Wave lap winding motor
By designing a wave stacked winding motor, two sets of three-phase windings and a U-shaped ejector are used to connect the structure in series, the complexity of the existing flat-line motor winding structure is solved, and a simpler assembly process and higher power density is achieved.
Patent Information
- Application Number
- CN202510119960.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-01-25
- Publication Date
- 2025-04-29
AI Technical Summary
The winding structure of existing flat wire motors is complex and requires a variety of special-shaped conductors or jumpers to realize the wiring of six-phase windings, which makes assembly difficult and costly.
A wave stacked winding motor is designed, using two sets of three-phase windings, each phase winding includes two coil rings. By adjusting the legs of the coil conductor, the legs are avoided, and the types of cards and jumpers are connected in series through the U-shaped card.
It achieves reasonable structural design, reduces the types of card issuing and jumpers, facilitates assembly, reduces the cost and debugging difficulty of the motor drive system, reduces the heat generation of the entire machine and has a greater power.
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Abstract
Description
Technical Field
[0001] The invention relates to the technical field of flat wire motors, and in particular to a wave winding motor. Background Art
[0002] In recent years, miniaturization and high speed have become the main development trends of new energy electric vehicle motors. Compared with traditional permanent magnet motors, flat wire motors have the characteristics of high copper full rate in their windings, which can greatly improve the torque density and power density of the motors. The winding ends of flat wire motors are relatively short, which can further improve the utilization rate of vehicle space. The larger contact area between the wires effectively enhances the heat dissipation capacity of the motor. Therefore, flat wire motors have good application prospects in new energy electric vehicles.
[0003] Compared with three-phase motors, six-phase motors can offset specific order harmonics, reduce torque pulsation, and improve motor NVH performance; as the number of motor phases increases, the motor fault tolerance is enhanced and the working reliability is higher. In order to realize the wiring of six-phase windings, the winding structure in the prior art requires a variety of conductors or jumpers of special shapes to achieve cross-connection between hairpin conductor layers, resulting in a wide variety of hairpin conductors, increasing assembly difficulty and cost. Summary of the invention
[0004] In view of the above-mentioned deficiencies of the prior art, the technical problem to be solved by the present invention is: how to provide a wave winding motor with a reasonable structural design, which can reduce the types of hairpins and jumpers and is easy to assemble.
[0005] In order to solve the above technical problems, the present invention adopts the following technical solutions: A wave winding motor comprises two groups of three-phase windings, each phase of the phase winding comprises two coil rings arranged at adjacent magnetic pole positions, the coil ring comprises P first coil conductors and P second coil conductors uniformly arranged in the circumferential direction, P is the number of pole pairs; the first coil conductor and the second coil conductor both have a card-isolating body with a pitch of Y, the card-isolating body of the first coil conductor has two legs that deflect and bend in opposite directions in the circumferential direction, the card-isolating body of the second coil conductor has two legs that deflect and bend towards each other, the first coil conductor and the second coil conductor are alternately arranged in the circumferential direction and are connected in series in sequence through the legs; at a magnetic pole position in any of the phase windings, in two legs at adjacent positions on the first coil conductor and the second coil conductor belonging to different coil rings, the leg of the first coil conductor is retracted inward by one slot and deflected inward in the opposite direction to be connected in series to the other coil ring in a zigzag manner, and the corresponding leg on the second coil conductor is expanded outward by one slot and deflected outward in the opposite direction to be connected in series to the other coil ring in a zigzag manner.
[0006] In the above structure, since each phase winding has only two coil rings at adjacent magnetic pole positions, which are responsible for the S pole and the N pole respectively, by adjusting the legs of the first coil conductor and the second coil conductor at a magnetic pole position on the two coil rings, the legs of the first coil conductor are retracted one slot and deflected inward, and the corresponding legs on the second coil conductor are expanded one slot and deflected outward, thereby avoiding interference between the legs of the two. The corresponding phase winding can also be formed by directly connecting the two coil rings in series, reducing the types of hairpins and jumpers, and facilitating installation. In addition, the two sets of three-phase windings can use the same set of control programs to achieve single-winding and double-winding operation, reducing the cost and debugging difficulty of the six motor drive systems, and greatly reducing the heat generation of the whole machine. Greater power.
[0007] Furthermore, the hairpin body of the second coil conductor includes a U-shaped hairpin, which includes two leg portions arranged parallel to each other and a head portion integrally connected to one end of the two leg portions, and the other ends of the two leg portions are bent toward the middle in the width direction of the hairpin body to form the legs.
[0008] Furthermore, the hairpin body of the second coil conductor includes at least two U-shaped hairpins arranged side by side in the thickness direction, and the two legs of each U-shaped hairpin are bent toward the middle in the width direction of the hairpin body to form the legs, and are arranged in series in sequence.
[0009] Furthermore, the hairpin body of the first coil conductor includes a U-shaped hairpin, and the two leg portions of the U-shaped hairpin are bent in opposite directions in the width direction of the hairpin body to form the legs.
[0010] Furthermore, the hairpin body of the first coil conductor includes two U-shaped hairpins arranged side by side in the thickness direction, wherein the two leg portions of one of the U-shaped hairpins are deflected and bent in the clockwise or counterclockwise direction of the phase winding, and the two leg portions of the other U-shaped hairpin are deflected and bent in the counterclockwise or clockwise direction of the phase winding, and the legs of the two U-shaped hairpins that are deflected and bent in opposite directions are connected in series with each other.
[0011] Furthermore, a U-shaped hairpin is connected in series between the two U-shaped hairpins, wherein at least one leg portion of the U-shaped hairpin is bent toward the middle in the width direction of the hairpin body.
[0012] Furthermore, the two groups of three-phase windings are arranged 90° apart in the circumferential direction.
[0013] Furthermore, the legs for connecting the power supply and the star point on one group of the three-phase windings are located at the innermost layer and the second innermost layer; the legs for connecting the power supply and the star point on another group of the three-phase windings are located at the outermost layer and the second outermost layer.
[0014] In summary, the present invention has the advantages of reasonable structural design, capable of reducing the types of hairpins and jumpers, and convenient assembly. BRIEF DESCRIPTION OF THE DRAWINGS
[0015] Figure 1 This is a schematic diagram of the overall structure of Example 1.
[0016] Figure 2 for Figure 1 Schematic diagram of the two-phase structure.
[0017] Figure 3 Schematic diagram of the structure of the first coil conductor and the second coil conductor.
[0018] Figure 4 and Figure 5 This is a schematic diagram of the structure of two coil rings on the same phase winding.
[0019] Figure 6 for Figure 4 and Figure 5 Schematic diagram of the connection relationship between the conductor 41 and the conductor 52.
[0020] Figure 7 Schematic diagram of the connection relationship between the conductor 41 and the conductor 52 on another set of phase windings.
[0021] Figure 8 for Figure 4 and Figure 5 Schematic diagram of the structure of the phase winding.
[0022] Fig. 9 for Figure 8 Schematic diagram of some structures in .
[0023] Fig.10 Schematic diagram of the structure of the first coil conductor and the second coil conductor in Example 2.
[0024] Fig.11 Schematic diagram of the structure of the first coil conductor in Example 3.
[0025] Fig.12 Schematic diagram of the structure of the first coil conductor and the second coil conductor in Example 3.
[0026] Fig.13 Schematic diagram of the structure of the first coil conductor and the second coil conductor in Example 4. DETAILED DESCRIPTION
[0027] The present invention is further described in detail below in conjunction with embodiments.
[0028] Example 1: Figure 1 and Figure 2As shown, a wave winding motor includes a stator assembly, wherein the stator assembly includes a stator core 1 and two sets of three-phase windings, wherein the stator core 1 includes a main body which is generally cylindrical, and a plurality of stator core slots which are radially open inward are circumferentially arranged on the inner ring of the stator core 1, wherein the lower end of the stator core slot is an insertion side (or crown side), and the upper end is a connection side.
[0029] In this embodiment, each phase winding 2 includes two coil rings 3 arranged at adjacent magnetic pole positions, and the coil ring 3 includes P first coil conductors 4 and P second coil conductors 5 uniformly distributed along the circumferential direction, where P is the number of pole pairs; the first coil conductor 4 and the second coil conductor 5 both have a card-isolating body with a pitch of Y, the card-isolating body of the first coil conductor 4 has two legs that are deflected and bent in opposite directions in the circumferential direction, and the card-isolating body of the second coil conductor 5 has two legs that are deflected and bent towards each other, and the first coil conductor 4 and the second coil conductor 5 are alternately arranged along the circumferential direction and are connected in series in sequence through the legs; at a magnetic pole position in any of the phase windings, in two legs at adjacent positions on the first coil conductor 4 and the second coil conductor 5 belonging to different coil rings, the leg of the first coil conductor 4 is retracted inward by one slot and is deflected inward in the opposite direction to be connected in series to the other coil ring 3 in a zigzag manner, and the corresponding leg on the second coil conductor 5 is expanded outward by one slot and is deflected outward in the opposite direction to be connected in series to the other coil ring 3 in a zigzag manner.
[0030] In this embodiment, Figure 3 As shown, the hairpin body of the second coil conductor 5 includes a U-shaped hairpin, the U-shaped hairpin includes two legs arranged in parallel with each other and a head integrally connected to one end of the two legs, and the other ends of the two legs are bent toward the middle in the width direction of the hairpin body to form the legs. The hairpin body of the first coil conductor 4 includes a U-shaped hairpin, and the two legs of the U-shaped hairpin are bent in opposite directions in the width direction of the hairpin body to form the legs.
[0031] like Figure 4 and Figure 5 As shown, the number of pole pairs P=4, and each of the coil rings 3 has four first coil conductors 4 and four second coil conductors 5. Figure 4 At the middle position, the right leg of the first coil conductor 4 on a coil ring is retracted by one slot and deflected inward in the opposite direction to form a conductor 41 with a pitch of Y-1; Figure 5 At the middle position, the right leg of the second coil conductor 5 on the other coil ring expands outward by one slot and deflects outward in the opposite direction to form a conductor 51 with a pitch of Y+1. In this way, a concentric structure is formed between the conductor 41 and the conductor 51, that is, the conductor 41 is located in the middle of the conductor 51, as shown in FIG. Figure 6As shown, the structure of the conductor 41 and the conductor 51 on the other phase winding is as shown in FIG. Figure 7 At this time, the two legs deflected in opposite directions do not interfere with each other, wherein the conductor 41 (coil ring A) is connected to the first coil conductor 4 on the other coil ring (coil ring B); the conductor 51 (coil ring B) is connected to the second coil conductor 5 on the other coil ring (coil ring A), as shown in FIG. Figure 8-Figure 9 shown.
[0032] like Figure 1 and Figure 2 As shown, the two groups of three-phase windings are arranged 90° apart in the circumferential direction, and the legs for connecting the power supply and the star point on one group of the three-phase windings are located in the innermost layer and the second innermost layer; the legs for connecting the power supply and the star point on the other group of the three-phase windings are located in the outermost layer and the second outermost layer.
[0033] In this embodiment, since each phase winding has only two coil rings at adjacent magnetic pole positions, which are responsible for the S pole and the N pole respectively, by adjusting the legs of the first coil conductor and the second coil conductor at a magnetic pole position on the two coil rings, the legs of the first coil conductor are retracted one slot and deflected inward, and the corresponding legs on the second coil conductor are expanded one slot and deflected outward, thereby avoiding interference between the legs of the two. The corresponding phase winding can also be formed by directly connecting the two coil rings in series, reducing the types of hairpins and jumpers, and facilitating installation. In addition, the two sets of three-phase windings can use the same set of control programs to achieve single-winding and double-winding operation, reducing the cost and debugging difficulty of the six motor drive systems, and greatly reducing the heat generation of the whole machine. Greater power.
[0034] Example 2: Fig.10 As shown, the main difference from Example 1 is that the hairpin body of the second coil conductor 5 includes two U-shaped hairpins arranged side by side in the thickness direction, and the two leg parts of each U-shaped hairpin are bent toward the middle in the width direction of the hairpin body to form the legs, and are arranged in series in sequence.
[0035] Example 3: Fig.11 and Fig.12 As shown, the main difference from Example 1 is that the hairpin body of the first coil conductor 4 includes two U-shaped hairpins arranged side by side in the thickness direction, wherein the two leg portions of one of the U-shaped hairpins are deflected and bent in the clockwise direction of the phase winding, and the two leg portions of the other U-shaped hairpin are deflected and bent in the counterclockwise direction of the phase winding, and the legs of the two U-shaped hairpins that are deflected and bent in opposite directions are connected in series with each other.
[0036] Example 4: Fig.13As shown, the main difference from Example 1 is that the hairpin body of the first coil conductor 4 includes three U-shaped hairpins arranged side by side in the thickness direction, the two leg portions of the outermost U-shaped hairpin 42 are deflected and bent in the clockwise direction of the phase winding, the two leg portions of the innermost U-shaped hairpin 43 are deflected and bent in the counterclockwise direction of the phase winding, and the two leg portions of the U-shaped hairpin 44 located in the middle are deflected and bent toward the middle in the width direction of the hairpin body, and are respectively connected in series with the legs of the innermost U-shaped hairpin 42 and the outermost U-shaped hairpin 43.
[0037] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the protection scope of the present invention.
Claims
1. A wave winding motor, characterized in that: The invention comprises two groups of three-phase windings, each phase winding comprises two coil rings arranged at adjacent magnetic pole positions, the coil rings comprise P first coil conductors and P second coil conductors uniformly arranged in the circumferential direction, P being the number of pole pairs; the first coil conductor and the second coil conductor both have a card-isolating body with a pitch of Y, the card-isolating body of the first coil conductor has two legs deflected and bent in opposite directions in the circumferential direction, the card-isolating body of the second coil conductor has two legs deflected and bent towards each other, the first coil conductor and the second coil conductor are alternately arranged in the circumferential direction and are connected in series in sequence through the legs; at a magnetic pole position in any of the phase windings, in two legs in adjacent positions on the first coil conductor and the second coil conductor belonging to different coil rings, the leg of the first coil conductor is retracted inward by one slot and is deflected inward in the opposite direction to be connected in series to the other coil ring in a zigzag manner, and the corresponding leg on the second coil conductor is expanded outward by one slot and is deflected outward in the opposite direction to be connected in series to the other coil ring in a zigzag manner.
2. The wave winding motor according to claim 1, characterized in that: The hairpin body of the second coil conductor includes a U-shaped hairpin, which includes two legs arranged parallel to each other and a head integrally connected to one end of the two legs, and the other ends of the two legs are bent toward the middle in the width direction of the hairpin body to form the legs.
3. The wave winding motor according to claim 2, characterized in that: The hairpin body of the second coil conductor includes at least two U-shaped hairpins arranged side by side in the thickness direction, and the two legs of each U-shaped hairpin are bent toward the middle in the width direction of the hairpin body to form the legs, and are arranged in series in sequence.
4. The wave winding motor according to claim 2 or 3, characterized in that: The hairpin body of the first coil conductor includes a U-shaped hairpin, and the two leg portions of the U-shaped hairpin are bent in opposite directions in the width direction of the hairpin body to form the legs.
5. The wave winding motor according to claim 2 or 3, characterized in that: The hairpin body of the first coil conductor includes two U-shaped hairpins arranged side by side in the thickness direction, wherein the two leg portions of one of the U-shaped hairpins are deflected and bent in the clockwise or counterclockwise direction of the phase winding, and the two leg portions of the other U-shaped hairpins are deflected and bent in the counterclockwise or clockwise direction of the phase winding, and the legs of the two U-shaped hairpins that are deflected and bent in opposite directions are connected in series with each other.
6. The wave winding motor according to claim 5, characterized in that: A U-shaped hairpin is connected in series between the two U-shaped hairpins, wherein at least one leg portion of the U-shaped hairpin is bent toward the middle in the width direction of the hairpin body.
7. The wave winding motor according to claim 1, characterized in that: The two groups of three-phase windings are arranged 90° apart in the circumferential direction.
8. The wave winding motor according to claim 1, characterized in that: The legs for connecting the power supply and the star point on one group of the three-phase windings are located at the innermost layer and the second innermost layer; the legs for connecting the power supply and the star point on the other group of the three-phase windings are located at the outermost layer and the second outermost layer.