Winding structure based on flat wire conductor

Abstract

The invention belongs to the technical field of flat wire motors, and provides a winding structure based on a flat wire conductor, which comprises a stator core and a three-phase coil, a plurality of stator grooves are formed in the inner surface of the stator core, three-phase coils are installed in the stator grooves, the three-phase coils are divided into n layers from the groove bottoms of the stator grooves to groove openings, and n is larger than 1. The three-phase leading-out ends of the other three-phase coils are located on the ith layer, n > = i > = 1, and the neutral ends are located on any adjacent layer of the three-phase leading-out ends; the three-phase leading-out end is connected with a leading-out assembly, and the neutral end is connected with a neutral bar. The three-phase leading-out ends and the neutral ends are adjacently arranged in a staggered mode, current flowing-in and flowing-out paths are spatially separated, meanwhile, the neutral ends and the three-phase leading-out ends of adjacent layers form natural shielding layers, electromagnetic radiation generated by high-frequency harmonic waves is reduced, the three-phase leading-out ends are intensively arranged in the middle layer, excessive concentration of a high-current-density area is avoided, and the electromagnetic radiation is reduced. And the local temperature rise condition is reduced.

Description

Technical Field

[0001] The present invention belongs to the technical field of flat wire motors, and particularly relates to a winding structure based on flat wire conductors. Background Art

[0002] At present, the requirements for the number of layers, the number of parallel branches, and the winding form of flat wire motors are getting higher and higher. The existing winding method of the stator winding (using flat wire conductors) of flat wire motors is mostly full-pitch winding. The flat wire motor with a full-pitch structure has a high harmonic winding coefficient, large torque fluctuation during operation, deteriorates the noise, vibration, and harshness of the motor, and reduces the performance of the motor. Therefore, by setting the stator winding as a short-pitch winding, the harmonic winding coefficient of the flat wire motor can be reduced, and further the noise, vibration, and harshness (NVH, Noise, Vibration, Harshness) performance of electric vehicles can be improved.

[0003] However, the existing flat wire short-pitch winding with balanced multi-branches has a complex structure, which makes the winding processing difficult and the wire winding difficult. Moreover, the short-pitch setting method is limited by the winding form. It is difficult to obtain a high fundamental winding coefficient while reducing the harmonic winding coefficient, thus reducing the performance of the flat wire motor. Summary of the Invention

[0004] In order to solve the problems in the background art, the present invention proposes a winding structure based on flat wire conductors.

[0005] In order to achieve the above object, the present invention adopts the following technical solutions:

[0006] A winding structure based on flat wire conductors, comprising a stator core and three-phase coils;

[0007] A plurality of stator slots are formed on the inner surface of the stator core;

[0008] The three-phase coils are installed in the stator slots, and the three-phase coils are divided into n layers from the bottom to the opening of the stator slots, where n > 1;

[0009] The three-phase leads of the three-phase coils are located in the i-th layer, where n ≥ i ≥ 1;

[0010] The neutral ends of the three-phase coils are located in any adjacent layer of the three-phase leads;

[0011] The three-phase leads and the neutral ends are located at the same end of the three-phase coils;

[0012] The three-phase leads are connected with lead-out components, and the neutral ends are connected with neutral bars.

[0013] Preferably, the three-phase coils include a U-phase coil, a V-phase coil, and a W-phase coil that are symmetrically distributed at 120°;

[0014] Each of the U-phase coil, V-phase coil, and W-phase coil is provided with a plurality of parallel branch coils.

[0015] The starting point of each branch coil serves as a three-phase lead-out end and is connected to the lead-out component, and the end point serves as a neutral end and is connected to the neutral busbar.

[0016] Preferably, the branch coil includes a lead-out hairpin, a U-shaped hairpin, and a reverse-twist hairpin.

[0017] Along the current flow direction, the lead-out hairpin, as the starting point of the branch coil, sequentially connects the U-shaped hairpin and the reverse-twist hairpin across layers until it crosses layers to the first layer or the nth layer, forming a first branch coil.

[0018] In the first branch coil, if the lead-out hairpin is located on the second layer, the reverse-twist hairpin is located on the nth layer; if the lead-out hairpin is located on the (n - 1)th layer, the reverse-twist hairpin is located on the first layer.

[0019] Along the current direction, the first U-shaped hairpin sequentially connects the next U-shaped hairpin and the next reverse-twist hairpin across layers until it connects across layers to the first layer or the nth layer, forming a second branch coil.

[0020] In the second branch coil, if the first U-shaped hairpin is located on the second layer, the reverse-twist hairpin is located on the nth layer; if the first U-shaped hairpin is located on the (n - 1)th layer, the reverse-twist hairpin is located on the first layer.

[0021] In the branch coil, the first branch coil sequentially connects a plurality of second branch coils until the last reverse-twist hairpin is located on the adjacent layer of the lead-out hairpin.

[0022] Preferably, the lead-out hairpin includes a first U-shaped conductor, a first welding section, and a lead-out section.

[0023] The first U-shaped conductor is in a U shape.

[0024] The first welding section is connected to one end of the first U-shaped conductor.

[0025] The lead-out section is connected to the other end of the first U-shaped conductor, and the lead-out section is used to connect to the lead-out component.

[0026] The first welding section and the lead-out section are arranged back to back at the U-shaped opening of the first U-shaped conductor.

[0027] Preferably, the U-shaped hairpin includes a second U-shaped conductor and second welding sections that are symmetric and face away from each other.

[0028] The second U-shaped conductor is in a U shape.

[0029] The symmetric and mutually facing-away second welding sections are respectively connected to the two U-shaped openings of the second U-shaped conductor.

[0030] Preferably, the reverse-twist hairpin includes a third U-shaped conductor and third welding sections with the same orientation;

[0031] The third U-shaped conductor is U-shaped;

[0032] The third welding sections with the same orientation are respectively connected to the two U-shaped openings of the third U-shaped conductor.

[0033] Preferably, in the branch circuit coil:

[0034] A lead-out hairpin and a U-shaped hairpin are lap-welded and connected through a first welding section and a second welding section;

[0035] Between two U-shaped hairpins, a second welding section of a first U-shaped hairpin and a second welding section of a second U-shaped hairpin are lap-welded;

[0036] The U-shaped hairpin and the reverse-twist hairpin are lap-welded through a second welding section and a third welding section.

[0037] Preferably, the lead-out assembly includes:

[0038] A connecting housing, which is arc-shaped;

[0039] A first lead-out wire, which is connected to a first lead-out row;

[0040] The first lead-out row is provided with a plurality of welding feet for connecting to three-phase lead-out terminals;

[0041] A second lead-out wire, which is connected to a second lead-out row;

[0042] The second lead-out row is provided with a plurality of welding feet for connecting to three-phase lead-out terminals;

[0043] A third lead-out wire, which is connected to a third lead-out row;

[0044] The third lead-out row is provided with a plurality of welding feet for connecting to three-phase lead-out terminals;

[0045] The first lead-out row, the second lead-out row and the third lead-out row are insulated from each other and are all installed in the connecting housing.

[0046] Preferably, the first lead-out row includes a first lead-out copper row, a first overlapping row and a plurality of first welding feet which are integrally connected; the first overlapping row is used for connecting the first lead-out wire, and the first welding feet are used for connecting the three-phase lead-out terminals;

[0047] The first lead-out copper row is embedded in the connecting housing;

[0048] The first overlapping row is bent relative to the first lead-out copper row and is located on one side surface of the first lead-out copper row;

[0049] The first welding foot is bent relative to the first lead copper bar and is located on the other side of the first lead copper bar.

[0050] Preferably, the second lead row includes a second overlapping row and a plurality of second welding feet integrally connected;

[0051] The second overlapping row is bent relative to the second welding feet, and the connection position between the second overlapping row and the second welding feet is embedded in the connection housing;

[0052] The second overlapping row is used to connect the second lead wire, and the second welding feet are used to connect the three-phase lead-out ends.

[0053] Preferably, the third lead row includes a second lead copper bar, a third overlapping row and a plurality of third welding feet integrally connected; the third overlapping row is used to connect the third lead wire, and the third welding feet are used to connect the three-phase lead-out ends;

[0054] The second lead copper bar is embedded in the connection housing;

[0055] The third overlapping row is bent relative to the second lead copper bar and is located on one side of the second lead copper bar;

[0056] The third welding feet are bent relative to the second lead copper bar and are located on the other side of the second lead copper bar.

[0057] Preferably, a plurality of locking blocks are further provided on the arc surface of the connection housing;

[0058] The surface of the locking block facing the connection housing abuts against the surface of the neutral row far from the connection housing, and is used to limit the radial movement of the neutral row along the stator core.

[0059] Preferably, the neutral row is arc-shaped, and a plurality of welding feet connected to the neutral end are provided on the neutral row.

[0060] Advantages of the present invention:

[0061] 1. The present invention adopts a misaligned layout where the three-phase lead-out ends and the neutral end are adjacent, so that the current inflow and outflow paths are spatially separated, effectively suppressing the electromagnetic coupling interference between windings. At the same time, the neutral end and the three-phase lead-out ends of adjacent layers form a natural shielding layer, reducing the electromagnetic radiation generated by high-frequency harmonics. Secondly, the three-phase lead-out ends are concentratedly arranged in the middle layer, avoiding excessive concentration of high-current density areas and reducing the situation of local temperature rise;

[0062] 2. The present invention adopts the structure of the first branch coil and the second branch coil, providing a winding form of three-branch parallel connection, which can obtain a higher fundamental winding coefficient, improve the harmonic winding coefficient, and is beneficial to improving the performance of the flat wire motor;

[0063] 3. The lead-out component of the present invention replaces the traditional three-phase copper busbar structure. The structures of the first lead-out row, the second lead-out row, and the third lead-out row are more simplified and integrated through the connection housing, which can reduce the occupied space of the lead-out component at the end of the three-phase coil while ensuring the insulation effect between the lead-out rows.

[0064] Other features and advantages of the present invention will be described in the following specification, and in part, will be obvious from the specification, or will be understood by implementing the present invention. The objectives and other advantages of the present invention can be achieved and obtained through the structures pointed out in the specification and the drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0065] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings required for the description of the embodiments or the prior art. Obviously, the drawings in the following description are some embodiments of the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can be obtained based on these drawings.

[0066] Figure 1 FIG. shows a schematic diagram of a winding structure based on a flat wire conductor of the present invention;

[0067] Figure 2 FIG. shows a schematic diagram of the first lead-out wire and the first lead-out row of the present invention;

[0068] Figure 3 FIG. shows a schematic diagram of the second lead-out wire and the second lead-out row of the present invention;

[0069] Figure 4 FIG. shows a schematic diagram of the third lead-out wire and the third lead-out row of the present invention;

[0070] Figure 5 FIG. shows a schematic diagram of the lead-out component (the first lead-out wire, the second lead-out wire, and the third lead-out wire are not drawn) of the present invention;

[0071] Figure 6 FIG. shows a schematic diagram of the connection housing of the present invention;

[0072] Figure 7 FIG. shows a schematic diagram of a single branch wire coil of the present invention;

[0073] Figure 8 FIG. shows a schematic diagram of the lead-out hairpin of the present invention;

[0074] Figure 9 FIG. shows a schematic diagram of the U-shaped hairpin of the present invention;

[0075] Figure 10Shows a schematic structural diagram of the anti-twist hairpin of the present invention;

[0076] Figure 11 Shows the path diagram of the alternating current of the three-phase coil of the present invention in the stator slots;

[0077] Figure 12 Shows the layout of the hairpins in the stator slots of the present invention Figure 1 ;

[0078] Figure 13 Shows the layout of the hairpins in the stator slots of the present invention Figure 2 ;

[0079] Figure 14 Shows the layout of the hairpins in the stator slots of the present invention Figure 3 ;

[0080] Figure 15 Shows the developed view of the single-phase coil of the present invention.

[0081] In the figure: 1, stator core; 2, three-phase coil; 3, lead-out assembly; 301, first lead wire; 302, first lead-out row; 3021, first lead-out copper row; 3022, first lap joint row; 3023, first welding foot; 303, second lead wire; 304, second lead-out row; 3041, second lap joint row; 3042, second welding foot; 305, third lead wire; 306, third lead-out row; 3061, second lead-out copper row; 3062, third lap joint row; 3063, third welding foot; 307, connection housing; 3071, locking block; 4, neutral row; 5, lead-out hairpin; 501, first U-shaped conductor; 502, first welding section; 503, lead-out section; 6, U-shaped hairpin; 601, second U-shaped conductor; 602, second welding section; 7, anti-twist hairpin; 701, third U-shaped conductor; 702, third welding section. Detailed implementation manners

[0082] To make the objectives, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are some, but not all, of the embodiments of the present invention. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0083] A winding structure based on a flat wire conductor, which includes a stator core 1 and a three-phase coil 2. A plurality of stator slots are provided on the inner surface of the stator core 1, and the three-phase coil 2 is embedded in the stator slots by a multi-layer overlapping winding process. The three-phase coil 2 is divided into n layers from the bottom to the opening of the stator slot, and n is greater than 1. At the same time, the three-phase lead-out ends (the positions where current flows in) of the three-phase coil 2 are located in the i-th layer, n≥i≥1, and the neutral end (the position where current flows out) of the three-phase coil 2 is located in any adjacent layer of the three-phase lead-out ends, and the three-phase lead-out ends and the neutral end are located at the same end of the three-phase coil 2. Then the three-phase lead-out ends are connected to a lead-out assembly 3, and the neutral end is connected to a neutral busbar 4.

[0084] It should be noted that in the above structure, the staggered layout of input and output in adjacent layers is adopted, so that the current inflow and outflow paths are spatially separated, effectively suppressing the electromagnetic coupling interference between windings. At the same time, the neutral ends and lead-out ends of adjacent layers form a natural shielding layer, reducing the electromagnetic radiation generated by high-frequency harmonics. Secondly, the three-phase lead-out ends are concentrated in the i-th layer, avoiding excessive concentration of high-current density areas and reducing the local temperature rise.

[0085] As a preferred solution, the three-phase coil 2 includes a U-phase coil, a V-phase coil, and a W-phase coil that are symmetrically distributed at 120°. Moreover, the U-phase coil, the V-phase coil, and the W-phase coil are each provided with a plurality of parallel branch coils, and the branch coils can preferably be three. The starting point of each branch coil is used as the three-phase lead-out end to be connected to the lead-out assembly 3, and the end point is used as the neutral end to be connected to the neutral busbar 4.

[0086] As a preferred solution, the following is combined with Figures 1 - 15 to introduce a winding structure based on a flat wire conductor:

[0087] As Figure 1 shown, in the winding structure of the flat wire motor, the number of stator slots is 54, and the number of layers of the three-phase coil 2 is 6. The opening of the stator slot is the first layer, and the bottom of the slot is the sixth layer. In addition, the U-phase coil, the V-phase coil, and the W-phase coil are each provided with three parallel branch coils. The lead-out assembly 3 is connected to the three-phase lead-out ends located in the fifth layer, and the neutral busbar 4 is connected to the neutral ends located in the sixth layer.

[0088] Combined with Figures 2 to 6 it can be known that the lead-out assembly 3 includes a first lead-out wire 301, a first lead-out busbar 302, a second lead-out wire 303, a second lead-out busbar 304, a third lead-out wire 305, a third lead-out busbar 306, and a connection housing 307.

[0089] As Figure 2As shown in the figure, the first lead-out row 302 can be made of a copper row, which is composed of a first lead-out copper row 3021, a first overlapping row 3022, and a first welding foot 3023. Among them, the first lead-out copper row 3021 is embedded and connected inside the connection housing 307. At the same time, the first overlapping row 3022 and three first welding feet 3023 (corresponding to three branch coils) are respectively located on both sides of the first lead-out copper row 3021 (obtained by bending process and integrated with the first lead-out copper row 3021). Moreover, the first overlapping row 3022 can be welded to the first lead-out wire 301, and the first welding foot 3023 is welded to the three-phase lead-out end.

[0090] As Figure 3 shown in the figure, the second lead-out row 304 can be made of a copper row, which is composed of a second overlapping row 3041 and several second welding feet 3042. Among them, the second overlapping row 3041 and the second welding feet 3042 are bent relative to each other, and the connection position between them is embedded in the connection housing 307. The second overlapping row 3041 extends to the outside of the connection housing 307 and is welded to the second lead-out wire 303, and the second welding feet 3042 (three are provided, corresponding to three branch coils) are welded to the three-phase lead-out end.

[0091] As Figure 4 shown in the figure, the third lead-out row 306 can be made of a copper row, which is composed of a second lead-out copper row 3061, a third overlapping row 3062, and a third welding foot 3063. Among them, the second lead-out copper row 3061 is embedded and connected inside the connection housing 307. At the same time, the third overlapping row 3062 and three third welding feet 3063 (corresponding to three branch coils) are respectively located on both sides of the second lead-out copper row 3061 (obtained by bending process and integrated with the second lead-out copper row 3061). Moreover, the third overlapping row 3062 can be welded to the third lead-out wire 305, and the third welding foot 3063 is welded to the three-phase lead-out end.

[0092] As Figure 5 shown in the figure, the connection housing 307 is arc-shaped; the first lead-out row 302, the second lead-out row 304, and the third lead-out row 306 are insulated from each other and are all installed on the connection housing 307. Combining Figure 6 it can be known that a locking block 3071 is also provided on the arc surface of the connection housing 307. The surface of the locking block 3071 facing the connection housing 307 abuts against the surface of the neutral row 4 far from the connection housing 307. Therefore, the locking block 3071 can lock the neutral row 4, thereby restricting the radial movement of the neutral row 4 along the stator core 1. Similarly, the neutral row 4 is arc-shaped and is embedded in the locking block 3071, and nine welding feet connected to the neutral end are provided on one side of it.

[0093] It should be noted that the lead-out component 3 replaces the traditional three-phase copper bus structure. The structures of the first lead-out row 302, the second lead-out row 304, and the third lead-out row 306 are more simplified and integrated through the connection housing 307. While ensuring the insulation effect between the lead-out rows, it can also reduce the occupied space of the lead-out component 3 at the end of the three-phase coil 2.

[0094] As Figure 7 shown, the three-phase coil 2 has a total of nine branch coils, with three parallel branch coils corresponding to each phase. Each branch coil includes a lead-out hairpin 5, a U-shaped hairpin 6, and a reverse-twist hairpin 7, and these three hairpins can be combined with different spans.

[0095] For example, along the current flow direction, the lead-out hairpin 5 serves as the starting point of the branch coil and sequentially connects the U-shaped hairpin 6 and the reverse-twist hairpin 7 across layers until it crosses to the first layer or the nth layer, forming the first branch coil. At the same time, along the current direction, the U-shaped hairpin 6 located on the (n - 1)th layer or the second layer sequentially connects the next U-shaped hairpin 6 and the next reverse-twist hairpin 7 across layers until it crosses to the first layer or the nth layer, forming the second branch coil. In the branch coil, the first branch coil sequentially connects several second branch coils until the last reverse-twist hairpin 7 is located on the adjacent layer of the lead-out hairpin 5.

[0096] It should be noted that the lead-out hairpin 5 can be set on any layer from the first to the sixth layer, while the reverse-twist hairpin 7 is located on the first layer or the sixth layer. The last reverse-twist hairpin 7 of the final branch coil can cross to the adjacent layer of the lead-out hairpin 5. Therefore, in the first branch coil, if the lead-out hairpin 5 is located on the second layer, the reverse-twist hairpin 7 is located on the nth layer; if the lead-out hairpin 5 is located on the (n - 1)th layer, the reverse-twist hairpin 7 is located on the first layer. In the second branch coil, if the first U-shaped hairpin 6 is located on the second layer, the reverse-twist hairpin 7 is located on the nth layer; if the first U-shaped hairpin 6 is located on the (n - 1)th layer, the reverse-twist hairpin 7 is located on the first layer.

[0097] As Figure 8 shown, the lead-out hairpin 5 is mainly composed of a first U-shaped conductor 501, a first welding section 502, and a lead-out section 503. The first U-shaped conductor 501 is in a U-shaped structure. The first welding section 502 is closely connected to one end of the first U-shaped conductor 501. The lead-out section 503 is connected to the other end of the first U-shaped conductor 501, and its main function is to establish a connection with the lead-out component 3 to achieve functions such as relevant electrical conduction or signal transmission. In addition, the first welding section 502 and the lead-out section 503 are arranged in a back-to-back manner at the U-shaped opening of the first U-shaped conductor 501 (specifically, first bent towards both sides and then bent vertically). This layout method can effectively optimize the spatial structure of the lead-out hairpin 5, reduce possible interference between parts, and ensure the stability and reliability of its overall performance.

[0098] As Figure 9 shown, the U-shaped hairpin 6 includes a second U-shaped conductor 601 and second welding segments 602 that are symmetric and face away from each other. The second U-shaped conductor 601 is U-shaped, and the symmetric and mutually facing second welding segments 602 are respectively connected to the two U-shaped open ends of the second U-shaped conductor 601.

[0099] As Figure 10 shown, the reverse-twist hairpin 7 includes a third U-shaped conductor 701 and third welding segments 702 that face the same direction. The third U-shaped conductor 701 is U-shaped, and the third welding segments 702 that face the same direction are respectively connected to the two U-shaped open ends of the third U-shaped conductor 701. This structure of the reverse-twist hairpin 7 can change the winding direction of the branch circuit coil, for example, twisting the clockwise direction into the counterclockwise direction.

[0100] Combined with Figures 7 to 10 it can be known that in the branch circuit coil, a lead hairpin 5 and a U-shaped hairpin 6 can be lap-welded and connected through the first welding segment 502 and the second welding segment 602; between two U-shaped hairpins 6, one second welding segment 602 of the first U-shaped hairpin 6 and one second welding segment 602 of the second U-shaped hairpin 6 can be lap-welded and connected; between the U-shaped hairpin 6 and the reverse-twist hairpin 7, they are lap-welded and connected through the second welding segment 602 and the third welding segment 702.

[0101] Next, combined with Figures 7 - 10 the structure below, the layout rule of a single branch circuit coil in the stator core 1 with 54 stator slots is introduced as follows:

[0102] Lead hairpin 5( Figure 10 The position A in it is the starting point of the first coil branch, and it crosses from the 5th layer to the 4th layer in the clockwise direction) → U-shaped hairpin 6 (crosses from the 3rd layer to the 2nd layer in the clockwise direction) → reverse-twist hairpin 7 (the end point of the first coil branch, located in the first layer, will twist the clockwise direction into the counterclockwise direction) → U-shaped hairpin 6 (the starting point of the second branch circuit coil, crosses from the 2nd layer to the 3rd layer in the counterclockwise direction) → U-shaped hairpin 6 (crosses from the 4th layer to the 5th layer in the counterclockwise direction) → reverse-twist hairpin 7 (the end point of the second coil branch, located in the 6th layer, will twist the counterclockwise direction into the clockwise direction) → U-shaped hairpin 6 (the starting point of the second coil branch, crosses from the 5th layer to the 4th layer in the clockwise direction) → U-shaped hairpin 6 (crosses from the 3rd layer to the 2nd layer in the clockwise direction) → reverse-twist hairpin 7 (the end point of the second coil branch, located in the first layer, will twist the clockwise direction into the counterclockwise direction) → set the second coil branch in the counterclockwise direction → set the second coil branch in the clockwise direction → set the second coil branch in the counterclockwise direction → complete.

[0103] It should be noted that there are 18 hairpins in the above single branch line coil, and the third welding section 702 of the last reverse twist hairpin 7 ( Figure 10 position B therein) corresponds to the lead-out section 503. In addition, the slot-crossing situation of the hairpins at the crown end ( Figure 1 lower end) is as follows: the first layer crosses 9 slots of the same-layer hairpins, the second and third layers cross 10 slots of hairpins, the fourth and fifth layers cross 10 slots of hairpins, the sixth layer crosses 8 slots of the same-layer hairpins, and the sixth layer crosses 11 slots of the same-layer hairpins; the same-layer hairpins are concentrated in position, and the same-layer wires in the inner layer and the same-layer wires in the outer layer are concentratedly arranged and evenly distributed in the circumferential direction.

[0104] As Figure 11 shown, it is the distribution diagram of the three-phase coil 2 in 54 stator slots. From the content in the figure, it can be known that the number of pole pairs of the three-phase coil 2 is 3 (there are a total of 6 gray areas in the figure, so the number of pole pairs is 3). For the stator slots corresponding to each phase and each pole, the distribution rule can be seen in Figures 12 - 14 .

[0105] As Figure 12 shown, for a single pole, all the three-phase coils 2 accommodated in the 24th stator slot are used to transmit the first-phase alternating current in the three-phase alternating current.

[0106] As Figure 13 shown, the 23rd and 25th stator slots are respectively located on both sides of the 24th stator slot. Among them, the three-phase coils 2 in the gray areas of the 23rd and 25th stator slots are used to transmit the first-phase alternating current, and the three-phase coils 2 in the remaining areas are used to transmit the other two-phase alternating currents. The number of hairpins transmitting the first-phase alternating current is 2 more than the number of those transmitting the other two-phase alternating currents.

[0107] As Figure 14 shown, the 22nd and 26th stator slots are located on the outermost side. Among them, the three-phase coils 2 in the gray areas of the 22nd and 26th stator slots are used to transmit the first-phase alternating current, and the three-phase coils 2 in the remaining areas are used to transmit the other two-phase alternating currents. The number of hairpins transmitting the first-phase alternating current is 2 less than the number of those transmitting the other two-phase alternating currents.

[0108] In the above scheme, by adopting a double-layer staggered form in the slot, there is only one flat wire surface contact between two phases, reducing the insulation contact surface between two phases and improving the insulation effect. For the 54-slot short pitch, it changes from occupying 4 slots before to occupying 5 slots, effectively weakening the harmonic winding coefficient, thereby improving the performance of the motor.

[0109] As Figure 15 shown, it is the developed view of a single-phase (U-phase, V-phase or W-phase) coil, where the numbers 1 - 54 represent 54 stator slots. In addition, three parallel branches are provided at both the three-phase lead-out end and the neutral end.

[0110] Although the present invention has been described in detail with reference to the foregoing embodiments, those of ordinary skill in the art should understand that: they can still modify the technical solutions described in the foregoing embodiments, or perform equivalent replacements on some of the technical features; and these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A winding structure based on a flat wire conductor, characterized in that: It comprises a stator core (1) and a three-phase coil (2); The inner surface of the stator core (1) is provided with a plurality of stator slots; The three-phase coil (2) is installed in the stator slot, and the three-phase coil (2) is divided into n layers from the slot bottom to the slot opening of the stator slot, where n>1; The three-phase lead-out ends of the three-phase coil (2) are located at the i-th layer, n≥i≥1; The neutral end of the three-phase coil (2) is located at any adjacent layer of the three-phase lead-out end; The three-phase lead-out terminal and the neutral terminal are located at the same end of the three-phase coil (2); The three-phase lead-out end is connected to a lead-out component (3), and the neutral end is connected to a neutral bar (4).

2. A winding structure based on a flat wire conductor according to claim 1, characterized in that: The three-phase coil (2) comprises a U-phase coil, a V-phase coil and a W-phase coil which are symmetrically distributed at 120°; The U-phase coil, the V-phase coil and the W-phase coil are each provided with a plurality of branch coils connected in parallel; The starting point of each branch coil is connected to the lead-out component (3) as a three-phase lead-out terminal, and the end point is connected to the neutral bar (4) as a neutral terminal.

3. A winding structure based on a flat wire conductor according to claim 2, characterized in that: The branch coil comprises a lead-out hairpin (5), a U-shaped hairpin (6) and a reverse twist hairpin (7); Along the current flow direction, the hairpin (5) is used as the starting point of the branch coil and connected to the U-shaped hairpin (6) and the reverse twisted hairpin (7) in turn across the layers until it crosses the layers to the first layer or the nth layer, thereby forming the first branch coil; In the first branch coil, if the lead-out hairpin (5) is located at the second layer, the reverse twist hairpin (7) is located at the nth layer; if the lead-out hairpin (5) is located at the n-1th layer, the reverse twist hairpin (7) is located at the first layer; Along the current direction, the first U-shaped hairpin (6) sequentially crosses layers to connect to the next U-shaped hairpin (6) and the next reverse twisted hairpin (7), until it crosses layers to connect to the first layer or the nth layer, thereby forming a second branch coil; In the second branch coil, if the first U-shaped hairpin (6) is located at the second layer, the reverse twisted hairpin (7) is located at the nth layer; if the first U-shaped hairpin (6) is located at the n-1th layer, the reverse twisted hairpin (7) is located at the first layer; In the branch coils, the first branch coil is sequentially connected to a plurality of second branch coils until the last reverse-twisted hairpin (7) is located at an adjacent layer to the lead-out hairpin (5).

4. A winding structure based on a flat wire conductor according to claim 3, characterized in that: The lead-out card (5) comprises a first U-shaped conductor (501), a first welding section (502) and a lead-out section (503); The first U-shaped conductor (501) is U-shaped; The first welding section (502) is connected to one end of the first U-shaped conductor (501); The lead-out section (503) is connected to the other end of the first U-shaped conductor (501), and the lead-out section (503) is used to be connected to the lead-out component (3); The first welding section (502) and the lead-out section (503) are arranged opposite to each other at the U-shaped opening of the first U-shaped conductor (501).

5. A winding structure based on a flat wire conductor according to claim 4, characterized in that: The U-shaped hairpin (6) comprises a second U-shaped conductor (601) and second welding sections (602) which are symmetrical and face opposite to each other; The second U-shaped conductor (601) is U-shaped; The symmetrical second welding sections (602) facing opposite directions are respectively connected to the two U-shaped openings of the second U-shaped conductor (601).

6. A winding structure based on a flat wire conductor according to claim 5, characterized in that: The reverse twist hairpin (7) comprises a third U-shaped conductor (701) and a third welding section (702) facing the same direction; The third U-shaped conductor (701) is U-shaped; The third welding sections (702) facing in the same direction are respectively connected to the two U-shaped openings of the third U-shaped conductor (701).

7. A winding structure based on a flat wire conductor according to claim 4, characterized in that: In the branch coil: A lead-out hairpin (5) and a U-shaped hairpin (6) are lap-welded to each other via a first welding section (502) and a second welding section (602); The two U-shaped hairpins (6) are overlap-welded by a second welding section (602) of the first U-shaped hairpin (6) and a second welding section (602) of the second U-shaped hairpin (6); The U-shaped hairpin (6) and the reverse-twisted hairpin (7) are overlap-welded via the second welding section (602) and the third welding section (702).

8. A winding structure based on a flat wire conductor according to claim 1, characterized in that: The lead-out component (3) comprises: A connecting shell (307) is arc-shaped; A first lead wire (301) connected to a first lead row (302); The first lead row (302) is provided with a plurality of welding pins connected to the three-phase lead terminals; A second lead wire (303) connected to a second lead row (304); The second lead row (304) is provided with a plurality of welding pins connected to the three-phase lead terminals; A third lead wire (305) connected to a third lead row (306); The third lead row (306) is provided with a plurality of welding pins connected to the three-phase lead terminals; The first lead-out row (302), the second lead-out row (304) and the third lead-out row (306) are insulated from each other and are all installed in a connection housing (307).

9. A winding structure based on a flat wire conductor according to claim 8, characterized in that: The first lead-out row (302) comprises a first lead-out copper row (3021), a first lap row (3022) and a plurality of first welding legs (3023) which are integrally connected; the first lap row (3022) is used to connect the first lead wire (301), and the first welding legs (3023) are used to connect the three-phase lead-out terminals; The first lead-out copper bar (3021) is embedded in the connection housing (307); The first lap row (3022) is bent relative to the first lead-out copper row (3021) and is located on a side of the first lead-out copper row (3021); The first solder leg (3023) is bent relative to the first lead-out copper bar (3021) and is located on the other side of the first lead-out copper bar (3021).

10. A winding structure based on a flat wire conductor according to claim 8, characterized in that: The second lead-out row (304) includes a second lap row (3041) and a plurality of second welding legs (3042) connected in one piece; The second overlapping row (3041) is bent relative to the second welding leg (3042), and the connection position between the second overlapping row (3041) and the second welding leg (3042) is embedded in the connection shell (307); The second connecting row (3041) is used to connect the second lead wire (303), and the second welding leg (3042) is used to connect the three-phase lead terminal.

11. A winding structure based on a flat wire conductor according to claim 8, characterized in that: The third lead-out bar (306) comprises a second lead-out copper bar (3061), a third lap bar (3062) and a plurality of third solder legs (3063) which are integrally connected; the third lap bar (3062) is used to connect the third lead wire (305), and the third solder legs (3063) are used to connect the three-phase lead-out terminals; The second lead-out copper busbar (3061) is embedded in the connection housing (307); The third lap row (3062) is bent relative to the second lead-out copper row (3061) and is located on a side of the second lead-out copper row (3061); The third solder leg (3063) is bent relative to the second lead-out copper bar (3061) and is located on the other side of the second lead-out copper bar (3061).

12. A winding structure based on a flat wire conductor according to any one of claims 8 to 11, characterized in that: The arc-shaped surface of the connecting shell (307) is also provided with a plurality of locking blocks (3071); The surface of the locking block (3071) facing the connection shell (307) abuts against the surface of the neutral row (4) away from the connection shell (307), and is used to limit the radial movement of the neutral row (4) along the stator core (1).

13. A winding structure based on a flat wire conductor according to claim 12, characterized in that: The neutral row (4) is arc-shaped, and a plurality of welding feet connected to the neutral ends (4) are arranged on the neutral row (4).

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