Cross-layer lead-out winding structure, stator assembly and motor

Abstract

This application relates to a multi-layer lap winding structure, a stator assembly, and a motor. The core has Z conductor slots spaced equally circumferentially. The winding structure includes three phases of winding lines, with each phase comprising two winding branches. When Z / 6 is odd, the second winding branch enters from the first layer, is wound sequentially, then wound again in the nth layer, and so on, repeating this cycle until the final cycle. In the final cycle, when the second winding branch is wound sequentially from the nth layer, it is directly wound from the first layer to the nth layer via a multi-layer lap wire, then wound sequentially, and exits from the first layer. The three-phase lap winding structure of this application has more concentrated entry and exit points, which can reduce the size of the small busbar assembly, lower its manufacturing difficulty, and reduce the risk of busbar assembly failure due to vibration during motor operation.

Description

Technical Field

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

[0002] Electric motors can be used as one of the components of the power system of new energy vehicles. Their stator assembly can include a core and a three-phase winding structure wound on the core, meaning the winding structure includes winding lines for three phases. During motor development, adjusting the number of parallel winding branches for each phase is often used to simultaneously accommodate both high-voltage and low-voltage motors. In this case, the winding structure can employ a lap winding method. Existing three-phase lap winding structures can use a centralized input and output line scheme to reduce the size of the busbar assembly and lower the risk of failure due to vibration during motor operation. However, in existing three-phase lap winding structures, the input and output positions of several winding branches in any phase are merely adjacent, and the effect of centralized input and output line configuration still needs further improvement. Summary of the Invention

[0003] Based on this, this application provides a cross-layer outgoing winding structure, stator assembly, and motor to improve the problem that the effect of concentrated incoming and outgoing lines in the existing three-phase lap winding structure needs to be improved.

[0004] In a first aspect, this application provides a cross-layer lead-out winding structure, which is used in a stator assembly. The stator assembly has three phases and 2p poles. The stator assembly also includes an iron core. The iron core is provided with Z conductor slots at equal intervals along the circumference, where Z is a natural number that is an integer multiple of 6. Each conductor slot is provided with n slot layers, where n is an even number not less than 4. The first, second, ..., nth layers of the conductor slots are arranged sequentially from the outside to the inside. The cross-layer lead-out winding structure includes three phase winding lines. Each phase winding line includes two parallel winding branches. Each winding branch adopts a lap winding method and includes several lap winding coils.

[0005] When Z / 6 is odd, in any phase, the first winding branch enters from layer 1, then winds sequentially through layers 2, 3...n, then winds again through layer n, and then winds sequentially through layers n-1...2, 1, and so on, until exiting from layer n; the second winding branch enters from layer 1, then winds sequentially through layers 2, 3...n, then winds again through layer n, and then winds sequentially through layers n-1...2, 1, and so on, until exiting from layer n. The process is repeated until the final winding cycle. During the final winding cycle, when the second winding branch is wound sequentially from layer n to layers n-1...2 and 1, it is wound directly from layer 1 to layer n via a cross-layer wire, and then sequentially wound to layers n-1...2 and 1, with the wire exiting from layer 1. This ensures that the entry positions of the two winding branches of the same phase are the first layers of two consecutive conductor slots, and the exit positions are the first and nth layers of the same conductor slot, respectively.

[0006] When Z / 6 is even, in any phase, the first winding branch enters from layer 1, then winds sequentially in layers 2, 3...n, then winds again in layer n, and then winds sequentially in layers n-1...2, 1, and so on, until it exits from layer 1; the second winding branch enters from layer 1, then winds sequentially in layers 2, 3...n, then winds again in layer n, and then winds sequentially in layers n-1... 2. Within the first layer, the winding is repeated until the last winding process. In the last winding process, when the second winding branch is wound from the first layer to the second, third...n layers, it is directly wound from the nth layer into the first layer through the cross-layer line, and then wound in the second, third...n layers in sequence, and exits from the nth layer, so that the inlet position of the two winding branches of the same phase is the first layer of the two consecutive conductor slots, and the outlet position is the first layer and the nth layer of the same conductor slot.

[0007] In one embodiment, the cross-layer line includes a cross-layer welding end and a cross-layer connecting line. Two cross-layer welding ends are provided and are respectively located near the first layer and the nth layer of the conductor groove. The cross-layer connecting line connects the two cross-layer welding ends.

[0008] In one embodiment, the lapped coil includes an effective lapped edge, a lapped welding end, and a lapped hairpin end. The effective lapped edge is disposed in the conductor groove, and there are two such effective lapped edges, which are spaced apart. The lapped welding end is connected to the effective lapped edge in a one-to-one correspondence. The two lapped welding ends are disposed at the same end of the two effective lapped edges and extend in a direction that brings them closer to each other. The lapped hairpin end is connected between the other ends of the two effective lapped edges.

[0009] In one embodiment, the two cross-layer welding ends of the cross-layer line are respectively connected to one of the lap-wound welding ends of one of the lap-wound coils, such that the cross-layer line connects two of the lap-wound coils, and the two lap-wound welding ends connected to the two cross-layer welding ends of the cross-layer line extend in a direction that approaches each other.

[0010] In one embodiment, each winding branch further includes a connecting coil, and the plurality of the lapped coils of any winding branch form a plurality of lapped winding groups. The cross-layer line connects the last two lapped winding groups of the second winding branch. The connecting coil connects two other consecutive lapped winding groups. The connecting coil includes a connecting effective side, a connecting welding end, and a connecting hairpin end. The connecting effective side is disposed in the conductor groove, and there are two such sides. The two connecting effective sides are spaced apart. The connecting welding end is connected to the connecting effective side in a one-to-one correspondence. The two connecting welding ends are disposed at the same end of the two connecting effective sides and extend in the same direction. The connecting hairpin end is connected between the other ends of the two connecting effective sides.

[0011] In one embodiment, Z = 54, P = 3, n = 8, and the three phases of the stator assembly are U phase, V phase, and W phase. The winding lines of the V phase and the W phase are obtained by shifting the winding line of the U phase by 6 and 12 conductor slots, respectively. The first winding branch of the U phase is:

[0012] 1.1-10.2-1.3-10.4-1.5-10.6-1.7-10.8-19.8-10.7-19.6-10.5-19.4-10.3-19.2-10.1-20.1-29.2-20.3-29.4-20.5-29.6-20.7-29.8-38.8-29.7-38.6-29.5-38.4-29.3-38.2-29.1-21.1-30.2-21.3-30.4- 21.5-30.6-21.7-30.8-39.8-30.7-39.6-30.5-39.4-30.3-39.2-30.1-38.1-47.2-38.3-47.4-38.5-47.6-38.7-47.8-1.8-46.7-1.6-46.5-1.4-46.3-1.2-46.1-39.1-48.2-39.3-48.4-39.5-48.6-39.7-48.8;

[0013] The second winding branch of the U phase is:

[0014] 2.1-11.2-2.3-11.4-2.5-11.6-2.7-11.8-20.8-11.7-20.6-11.5-20.4-11.3-20.2-11.1-3.1-12.2-3.3-12.4-3.5-12.6-3.7-12.8-21.8-12.7-21.6-12.5-21.4-12.3-21.2-12.1-19.1-28.2-19.3-28.4- 19.5-28.6-19.7-28.8-37.8-28.7-37.6-28.5-37.4-28.3-37.2-28.1-37.1-46.2-37.3-46.4-37.5-46.6-37.7-46.8-2.8-47.7-2.6-47.5-2.4-47.3-2.2-47.1-3.8-48.7-3.6-48.5-3.4-48.3-3.2-48.1.

[0015] In one embodiment, the cross-layer outgoing winding structure further includes a phase copper busbar, which corresponds one-to-one with the three phases of the stator assembly, and the phase copper busbar is connected to the input positions of the two winding branches of its corresponding phase.

[0016] In one embodiment, the cross-layer lead-out winding structure further includes a star-point copper busbar, which is connected to the lead-out positions of the three phases, totaling six winding branches.

[0017] Secondly, this application provides a stator assembly, which includes any of the cross-layer lead-out winding structures provided in this application.

[0018] Thirdly, this application provides an electric motor, which includes any of the stator components provided in this application.

[0019] This application achieves a more concentrated three-phase lap winding structure by rationally configuring the cross-layer method of two parallel winding branches of any phase. Specifically, the first winding branch adopts a layer-by-layer cyclic winding method, while the second winding branch, during the last cycle of winding, crosses directly from the innermost layer to the outermost layer or directly from the outermost layer to the innermost layer via a cross-layer line. This allows the inlet positions of the two winding branches of the same phase to be the first layer of two consecutive conductor slots, and the outlet positions to be the first and nth layers of the same conductor slot, respectively. Consequently, the inlet and outlet positions of the three-phase lap winding structure are more concentrated. When subsequently manufacturing a smaller busbar component, this application can reduce its size and manufacturing difficulty, while also reducing the risk of busbar component failure due to vibration during motor operation. Attached Figure Description

[0020] Figure 1This is a schematic diagram of the stator assembly to which the cross-layer outgoing winding structure provided in Embodiment 1 of this application is applicable;

[0021] Figure 2 A schematic diagram of the conductor slot layer of the stator assembly to which the cross-layer lead-out winding structure provided in Embodiment 1 of this application is applicable;

[0022] Figure 3 This is a winding diagram of the cross-layer lead-out winding structure provided in Embodiment 1 of this application;

[0023] Figure 4 The winding diagram of the first winding branch of the U phase of the cross-layer outgoing winding structure provided in Embodiment 1 of this application;

[0024] Figure 5 The winding diagram of the second winding branch of the U phase of the cross-layer outgoing winding structure provided in Embodiment 1 of this application;

[0025] Figure 6 This is a schematic diagram of the structure of the cross-layer lead-out winding structure provided in Embodiment 1 of this application;

[0026] Figure 7 This is a schematic diagram of the lapped coil structure of the cross-layer lead-out winding structure provided in Embodiment 1 of this application;

[0027] Figure 8 This is a schematic diagram of the connecting coil of the cross-layer outgoing winding structure provided in Embodiment 1 of this application;

[0028] Figure 9 This is a schematic diagram of the star-shaped copper busbar structure of the cross-layer outgoing winding structure provided in Embodiment 1 of this application.

[0029] Reference numerals: 100, Overlapped coil; 110, Effective overlapped edge; 120, Overlapped welding end; 130, Overlapped hairpin end; 200, Cross-layer wire; 210, Cross-layer welding end; 220, Cross-layer connecting wire; 300, Connecting coil; 310, Effective connecting edge; 320, Connecting welding end; 330, Connecting hairpin end; 400, Iron core component; 410, Conductor groove; 500, Phase copper busbar; 600, Star copper busbar; 610, Copper busbar component; 620, Star terminal. Detailed Implementation

[0030] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0031] It should be noted that the illustrations provided in this embodiment are only schematic representations of the basic concept of the present invention.

[0032] The structures, proportions, sizes, etc., shown in the accompanying drawings of this specification are only for the purpose of assisting those skilled in the art in understanding and reading the content disclosed in the specification, and are not intended to limit the conditions under which the present invention can be implemented. Any modifications to the structure, changes in the proportions, or adjustments to the size, without affecting the effects and objectives that the present invention can produce, should still fall within the scope of the technical content disclosed in the present invention.

[0033] The orientations or positional relationships indicated by terms such as "upper," "lower," "left," "right," "middle," "longitudinal," "lateral," "horizontal," "inner," "outer," "radial," and "circumferential" used in this specification are based on the orientations or positional relationships shown in the accompanying drawings and are only for the purpose of simplifying the description. They do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as limiting the present invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0034] Example 1

[0035] Embodiment 1 of this application provides a cross-layer outgoing winding structure, such as Figures 1 to 9 As shown, the cross-layer outgoing winding structure is used for the stator assembly. The stator assembly has three phases and 2p poles. The stator assembly also includes a core 400. The core 400 is provided with Z conductor slots 410 at equal intervals along the circumference, where Z is a natural number that is an integer multiple of 6. Each conductor slot 410 is provided with n slot layers, where n is an even number not less than 4. The first, second...n layers of the conductor slots 410 are arranged sequentially from the outside to the inside. The cross-layer outgoing winding structure includes three phase winding lines. Each phase winding line includes two parallel winding branches. Each winding branch adopts a lap winding method and includes several lap winding coils 100.

[0036] When Z / 6 is odd, in any phase, the first winding branch enters from layer 1, then winds sequentially in layers 2, 3...n, then winds again in layer n, and then winds sequentially in layers n-1...2, 1, and so on, until it exits from layer n; the second winding branch enters from layer 1, then winds sequentially in layers 2, 3...n, then winds again in layer n, and then winds sequentially in layers n-1...2, 1. Then, the process is repeated until the last winding process. In the last winding process, when the second winding branch is wound from the nth layer to the n-1...2, 1 layers, it is directly wound from the 1st layer into the nth layer through the cross-layer line 200, and then wound from the n-1...2, 1 layers in sequence, and exits from the 1st layer, so that the inlet position of the two winding branches of the same phase is the 1st layer of two consecutive conductor slots 410, and the outlet position is the 1st layer and the nth layer of the same conductor slot 410.

[0037] When Z / 6 is even, in any phase, the first winding branch enters from layer 1, then winds sequentially in layers 2, 3...n, then winds again in layer n, and then winds sequentially in layers n-1...2, 1, and so on, until it exits from layer 1; the second winding branch enters from layer 1, then winds sequentially in layers 2, 3...n, then winds again in layer n, and then winds sequentially in layers n-1...2, 1, and so on, and so on. The process is repeated until the final winding cycle. During the final winding cycle, when the second winding branch is wound from layer 1 to layers 2, 3...n, it is directly wound from layer n to layer 1 via the cross-layer line 200, and then wound to layers 2, 3...n, with the output line coming out from layer n. This ensures that the input positions of the two winding branches of the same phase are the first layers of two consecutive conductor slots 410, and the output positions are the first and nth layers of the same conductor slot 410, respectively.

[0038] like Figure 1 and Figure 2As shown in this embodiment, the number of pole pairs in the stator assembly can be p, meaning the stator assembly includes p pairs of magnetic poles, where p is a positive integer, such as p = 1, 2, or 3. Specifically, the stator assembly may include a core 400 and a winding structure wound on the core 400. The core 400 may include several stator laminations, which can be fabricated by stacking. The core 400 may be cylindrical and hollow, with Z conductor slots 410 evenly spaced along its circumference on its inner side. At least part of the winding structure is wound within the conductor slots 410; where Z is a natural number that is an integer multiple of 6, such as Z = 36, 48, or 54. Based on the distribution of the winding structure within the conductor slots 410, the conductor slots 410 can be divided into n slot layers along the radial direction of the core 400, where n is an even number not less than 4, such as n = 4, 6, or 8. Meanwhile, the first, second...n layers of the conductor groove 410 are arranged sequentially from the outside to the inside, that is, the first layer of the conductor groove 410 is located on the outermost side, and the nth layer of the conductor groove 410 is located on the innermost side.

[0039] like Figure 3 As shown, in this embodiment, the winding structure wound on the iron core 400 is a cross-layer lead-out winding structure, which includes three phase winding lines. Each phase winding line includes two parallel winding branches, and each winding branch includes several lapped coils 100. The several lapped coils 100 adopt a lapped winding method to form a three-phase lapped winding.

[0040] like Figure 4 and Figure 5 As shown, during the winding process, both winding branches of any phase are wound in a specific cross-layer manner. In this embodiment, when a winding branch winds from the outermost layer to the innermost layer, i.e., from layer 1 to layer n; or when a winding branch winds from the innermost layer to the outermost layer, i.e., from layer n to layer 1, it can be considered as one cycle of winding of the winding branch. When Z / 6 is odd, any winding branch undergoes an odd number of cycle windings, and if it enters from layer 1, it should exit from layer n; while when Z / 6 is even, any winding branch undergoes an even number of cycle windings, and if it enters from layer 1, it should exit from layer 1.

[0041] like Figure 4 As shown, in any phase, when Z / 6 is an odd number, for example, Z = 54, the first winding branch enters from the first layer and is then wound sequentially in the second, third...n layers, thus completing one cycle of winding; then it is wound again in the nth layer, and then sequentially wound in the n-1...2,1 layers, thus completing another cycle of winding; then the cycle continues until it exits from the nth layer, thus completing an odd number of cycles of winding.

[0042] like Figure 5 As shown, the second winding branch enters from layer 1 and is then wound sequentially into layers 2, 3...n, completing one cycle of winding. It is then wound again into layer n, and subsequently wound sequentially into layers n-1...2, 1, completing another cycle of winding. This cycle continues until the final cycle. It is easy to understand that in the penultimate cycle, the second winding branch undergoes an even number of cycles, starting from layer n and winding sequentially into layers n-1...2, 1. Notably, in the final cycle, the second winding branch no longer continues winding from layer 1. Instead, it uses the cross-layer line 200 to directly wind from layer 1 of the penultimate cycle into layer n to begin the final cycle, then winds sequentially into layers n-1...2, 1, and exits from layer 1.

[0043] In this embodiment, the aforementioned winding method is adopted so that the incoming positions of the two winding branches of the same phase can be the first layer of two consecutive conductor slots 410, and the outgoing positions can be the first layer and the nth layer of the same conductor slot 410, respectively.

[0044] When Z / 6 is even, for example, Z = 54, the first winding branch enters from layer 1, and then winds sequentially in layers 2, 3...n, thus completing one cycle of winding; then it winds again in layer n, and then winds sequentially in layers n-1...2,1, thus completing another cycle of winding; then the cycle continues until the wire exits from layer 1, thus completing an even number of cycles of winding.

[0045] The second winding branch enters from layer 1 and is then wound sequentially into layers 2, 3...n, completing one cycle of winding. It then winds again into layer n, and subsequently into layers n-1...2, 1, completing another cycle. This cycle continues until the final winding process. It's easy to understand that in the penultimate cycle, the second winding branch undergoes an even number of cycles, winding sequentially from layer 1 into layers 2, 3...n. Notably, in the final cycle, the second winding branch no longer continues winding from layer n. Instead, it uses the cross-layer line 200 to directly wind from layer n of the penultimate cycle into layer 1 to begin the final cycle, then winds sequentially into layers 2, 3...n, exiting from layer n.

[0046] Similarly, using the aforementioned winding method, the incoming positions of the two winding branches of the same phase can still be the first layer of two consecutive conductor slots 410, and the outgoing positions can still be the first layer and the nth layer of the same conductor slot 410.

[0047] In summary, this application achieves a more concentrated three-phase lap winding structure by rationally configuring the cross-layer method of the two parallel winding branches of any phase in the three-phase lap winding structure. Specifically, the first winding branch adopts a layer-by-layer cyclic winding method, while the second winding branch, during the last cyclic winding, crosses directly from the innermost layer to the outermost layer or directly from the outermost layer to the innermost layer via the cross-layer line 200. This allows the inlet positions of the two winding branches of the same phase to be the first layer of two consecutive conductor slots 410, and the outlet positions to be the first and nth layers of the same conductor slot 410, respectively. Consequently, the inlet and outlet positions of the three-phase lap winding structure are more concentrated. When subsequently manufacturing a smaller busbar component, this application can reduce its size and manufacturing difficulty, while also reducing the risk of the busbar component failing due to vibration during motor operation.

[0048] Specifically, the cross-layer line 200 includes a cross-layer welding end 210 and a cross-layer connecting line 220. There are two cross-layer welding ends 210, which are respectively located near the first layer and the nth layer of the conductor groove 410. The cross-layer connecting line 220 connects the two cross-layer welding ends 210.

[0049] like Figure 5 and Figure 6 As shown in this embodiment, by way of example, the winding lines of the three phases, after being wound, have a structure similar to a body of revolution, which is coaxially arranged with the core 400, and its two ends extend beyond the two ends of the core 400. The cross-layer line 200 can be specifically set on one end face of the winding lines of the three phases to facilitate its routing, thereby realizing the cross-layer connection of the winding branches from the innermost to the outermost or from the outermost to the innermost.

[0050] In this embodiment, the cross-layer wire 200 can be integrally formed and can be made of the same material as the lapped coil 100 of the winding structure, such as flat enameled wire. The enameled wire can include copper wire and insulating material wrapped around the copper wire. The cross-layer wire 200 can include cross-layer welding ends 210 and cross-layer connecting wires 220. There are two cross-layer welding ends 210, which are respectively connected to the first layer of the penultimate cycle and the nth layer of the last cycle of the second winding branch, or respectively connected to the nth layer of the penultimate cycle and the first layer of the last cycle of the second winding branch. The cross-layer connecting wires 220 connect the two cross-layer welding ends 210 so that the winding branch can be wound continuously.

[0051] It is understood that this embodiment, by reasonably setting the structure of the cross-layer line 200, facilitates the cross-layer connection of the winding branch from the innermost side to the outermost side or from the outermost side to the innermost side, thereby obtaining the required cross-layer outgoing winding structure.

[0052] More specifically, the lapped coil 100 includes an effective lapped edge 110, a lapped welding end 120, and a lapped hairpin end 130. The effective lapped edge 110 is disposed in the conductor groove 410, and there are two such edges. The two effective lapped edges 110 are spaced apart. The lapped welding end 120 is connected to the effective lapped edge 110 in a one-to-one correspondence. The two lapped welding ends 120 are disposed at the same end of the two effective lapped edges 110 and extend in a direction that approaches each other. The lapped hairpin end 130 is connected between the other ends of the two effective lapped edges 110.

[0053] like Figure 7 As shown in this embodiment, by way of example, the lapped coil 100 can also be manufactured using an integral molding method. When the lapped coil 100 is made of flat enameled wire, the stator assembly is suitable for a flat wire motor. The lapped coil 100 may include two lapped effective edges 110, two lapped welding ends 120, and one lapped hairpin end 130, wherein the lapped effective edges 110 are all disposed within conductor slots 410 and arranged in one of the slot layers of conductor slots 410. The two lapped effective edges 110 of the lapped coil 100 are spaced apart, and the number of conductor slots 410 between the two lapped effective edges 110 is the pitch of the lapped coil 100. The two lapped welding ends 120 are respectively disposed at the same end of the two lapped effective edges 110, and the two lapped welding ends 120 extend obliquely in a direction that approaches each other. The lapped hairpin end 130 connects to the other end of the two lapped effective edges 110, and can be configured in a V-shape, with the tip of the V-shape facing outwards from the stator core. When two lapped coils 100 are connected, they are connected through one of their lapped welding ends 120, which can be fixed by welding. It is easy to see that the two ends of the three-phase winding lines extending outwards from the stator core are respectively composed of the lapped welding ends 120 and lapped hairpin ends 130 of several lapped coils 100.

[0054] It is understood that this embodiment, by reasonably setting the structure of the lapped coil 100, facilitates the lapping of several lapped coils 100, thereby obtaining the required cross-layer lead-out winding structure.

[0055] More specifically, the two cross-layer welding ends 210 of the cross-layer line 200 are respectively connected to a lap-wound welding end 120 of a lap-wound coil 100, so that the cross-layer line 200 connects two lap-wound coils 100, and the two lap-wound welding ends 120 connected to the two cross-layer welding ends 210 of the cross-layer line 200 extend in a direction that approaches each other.

[0056] like Figure 1 and Figure 5As shown in this embodiment, by way of example, the cross-layer line 200 can be used to connect two lapped coils 100. In the two lapped coils 100, the cross-layer arrangement of the two effective lapped edges 110 of one lapped coil 100 should be the (n-1)th layer and the nth layer, and the cross-layer arrangement of the two effective lapped edges 110 of the other lapped coil 100 should be the 1st layer and the 2nd layer. When the cross-layer line 200 is connected to the two lapped coils 100, its two cross-layer welding ends 210 can be connected to the lapped welding ends 120 corresponding to the 1st layer and the lapped welding ends 120 corresponding to the nth layer of the two lapped coils 100, respectively. The connection can still be made by welding. The lapped welding ends 120 corresponding to the 1st layer and the lapped welding ends 120 corresponding to the nth layer also extend in a direction that approaches each other, so that the two cross-layer welding ends 210 are adjacent to each other in the circumferential direction of the core 400.

[0057] It is understood that in this embodiment, by connecting the two overlapping welded ends 120 of the two overlapping coils 100 in a direction that approaches each other through the cross-layer line 200, the span of the cross-layer line 200 along the circumference of the iron core 400 can be relatively small, so that the cross-layer line 200 has a relatively small size. This makes the preparation and processing of the cross-layer line 200 more convenient, and at the same time makes the connection of the cross-layer line 200 in the winding branch less likely to fail due to vibration.

[0058] More specifically, each winding branch also includes a connecting coil 300. Several lapped coils 100 of any winding branch form several lapped winding groups. The cross-layer line 200 connects the last two lapped winding groups of the second winding branch. The connecting coil 300 connects two other consecutive lapped winding groups. The connecting coil 300 includes a connecting effective side 310, a connecting welding end 320, and a connecting hairpin end 330. The connecting effective side 310 is disposed in the conductor groove 410 and there are two of them. The two connecting effective sides 310 are spaced apart. The connecting welding end 320 is connected to the connecting effective side 310 one by one. The two connecting welding ends 320 are disposed at the same end of the two connecting effective sides 310 and extend in the same direction. The connecting hairpin end 330 is connected between the other ends of the two connecting effective sides 310.

[0059] like Figure 8As shown in this embodiment, each winding branch also includes a connecting coil 300, which can be integrally formed or made of flat enameled wire. The connecting coil 300 also has two effective sides disposed within conductor slots 410, namely the connecting effective sides 310, and the number of conductor slots 410 between the two connecting effective sides 310 is the pitch of the connecting coil 300. The connecting coil 300 also includes two connecting welding ends 320, which are respectively connected to the same end of the two connecting effective sides 310 and extend obliquely in the same direction. The connecting coil 300 also includes a connecting hairpin end 330, which can also be configured in a "V" shape and connected between the other ends of the two connecting effective sides 310. Each winding branch forms several lapped winding groups during lap winding. The connecting coil 300 is used to connect two consecutive lapped winding groups, specifically connected to two lapped coils 100. During connection, the two connecting welding ends 320 of the connecting coil 300 are respectively connected to one lap welding end 120 of a lap-wound coil 100, and the connection method can still be welding fixation. It is easy to see that since both the lap-wound coil 100 and the connecting coil 300 include two effective sides, and the number of slot layers n of the conductor slot 410 is even, any winding branch can be wired into the lap-wound coil 100, and in the cyclic winding process, in addition to including several lap-wound coils 100, it can also include one connecting coil 300, and any winding branch can be wired out of the lap-wound coil 100. It should be noted that since the last cyclic winding of the second winding branch of any phase adopts the cross-layer winding method through the cross-layer line 200, in the second winding branch, the last two lap winding groups are connected by the cross-layer line 200 without the need to set up a connecting coil 300.

[0060] It is understood that, by setting up the connecting coil 300 and by reasonably setting the structure of the connecting coil 300, it is convenient for the first winding branch of any phase to be wound layer by layer with several overlapping coils 100 and connecting coil 300; and it is convenient for the second winding branch to be wound layer by layer with several overlapping coils 100 and connecting coil 300, and to continue to be wound layer by layer after crossing the layer with the cross-layer line 200, thereby obtaining the required cross-layer output winding structure.

[0061] More specifically, Z=54, P=3, n=8, the three phases of the stator assembly are U phase, V phase and W phase. The winding lines of V phase and W phase are obtained by shifting the winding line of U phase by 6 and 12 conductor slots 410 respectively. The first winding branch of U phase is:

[0062] 1.1-10.2-1.3-10.4-1.5-10.6-1.7-10.8-19.8-10.7-19.6-10.5-19.4-10.3-19.2-10.1-20.1-29.2-20.3-29.4-20.5-29.6-20.7-29.8-38.8-29.7-38.6-29.5-38.4-29.3-38.2-29.1-21.1-30.2-21.3-30.4- 21.5-30.6-21.7-30.8-39.8-30.7-39.6-30.5-39.4-30.3-39.2-30.1-38.1-47.2-38.3-47.4-38.5-47.6-38.7-47.8-1.8-46.7-1.6-46.5-1.4-46.3-1.2-46.1-39.1-48.2-39.3-48.4-39.5-48.6-39.7-48.8;

[0063] The second winding branch of phase U is:

[0064] 2.1-11.2-2.3-11.4-2.5-11.6-2.7-11.8-20.8-11.7-20.6-11.5-20.4-11.3-20.2-11.1-3.1-12.2-3.3-12.4-3.5-12.6-3.7-12.8-21.8-12.7-21.6-12.5-21.4-12.3-21.2-12.1-19.1-28.2-19.3-28.4- 19.5-28.6-19.7-28.8-37.8-28.7-37.6-28.5-37.4-28.3-37.2-28.1-37.1-46.2-37.3-46.4-37.5-46.6-37.7-46.8-2.8-47.7-2.6-47.5-2.4-47.3-2.2-47.1-3.8-48.7-3.6-48.5-3.4-48.3-3.2-48.1.

[0065] In this embodiment, an exemplary example is provided, using a 54-slot, 6-pole, 8-layer three-phase lap winding structure. The designations "U", "V", and "W" are merely for describing the three phases of the stator assembly and are not intended to limit them in any way. In some embodiments, the three phases of the stator assembly may also be represented by other designations. Similarly, the numbers "1" through "54" are also for describing the 54 conductor slots 410 on the core 400 and are not intended to limit them; any conductor slot 410 on the core 400 can be designated as conductor slot "1".

[0066] like Figure 4 As shown, in this embodiment, the first winding branch of phase U is taken as an example. The line corresponding to "1.1-10.2" represents the first lap-wound coil 100, whose two effective lap-wound edges 110 are respectively arranged in the first layer of conductor slot 410 with the number "1" and the second layer of conductor slot 410 with the number "10", and its pitch is 9 slots; at the same time, it indicates that the first winding branch of phase U is the incoming line from the first layer of conductor slot 410 with the number "1", referring to Figure 3 and Figure 4 U1 in the middle. The subsequent winding circuit is similar, where "1.7-10.8" indicates the first connecting coil 300, whose two effective connecting sides 310 are arranged in the 7th layer of conductor slot 410 with serial number "1" and the 8th layer of conductor slot 410 with serial number "10", and the pitch is 9 slots.

[0067] The circuit corresponding to “1.1-10.2-1.3-10.4-1.5-10.6” is the first lap winding, and the circuit corresponding to “19.8-10.7-19.6-10.5-19.4-10.3-19.2-10.1” is the second lap winding. These two lap windings are connected by the connecting coil 300 corresponding to “1.7-10.8”. It is easy to see that “1.1-10.2-1.3-10.4-1.5-10.6-1.7-10.8” corresponds to the first cycle winding, which includes three lap winding coils 100 and one connecting coil 300.

[0068] The sequence “19.8-10.7-19.6-10.5-19.4-10.3-19.2-10.1” corresponds to the second cycle of winding, which includes four overlapping coils of 100.

[0069] Meanwhile, the line corresponding to "39.7-48.8" indicates the last lapped coil 100, whose two effective lapped edges 110 are respectively arranged in the 7th layer of conductor slot 410 with serial number "39" and the 8th layer of conductor slot 410 with serial number "48", with a pitch of 9 slots; at the same time, it indicates that the first winding branch of phase U is the lead-out line from the 8th layer of conductor slot 410 with serial number "48", as shown in the reference. Figure 3 and Figure 4 X1 in the middle.

[0070] like Figure 5 As shown, the second winding branch of phase U is similar, where the line corresponding to "2.1-11.2" is the first lapped coil 100, which also indicates that the second winding branch of phase U is the first layer of the conductor slot 410 with the sequence number "2" as the first layer of the incoming line. Figure 3 and Figure 5U2 in the diagram; while the line corresponding to "3.2-48.1" is the last lapped coil 100, which also indicates that the second winding branch of phase U is the first layer output line of conductor slot 410 with sequence number "48", see reference. Figure 3 and Figure 5 X2 in the diagram. It is not difficult to see that the first winding branch and the second winding branch of phase U enter through the first layer of two consecutive conductor slots 410 and exit through the eighth layer of the same conductor slot 410.

[0071] like Figure 3 As shown, in this embodiment, the winding lines of phases V and W can be obtained by shifting the winding line of phase U by 6 and 12 conductor slots 410 respectively, which can ensure the balance among the three phases. Based on this, the two winding branches of phase V are respectively connected to the lines corresponding to "7.1" and "8.1", referring to... Figure 3 V1 and V2 in the diagram; simultaneously, the two winding branches of phase V are respectively output from the lines corresponding to "54.8" and "54.1", referring to... Figure 3 Y1 and Y2 in the diagram. The two bypass branches of phase W are respectively fed by the lines corresponding to "13.1" and "14.1", referring to... Figure 3 W1 and W2 in the diagram; simultaneously, the two bypass branches of phase W are respectively routed from the lines corresponding to "6.8" and "6.1", referring to... Figure 3 Z1 and Z2 in the example.

[0072] Specifically, the cross-layer outgoing winding structure also includes a phase copper busbar 500, which corresponds one-to-one with the three phases of the stator assembly. The phase copper busbar 500 is connected to the inlet positions of the two winding branches of its corresponding phase.

[0073] like Figure 3As shown in this embodiment, the cross-layer lead-out winding structure also includes a phase copper busbar 500 that connects two winding branches of the same phase in parallel. Three phase copper busbars 500 can be provided, each corresponding to one of the three phases of the stator assembly. During connection, the phase copper busbar 500 is connected to the input positions of the two winding branches of its corresponding phase. For example, the phase copper busbar 500 corresponding to U is connected to both U1 and U2, which correspond to the overlapping winding hairpin ends 130 of the overlapping coil 100. It is easy to understand that since U1 and U2 are the first layers of two consecutive conductor slots 410, the phase copper busbar 500 can even be a simple arc-shaped strip extending circumferentially along the core 400, and its material can specifically be flat enameled wire. With this structure, the phase copper busbar 500 is easy to manufacture and process, and it maintains high stability after installation and fixation. In some embodiments, the three phase copper busbars 500 can also be fabricated as an integral busbar assembly. For example, the three phase copper busbars 500 are fixed together by injection molding material. Under the premise that the dimensions of the three phase copper busbars 500 are relatively small, the busbar assembly also has a relatively small size and a relatively simple structure.

[0074] Specifically, the cross-layer outgoing winding structure also includes a star copper busbar 600, which is connected to the outgoing positions of the three phases and a total of six winding branches.

[0075] like Figure 3 and Figure 9 As shown in this embodiment, the cross-layer lead-out winding structure further includes a star-point copper busbar 600, which connects the lead-out positions of the three-phase winding lines. The star-point copper busbar 600 can be configured as one, simultaneously connecting to the lead-out positions of all six winding lines across the three phases. The star-point copper busbar 600 can include a copper busbar component 610 and star-point terminals 620, wherein there can be six star-point terminals 620, each corresponding to and connected to the lead-out positions of six winding branches. Referring to the aforementioned X1, X2, Y1, Y2, Z1, and Z2, X1, X2, Y1, Y2, Z1, and Z2 also correspond to the overlapping hairpin ends 130 of the overlapping coil 100. The copper busbar component 610 connects the six copper busbar terminals and can be configured as an arc-shaped segment extending circumferentially along the core component 400. Meanwhile, the copper busbar 610 can also be set between the innermost and outermost sides of the winding lines of the three phases.

[0076] It is understood that by setting the star-point copper busbar 600, the outgoing positions of the winding lines of the three phases can be connected so that the cross-layer outgoing winding structure forms a three-phase circuit. Since the two winding branches of any phase are outgoing from the first and nth layers of the same conductor slot 410, the star-point copper busbar 600 can have a small span. At the same time, when it is connected to the winding lines of the three phases, it can be stably, uniformly and effectively supported on the innermost and outermost sides of the iron core 400, thereby ensuring the stability after installation and fixing.

[0077] It is easy to understand that in some embodiments, the star copper busbar 600 can also be injection molded together with the three phase copper busbars 500 to form a busbar assembly. For example, the injection molding material is divided into two sections, one of which extends between the three phase copper busbars 500, and the other section covers the star copper busbar 600. These two sections of injection molding material are integrally formed. In other embodiments, the three cross-layer wires 200 can also be injection molded within the busbar assembly. For example, the injection molding material is further divided into a section that covers the three cross-layer wires 200, so that the cross-layer wires 200 can be installed and arranged together with the phase copper busbars 500 and the star copper busbar 600. This further reduces the difficulty of manufacturing the winding structure and ensures the stability of each welding position so that it is not easily damaged by vibration.

[0078] The implementation principle of the cross-layer outgoing winding structure provided in Embodiment 1 of this application is as follows:

[0079] The core component 400 is prepared and shaped, and then several stacked coils 100 and connecting coils 300 are wound on the core component 400. When winding any phase's winding branch, if Z / 6 is odd, its first winding branch enters from the first layer, then is wound sequentially in the second, third...n layers, then again in the nth layer, and subsequently in the (n-1)...2, 1 layers, and so on, until it exits from the nth layer; the second winding branch enters from the first layer, then is wound sequentially in the second, third...n layers, then again in the nth layer, and subsequently in the (n-1)...2, 1 layers, and so on, until it exits from the nth layer; Within the layer, the process is repeated sequentially until the final winding process. During the final winding process, when the second winding branch is wound sequentially from layer n to layers n-1...2, 1, it is directly wound from layer 1 into layer n via the cross-layer line 200, and then sequentially wound into layers n-1...2, 1, with the output wire exiting from layer 1. This ensures that the entry positions of the two winding branches of the same phase are the first layers of two consecutive conductor slots 410, and the exit positions are the first layers of the same conductor slot 410 and... Layer n; if Z / 6 is even, its first winding branch enters from layer 1, then winds sequentially in layers 2, 3...n, then winds again in layer n, and then winds sequentially in layers n-1...2, 1, and so on, until it exits from layer 1; the second winding branch enters from layer 1, then winds sequentially in layers 2, 3...n, then winds again in layer n, and then winds sequentially in layers n-1...2, 1, and so on, and so on. Until the final winding cycle, during the final winding cycle, when the second winding branch is wound sequentially from layer 1 to layers 2, 3...n, it is directly wound from layer n to layer 1 via the cross-layer wire 200, and then sequentially wound to layers 2, 3...n, with the wire exiting from layer n. This ensures that the entry positions of the two winding branches of the same phase are the first layers of two consecutive conductor slots 410, and the exit positions are the first and nth layers of the same conductor slot 410, respectively. The cross-layer wire 200 is installed and arranged together with the three phase copper busbars 500 and the star copper busbar 600. The cross-layer wire 200 is injection molded integrally with the three phase copper busbars 500 and the star copper busbar 600 using injection molding material. The phase copper busbar 500 is connected to the entry positions of the two winding branches of its corresponding phase, and the star copper busbar 600 is connected to the exit positions of all six winding branches of the three phases.

[0080] This application achieves a more concentrated three-phase lap winding structure by rationally setting the cross-layer method of the two parallel winding branches of any phase. Specifically, the first winding branch adopts a layer-by-layer cyclic winding method, while the second winding branch, during the last cyclic winding, crosses directly from the innermost layer to the outermost layer or directly from the outermost layer to the innermost layer via the cross-layer line 200. This allows the inlet positions of the two winding branches of the same phase to be the first layer of two consecutive conductor slots 410, and the outlet positions to be the first and nth layers of the same conductor slot 410, respectively. Consequently, the inlet and outlet positions of the three-phase lap winding structure are more concentrated. When subsequently manufacturing a smaller busbar component, this application can reduce its size and manufacturing difficulty, while also reducing the risk of busbar component failure due to vibration during motor operation.

[0081] Example 2

[0082] Embodiment 2 of this application provides a stator assembly, which includes any of the cross-layer lead-out winding structures provided in this application.

[0083] Example 3

[0084] Embodiment 3 of this application provides an electric motor, which includes any of the stator components provided in this application.

[0085] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0086] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

Claims

1. A cross-layer lead-out winding structure, characterized in that, The cross-layer outgoing winding structure is used for the stator assembly, which has three phases and 2p poles. The stator assembly also includes a core component (400), which has Z conductor slots (410) evenly spaced along the circumference, where Z is a natural number that is an integer multiple of 6. Each conductor slot (410) has n slot layers, where n is an even number not less than 4. The first, second, ..., nth layers of the conductor slots (410) are arranged sequentially from the outside to the inside. The cross-layer outgoing winding structure includes three phase winding lines. Each phase winding line includes two parallel winding branches. Each winding branch adopts a lap winding method and includes several lap coils (100). When Z / 6 is odd, in any phase, the first winding branch enters from layer 1, then winds sequentially through layers 2, 3...n, then winds again through layer n, and then winds sequentially through layers n-1...2, 1, and so on, until it exits from layer n; the second winding branch enters from layer 1, then winds sequentially through layers 2, 3...n, then winds again through layer n, and then winds sequentially through layers n-1...2, 1, and so on, until it exits from layer n. In the last cycle winding process, when the second winding branch is wound sequentially from the nth layer to the n-1...2, 1st layer, it is directly wound from the 1st layer to the nth layer through the cross-layer line (200), and then wound sequentially to the n-1...2, 1st layer, and exits from the 1st layer, so that the entry positions of the two winding branches of the same phase are the 1st layers of the two consecutive conductor slots (410), and the exit positions are the 1st layer and the nth layer of the same conductor slot (410); When Z / 6 is even, in any phase, the first winding branch enters from layer 1, then winds sequentially in layers 2, 3...n, then winds again in layer n, and then winds sequentially in layers n-1...2, 1, and so on, until it exits from layer 1; the second winding branch enters from layer 1, then winds sequentially in layers 2, 3...n, then winds again in layer n, and then winds sequentially in layers n-1...2, 1, and so on, and so on. Until the last cycle of winding, during the last cycle of winding, when the second winding branch is wound from the first layer to the second, third...n layers in sequence, it is directly wound from the nth layer into the first layer through the cross-layer line (200), and then wound in the second, third...n layers in sequence, and exits from the nth layer, so that the entry positions of the two winding branches of the same phase are the first layers of the two consecutive conductor slots (410), and the exit positions are the first layer and the nth layer of the same conductor slot (410).

2. The cross-layer lead-out winding structure according to claim 1, characterized in that, The cross-layer line (200) includes a cross-layer welding end (210) and a cross-layer connecting line (220). There are two cross-layer welding ends (210), which are respectively located near the first layer and the nth layer of the conductor groove (410). The cross-layer connecting line (220) connects the two cross-layer welding ends (210).

3. The cross-layer lead-out winding structure according to claim 2, characterized in that, The lapped coil (100) includes a lapped effective edge (110), a lapped welding end (120), and a lapped hairpin end (130). The lapped effective edge (110) is disposed in the conductor groove (410), and there are two lapped effective edges (110) disposed at intervals. The lapped welding end (120) is connected to the lapped effective edge (110) in a one-to-one correspondence. The two lapped welding ends (120) are disposed at the same end of the two lapped effective edges (110) and extend in a direction that approaches each other. The lapped hairpin end (130) is connected between the other ends of the two lapped effective edges (110).

4. The cross-layer lead-out winding structure according to claim 3, characterized in that, The two cross-layer welding ends (210) of the cross-layer line (200) are respectively connected to one of the lap-wound welding ends (120) of one of the lap-wound coils (100), so that the cross-layer line (200) connects two of the lap-wound coils (100), and the two lap-wound welding ends (120) connected to the two cross-layer welding ends (210) of the cross-layer line (200) extend in a direction that approaches each other.

5. The cross-layer lead-out winding structure according to claim 4, characterized in that, Each winding branch also includes a connecting coil (300), and the plurality of said lapped coils (100) of any winding branch form a plurality of lapped winding groups. In the first winding branch of any phase, the connecting coil (300) connects two consecutive lapped winding groups; in the second winding branch of any phase, the cross-layer line (200) connects the last two lapped winding groups of the second winding branch, and the connecting coil (300) connects the other two consecutive lapped winding groups of the second winding branch. The connecting coil (300) includes a connecting effective edge (31). 0) Connecting welding end (320) and connecting hairpin end (330), the effective connecting edge (310) is set in the conductor groove (410) and there are two of them. The two effective connecting edges (310) are spaced apart. The welding end (320) and the effective connecting edge (310) are connected one-to-one. The two welding ends (320) are set at the same end of the two effective connecting edges (310) and extend in the same direction. The hairpin end (330) is connected between the other ends of the two effective connecting edges (310).

6. The cross-layer lead-out winding structure according to claim 5, characterized in that, According to claim 5, the cross-layer lead-out winding structure is characterized in that Z=54, P=3, n=8, the three phases of the stator assembly are U phase, V phase and W phase respectively, the winding lines of the V phase and the W phase are obtained by shifting the winding line of the U phase by 6 and 12 conductor slots (410) respectively, and the first winding branch of the U phase is: 1.1-10.2-1.3-10.4-1.5-10.6-1.7-10.8-19.8-10.7-19.6-10.5-19.4-10.3-19.2-10.1-20.1-29.2-20.3-29.4-20.5-29.6-20.7-29.8-38.8-29.7-38.6-29.5-38.4-29.3-38.2-29.1-21.1-30.2-21.3-30.4-21.5-30.6-21.7-30.8-39.8-30.7-39.6-30.5-39.4-30.3-39.2-30.1-38.1-47.2-38.3-47.4-38.5-47.6-38.7-47.8-1.8-46.7-1.6-46.5-1.4-46.3-1.2-46.1-39.1-48.2-39.3-48.4-39.5-48.6-39.7-48.8； The second winding branch of the U phase is: 2.1-11.2-2.3-11.4-2.5-11.6-2.7-11.8-20.8-11.7-20.6-11.5-20.4-11.3-20.2-11.1-3.1-12.2-3.3-12.4-3.5-12.6-3.7-12.8-21.8-12.7-21.6-12.5-21.4-12.3-21.2-12.1-19.1-28.2-19.3-28.4-19.5-28.6-19.7-28.8-37.8-28.7-37.6-28.5-37.4-28.3-37.2-28.1-37.1-46.2-37.3-46.4-37.5-46.6-37.7-46.8-2.8-47.7-2.6-47.5-2.4-47.3-2.2-47.1-3.8-48.7-3.6-48.5-3.4-48.3-3.2-48.1。 7. The cross-layer lead-out winding structure according to claim 1, characterized in that, The cross-layer outgoing winding structure also includes a phase copper busbar (500), which corresponds one-to-one with the three phases of the stator assembly. The phase copper busbar (500) is connected to the inlet positions of the two winding branches of its corresponding phase.

8. The cross-layer lead-out winding structure according to claim 1, characterized in that, The cross-layer lead-out winding structure also includes a star-point copper busbar (600), which is connected to the lead-out positions of the three phases and a total of six winding branches.

9. A stator assembly, characterized in that, The stator assembly includes the cross-layer lead-out winding structure as described in any one of claims 1-8.

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

Images