In this embodiment, the first turn uses the first flat copper wire, whether it is an I-Pin wire type or a U-Pin wire type, which must be bent into shape first, and then a corona-resistant film is wrapped around the three-phase lead-out wires of the flat wire winding. The thickness of the corona-resistant film ranges from 0.1mm to 0.2mm. After the first turn of each parallel branch is formed, the corona-resistant film is wound in a single layer to obtain the first flat copper wire. In order to ensure the overall slot fill rate and reduce thermal resistance, multiple layers of corona-resistant film cannot be wrapped.

[0058] Considering that the corona-resistant film is wound in a manner that it is continuously wound from one end of the three-phase lead-out wire of the flat wire winding to the other end without interruption, the film winding direction forms a certain angle with the extension direction of the three-phase lead-out wire of the flat wire winding, and the angle formed by the winding direction of the corona-resistant film and the extension direction of the three-phase lead-out wire of the flat wire winding can range from 40° to 50°, and the overlap of the corona-resistant film in the width direction between turns during winding can be 52-55%, thereby ensuring comprehensive protection of the first turn coil.

[0059] Based on the above, it can be known that the raw material size of the first flat copper wire used in the first turn is smaller in width and thickness than the second flat copper wire used in other positions. In order to ensure the subsequent insertion process in the slot, the external dimensions of the first turn after being wrapped with corona-resistant film should be similar to other conventional flat copper wires.

[0060] Combining the above two solutions, compared with the conventional all-ultra-thick paint film solution, the motor performance parameters of the present invention are improved as shown in Table 1.

[0061] Table 1 Performance improvement of new technical measures compared with conventional solutions

[0062]

[0063] 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.

[0064] 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 current conventional method to deal with corona is to use ultra-thick corona-resistant paint film for the entire motor, which faces a series of manufacturing problems such as raw material preparation, Pin wire forming, Pin wire bending, etc., and also greatly increases the raw material and process costs. Based on the corona mechanism, the present invention only performs corona-resistant key protection for the first turn coil, which can greatly improve the one-time forming qualified rate and production beat of the U-Pin bending and twisting of the ultra-thick paint film flat copper wire. The first turn adopts a thick paint film corona-resistant coating film, or it can be a conventional thin paint film flat wire formed and then wrapped with a corona-resistant film. 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.

[0065] 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.

[0066] 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 current conventional method to deal with corona is to use ultra-thick corona-resistant paint film for the entire motor, which faces a series of manufacturing problems such as raw material preparation, Pin wire forming, Pin wire bending, etc., and also greatly increases the raw material and process costs. Based on the corona mechanism, the present invention only performs corona-resistant key protection for the first turn coil, which can greatly improve the one-time forming pass rate and production beat of the ultra-thick paint film flat copper wire U-Pin bending and twisting. The first turn adopts a thick paint film corona-resistant coating film, or it can be a conventional thin paint film flat wire formed and then wrapped with a corona-resistant film. 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.

[0067] 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.

[0068] 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; After each of the parallel branches in the flat wire winding of each phase is wound from the innermost layer of the stator slot opening to the outermost layer of the slot bottom, the first turn of each of the parallel branches uses the first flat copper wire, and the remaining turns of each of the parallel branches use 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.

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 0.20 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 2, 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: If the three-phase lead wires of the flat wire winding are located on the crown side of the stator of the flat wire winding motor, 6 layers of flat copper wires are wound in each stator slot and each phase of the flat wire winding includes two parallel branches, or 8 layers of flat copper wires are wound in each stator slot and each phase of the flat wire winding includes two parallel branches; And, if the three-phase lead wires of the flat wire winding are located on the crown side of the stator of the flat wire winding motor, 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; The first turn of each parallel branch uses the first flat copper wire as an I-Pin line type.

5. The flat wire winding motor stator according to claim 1, characterized in that: If the three-phase lead wires of the flat wire winding are located on the welding side of the stator of the flat wire winding motor, 6 layers of flat copper wires are wound in each stator slot and each phase of the flat wire winding includes two parallel branches, or 8 layers of flat copper wires are wound in each stator slot and each phase of the flat wire winding includes two parallel branches; And, if the three-phase lead wires of the flat wire winding are located on the welding side of the stator of the flat wire winding motor, 8 layers of flat copper wire are wound in each stator slot and each phase of the flat wire winding includes four parallel branches; The first turn of each parallel branch uses a first flat copper wire of U-Pin line type.

6. The flat wire winding motor stator according to claim 1, characterized in that: The first flat copper wire is obtained by winding the first turn coil of each parallel branch with a corona-resistant film after the first turn coil is formed, and the second flat copper wire is obtained by a normal flat wire forming process for the other turns coil of each parallel branch.

7. The flat wire winding motor stator according to claim 6, characterized in that: The thickness of the corona-resistant film ranges from 0.1 mm to 0.2 mm.

8. The flat wire winding motor stator according to claim 6, characterized in that: The corona-resistant film is wound in a single layer after the first turn of each parallel branch is formed to obtain the first flat copper wire. The angle between the winding direction of the corona-resistant film and the extension direction of the three-phase lead wires of the flat wire winding is in the range of 40° to 50°. The overlap of the corona-resistant film in the width direction between turns during winding is in the range of 52% to 55%.

9. A flat wire motor, characterized in that: The flat wire motor comprises the flat wire winding motor stator according to any one of claims 1-8.

10. A vehicle, characterized in that: The vehicle includes the flat wire motor according to claim 9.

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