Coil structure, flat wire stator assembly and winding method

Abstract

The invention relates to the technical field of generators, in particular to a coil structure which comprises a first three-phase total winding and a second three-phase total winding. Each of the first three-phase total winding and the second three-phase total winding comprises a first three-phase branch and a second three-phase branch; the first three-phase branch and the second three-phase branch are connected in parallel; compared with a traditional flat wire double-branch scheme, a scheme of four three-phase branches is adopted at the same time, the stator single-branch current is smaller, meanwhile, the number of the branches is increased, the skin effect of a stator set is weakened, loss is reduced, and the maximum output and efficiency value of the stator are effectively improved for an automobile alternating current generator applied to an alternating magnetic field; meanwhile, the flat wire stator adopts a six-phase winding scheme, four three-phase branches are connected in parallel to form double branches by using a parallel connection scheme among the four three-phase branches, and the single-phase resistance of the branches after parallel connection is lower by using the characteristics of parallel resistors, so that the stator impedance is greatly reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of generators. Specifically, the present invention relates to a coil structure, a flat wire stator assembly, and a winding method. Background Art

[0002] As the main power supply component of an automobile, the stator assembly of an alternator is an element that generates induced electromotive force and outputs externally; to improve the output power density of the stator, traditional generators currently mostly adopt a flat wire stator solution with the development of the industry, making the stator slot fill factor and output power density higher through the arrangement of the flat wire stator structure; at the same time, since the stator is the main heat-generating component, to reduce the stator temperature rise and improve the reliability of the motor, but due to the output characteristics of the alternator, when the motor speed reaches the rated speed, its output power will no longer increase with the speed due to the influence of impedance; the current generator has a high impedance, large stator power loss, and low stator output efficiency.

[0003] The applicant found through retrieval that the Chinese patent document with the publication number 117375340A discloses a winding mold for a stator coil, a stator coil, and a coil winding method on January 9, 2024. The winding mold includes a bottom plate and a side plate, both of which are made of insulating materials, avoiding the situation where the winding mold is prone to magnetic saturation under certain high magnetic field conditions and ensuring the normal operation of the linear motor; the stator coil includes a winding mold, a coil wound around the outside of the winding mold, and a tie strap passing through a binding hole for fixing the coil. The coil passes through a threading hole, making the surface of the stator coil smoother and the coil intact without insulation damage; the coil winding method includes the winding of the A-phase winding, the winding of the B-phase winding, the winding of the C-phase winding, and the formation of an insulating layer; this device also cannot solve the above technical problems.

[0004] Therefore, in order to improve or solve at least one of the above problems, it is necessary to provide a coil structure that can improve the stator output efficiency. Summary of the Invention

[0005] The purpose of the present invention is to provide a coil structure that can improve the stator output efficiency.

[0006] To solve the above technical problems, the technical solution adopted by the present invention is: a coil structure, including a first three-phase main winding and a second three-phase main winding; both the first three-phase main winding and the second three-phase main winding include a first three-phase branch and a second three-phase branch; the first three-phase branch and the second three-phase branch are connected in parallel.

[0007] The first three-phase branch includes three single-phase branches, namely: U1 branch, V1 branch, and W1 branch; the U1 branch, V1 branch, and W1 branch in the first three-phase branch are Y-connected; the second three-phase branch includes three single-phase branches, namely: U2 branch, V2 branch, and W2 branch; the U2 branch, V2 branch, and W2 branch in the second three-phase branch are Y-connected.

[0008] The U1 branch includes a U1 lead wire and a U1 neutral wire; the V1 branch includes a V1 lead wire and a V1 neutral wire; the W1 branch includes a W1 lead wire and a W1 neutral wire; the U2 branch includes a U2 lead wire and a U2 neutral wire; the V2 branch includes a V2 lead wire and a V2 neutral wire; the W2 branch includes a W2 lead wire and a W2 neutral wire; the U1 lead wire is connected to the U2 lead wire; the V1 lead wire is connected to the V2 lead wire; the W1 lead wire is connected to the W2 lead wire; the U1 neutral wire is respectively connected to the V1 neutral wire and the W1 neutral wire; the U2 neutral wire is respectively connected to the V2 neutral wire and the W2 neutral wire.

[0009] A flat wire stator assembly includes a stator structure and the coil structure; the first three-phase total winding and the second three-phase total winding in the coil structure are both arranged on the stator structure.

[0010] The stator structure includes stator slots; there are 2N layers of slot positions in the stator slots, where N is 1, 2, 3,...; the first three-phase branch is arranged in the (2N - 1)-th layer of slot positions; the second three-phase branch is arranged in the 2N-th layer of slot positions;

[0011] The stator structure includes a stator core; a central hole is provided on the stator core; the central hole is coaxially arranged with the stator core; the U1 lead wire, V1 lead wire, W1 lead wire, U2 lead wire, V2 lead wire, and W2 lead wire are arranged in the slot positions on one side of the stator slots close to or far from the central hole.

[0012] The U1 neutral wire, V1 neutral wire, W1 neutral wire, U2 neutral wire, V2 neutral wire, and W2 neutral wire are arranged in the slot positions on one side of the stator slots close to or far from the central hole; the U1 neutral wire and the U2 neutral wire are arranged in the same stator slot; the V1 neutral wire and the V2 neutral wire are arranged in the same stator slot; the W1 neutral wire and the W2 neutral wire are arranged in the same stator slot.

[0013] The number of stator slots spanned between the W1 neutral wire and the U1 neutral wire is the same as the number of stator slots spanned between the W1 neutral wire and the V1 neutral wire; the number of stator slots spanned between the W2 neutral wire and the U2 neutral wire is the same as the number of stator slots spanned between the W2 neutral wire and the V2 neutral wire.

[0014] Each single-phase branch in the first three-phase branch and / or the second three-phase branch includes a wave-wound coil; the wave-wound coil is connected with a trans-layer wire; each trans-layer wire includes a first pin and a second pin; the lead wire in the single-phase branch where each trans-layer wire is located and the first pin in this trans-layer wire are in the same stator slot; the neutral wire in the single-phase branch where each trans-layer wire is located and the second pin in this trans-layer wire are in the same stator slot;

[0015] Each wave-wound coil includes a U-pin wire; the lead wire and the neutral wire of each single-phase branch are both I-Pin wires.

[0016] A winding method for the flat wire stator assembly includes the following steps:

[0017] S1: Wind the first three-phase total winding and the second three-phase total winding on the stator structure;

[0018] S2: Connect the first three-phase branch and the second three-phase branch in a Y shape respectively; connect the first three-phase branch and the second three-phase branch in parallel.

[0019] In the said S1, the first three-phase total winding is arranged in the (2L - 1)th stator slot of the stator structure, where L is 1, 2, 3, …… 48; the second three-phase total winding is arranged in the 2Lth stator slot of the stator structure, where L is 1, 2, 3, …… 48;

[0020] Arrange the first three-phase branch in the (2N - 1)th layer of slots in the stator slot, where N is 1, 2, 3, ……; arrange the second three-phase branch in the 2Nth layer of slots; arrange the U1 lead wire, V1 lead wire, W1 lead wire, U2 lead wire, V2 lead wire and W2 lead wire in the slots on one side of the stator slot close to or far from the central hole;

[0021] Arrange the U1 neutral wire, V1 neutral wire, W1 neutral wire, U2 neutral wire, V2 neutral wire and W2 neutral wire in the slots on one side of the stator slot close to or far from the central hole; the U1 neutral wire and the U2 neutral wire are arranged in the same stator slot; the V1 neutral wire and the V2 neutral wire are arranged in the same stator slot; the W1 neutral wire and the W2 neutral wire are arranged in the same stator slot.

[0022] In the said S1, arrange the first pin of the trans-layer wire and the lead wire of the single-phase branch where this trans-layer wire is located in the same stator slot; arrange the second pin of the trans-layer wire and the neutral wire of the single-phase branch where this trans-layer wire is located in the same stator slot.

[0023] In S2, the number of stator slots spanned between the neutral line of W1 and the neutral line of U1 is the same as that between the neutral line of W1 and the neutral line of V1, both being 7; the number of stator slots spanned between the neutral line of W2 and the neutral line of U2 is the same as that between the neutral line of W2 and the neutral line of V2, both being 7.

[0024] The beneficial effects of the present invention are as follows:

[0025] This application uses a flat wire stator to increase the power density of the motor. At the same time, by adopting a four-three-phase branch scheme, compared with the traditional flat wire double-branch scheme, the single-branch current of the stator is smaller. At the same time, the increase in the number of branches weakens the skin effect of the stator for an automotive alternator applying an alternating magnetic field, reduces the loss, and effectively improves the maximum output and efficiency value of the stator. At the same time, the flat wire stator of this application adopts a six-phase winding scheme. At the same time, by using a parallel connection scheme between four three-phase branches, the four branches are paralleled into two branches. Utilizing the characteristics of parallel resistors, the single-phase resistance of the branches after parallel connection is lower, and the stator impedance is greatly reduced. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The following further details the specific embodiments of the present invention with reference to the drawings, where:

[0027] Figure 1 is a schematic structural diagram of the first three-phase total winding of the present invention.

[0028] Figure 2 is a schematic structural diagram of the second three-phase total winding of the present invention.

[0029] Figure 3 is a schematic structural diagram of the coil structure of the present invention.

[0030] Figure 4 is Figure 2 a partial enlarged view of point A of

[0031] Figure 5 is a schematic structural diagram of the stator structure of the present invention.

[0032] Figure 6 is Figure 4 a partial enlarged view of point B of

[0033] Figure 7 is a schematic structural diagram of the single-phase branch of the present invention.

[0034] Figure 8 is a schematic structural diagram of the slot of the present invention.

[0035] Figure 9 is an expanded schematic diagram of the connection principle of the first three-phase branch and the second three-phase branch in the stator structure of the present invention.

[0036] Figure 10 Schematic diagram showing the connection principle of the single-phase branch in the parallel branches of the present invention.

[0037] Figure 11 Schematic diagram showing the connection principle of the single-phase branch in the first three-phase branch of the present invention.

[0038] Figure 12 Schematic diagram showing the connection principle of the single-phase branch in the second three-phase branch of the present invention.

[0039] Figure 13 Schematic diagram showing the connection principle of the cross-layer line of the present invention.

[0040] Figure 14 Performance schematic diagram of the present invention.

[0041] The markings in the above figures are all:

[0042] The markings in the figure are:

[0043] 1. First three-phase main winding, 101. Second three-phase main winding,

[0044] 2. First three-phase branch,

[0045] 3. Second three-phase branch,

[0046] 4. U1 branch, 401. V1 branch, 402. W1 branch, 403. U1 lead wire, 404. V1 lead wire, 405. W1 lead wire,

[0047] 5. U2 branch, 501. V2 branch, 502. W2 branch, 503. U2 lead wire, 504. V2 lead wire, 505. W2 lead wire,

[0048] 6. U1 neutral line, 601. V1 neutral line, 602. W1 neutral line,

[0049] 7. U2 neutral line, 701. V2 neutral line, 702. W2 neutral line,

[0050] 8. Stator structure, 801. Stator slot, 802. Insert slot, 803. Central hole,

[0051] 9. Wave-wound coil, 901. Cross-layer line, 902. U-pin wire, 903. I-Pin wire, 904. Pin, 905. First pin, 906. Second pin. Detailed implementation manner

[0052] The following further describes in detail the specific embodiments of the present invention with reference to the accompanying drawings through the description of the embodiments, aiming to help those skilled in the art have a more complete, accurate and in-depth understanding of the inventive concept and technical solution of the present invention and facilitate its implementation.

[0053] As Figure 1 and Figure 2 shown in the coil structure, it includes a first three-phase main winding 1 and a second three-phase main winding 101; both the first three-phase main winding 1 and the second three-phase main winding 101 include a first three-phase branch 2 and a second three-phase branch 3; the first three-phase branch 2 and the second three-phase branch 3 are connected in parallel.

[0054] Both the first three-phase main winding 1 and the second three-phase main winding 101 include a first three-phase branch 2 and a second three-phase branch 3; the first three-phase branch 2 and the second three-phase branch 3 are connected in parallel; the present invention simultaneously adopts a four three-phase branch solution, compared with the traditional flat wire double branch solution, making the stator single branch current smaller. At the same time, the increase in the number of branches weakens the skin effect of the stator for an automotive alternator applying an alternating magnetic field, reduces the loss, and effectively improves the maximum output and efficiency value of the stator; at the same time, the flat wire stator of the present invention adopts a six-phase winding solution, and simultaneously by using a parallel connection solution between four three-phase branches, the four branches are paralleled into a double branch, taking advantage of the characteristics of parallel resistors to make the single-phase resistance of the parallel branches lower, greatly reducing the stator impedance.

[0055] As Figure 3 and Figure 4 shown, the first three-phase branch 2 includes three single-phase branches, and the three single-phase branches are respectively: U1 branch 4, V1 branch 401, and W1 branch 402; in the first three-phase branch 2, the U1 branch 4, V1 branch 401, and W1 branch 402 are Y-connected; the second three-phase branch 3 includes three single-phase branches, and the three single-phase branches are respectively: U2 branch 5, V2 branch 501, and W2 branch 502; in the second three-phase branch 3, the U2 branch 5, V2 branch 501, and W2 branch 502 are Y-connected.

[0056] The Y-connection, also known as the star connection, is a connection method for three-phase circuits; it connects the ends of the three-phase windings to form a neutral point, and the beginnings are led out as phase lines; the U1 branch 4, the V1 branch 401, and the W1 branch 402 are all single-phase branches of the first three-phase branch 2; the U1 branch 4, the V1 branch 401, and the W1 branch 402 are all provided with a neutral line, and the three neutral lines are all formed by bending and welding the I-Pin line 903; the U2 branch 5, the V2 branch 501, and the W2 branch 502 are all single-phase branches of the second three-phase branch 3, the U2 branch 5, the V2 branch 501, and the W2 branch 502 are all provided with a neutral line, and the three neutral lines are all formed by bending and welding the I-Pin line 903; the present invention includes four three-phase branches, there are 4 neutral point welding points, the busbar design is cancelled, and on the basis of the existing similar patent structure of the same specification, the number of neutral points is reduced from 6 to 4, reducing one-third compared with the existing scheme, making the stator production process simpler and the cost lower.

[0057] The U1 branch 4 includes a U1 lead-out wire 403 and a U1 neutral line 6; the V1 branch 401 includes a V1 lead-out wire 404 and a V1 neutral line 601; the W1 branch 402 includes a W1 lead-out wire 405 and a W1 neutral line 602; the U2 branch 5 includes a U2 lead-out wire 503 and a U2 neutral line 7; the V2 branch 501 includes a V2 lead-out wire 504 and a V2 neutral line 701; the W2 branch 502 includes a W2 lead-out wire 505 and a W2 neutral line 702; the U1 lead-out wire 403 is connected to the U2 lead-out wire 503; the V1 lead-out wire 404 is connected to the V2 lead-out wire 504; the W1 lead-out wire 405 is connected to the W2 lead-out wire 505; the U1 neutral line 6 is respectively connected to the V1 neutral line 601 and the W1 neutral line 602; the U2 neutral line 7 is respectively connected to the V2 neutral line 701 and the W2 neutral line 702.

[0058] The U1 neutral line 6 is respectively connected to the V1 neutral line 601 and the W1 neutral line 602, so as to realize the Y-connection of the first three-phase branch 2; the U2 neutral line 7 is respectively connected to the V2 neutral line 701 and the W2 neutral line 702, so as to realize the Y-connection of the second three-phase branch 3; the U1 lead-out wire 403 and the U2 lead-out wire 503 are both I-Pin lines 903, and the two are bent and welded to realize the parallel connection of the U1 branch 4 and the U2 branch 5; the V1 lead-out wire 404 and the V2 lead-out wire 504 are both I-Pin lines 903, and the two are bent and welded to realize the parallel connection of the V1 branch 401 and the V2 branch 501; the W1 lead-out wire 405 and the W2 lead-out wire 505 are both I-Pin lines 903, and the two are bent and welded to realize the parallel connection of the W1 branch 402 and the W2 branch 502.

[0059] Such as Figure 5As shown, a flat wire stator assembly includes a stator structure 8 and a coil structure; the first three-phase total winding 1 and the second three-phase total winding 101 in the coil structure are both arranged on the stator structure 8.

[0060] The stator structure 8 can be a 96-slot or 72-slot or 48-slot stator; the first three-phase total winding 1 and the second three-phase total winding 101 are both wound on the stator structure 8; thus, there are six phases and four three-phase branches on the stator structure 8. Compared with the traditional six-phase two-branch scheme, by using four groups of independent three-phase branch circuits, the current in a single branch is significantly reduced compared with the existing scheme, thereby reducing the influence of the stator skin effect, reducing the stator power loss, and improving the stator output efficiency.

[0061] As Figure 8 shown, the stator structure 8 includes stator slots 801; there are 2N layers of insertion slots 802 in the stator slots 801, where N is 1, 2, 3,...; the first three-phase branch 2 is arranged in the (2N - 1)th layer of insertion slots 802; the second three-phase branch 3 is arranged in the 2Nth layer of insertion slots 802;

[0062] The stator structure 8 includes a stator core; a central hole 803 is provided on the stator core; the central hole 803 is coaxially arranged with the stator core; the U1 lead wire 403, V1 lead wire 404, W1 lead wire 405, U2 lead wire 503, V2 lead wire 504, and W2 lead wire 505 are arranged in the insertion slots 802 on one side of the stator slot 801 close to or far from the central hole 803.

[0063] There are 96 or 72 or 48 stator slots 801 on the stator structure 8; the stator structure 8 includes a central hole 803; the stator slots 801 are arranged along the circumference of the central hole 803; the stator slots 801 are semi-closed through slots; there are multiple layers of insertion slots 802 in the stator slots 801, and the insertion slots 802 are arranged along the radial direction of the stator structure 8; the first three-phase branch 2 and the second three-phase branch 3 are respectively arranged in the odd-layer insertion slots 802 and the even-layer insertion slots 802 of the same stator slot 801, and the two adopt an interval winding connection method to make the winding lengths of the single-phase branches equal, so as to ensure that the lead lengths of any phase branch are the same and make the winding phase distribution more uniform;

[0064] The U1 lead wire 403, V1 lead wire 404, W1 lead wire 405, U2 lead wire 503, V2 lead wire 504, and W2 lead wire 505 are all arranged in the innermost or outermost layer of insertion slots 802 of the stator slot 801;

[0065] In this embodiment, the stator slot 801 includes six layers of slots 802; the U1 branch 4 and the U2 branch 5 are arranged in the same stator slot 801. The U1 branch 4 is arranged in the 1st, 3rd, and 5th layers of slots 802, and the U2 branch 5 is arranged in the 2nd, 4th, and 6th layers of slots 802, or the U1 branch 4 is arranged in the 2nd, 4th, and 6th layers of slots 802, and the U2 branch 5 is arranged in the 1st, 3rd, and 5th layers of slots 802; the V1 branch 401 and the V2 branch 501 are arranged in the same stator slot 801. The V1 branch 401 is arranged in the 1st, 3rd, and 5th layers of slots 802, and the V2 branch 501 is arranged in the 2nd, 4th, and 6th layers of slots 802, or the V1 branch 401 is arranged in the 2nd, 4th, and 6th layers of slots 802, and the V2 branch 501 is arranged in the 1st, 3rd, and 5th layers of slots 802; the W1 branch 402 and the W2 branch 502 are arranged in the same stator slot 801. The W1 branch 402 is arranged in the 1st, 3rd, and 5th layers of slots 802, and the W2 branch 502 is arranged in the 2nd, 4th, and 6th layers of slots 802, or the W1 branch 402 is arranged in the 2nd, 4th, and 6th layers of slots 802, and the W2 branch 502 is arranged in the 1st, 3rd, and 5th layers of slots 802; the U1 lead 403, the V1 lead 404, the W1 lead 405, the U2 lead 503, the V2 lead 504, and the W2 lead 505 are all arranged in different stator slots 801 and are arranged in the 1st layer or the 6th layer of the stator slot 801.

[0066] The U1 neutral line 6, the V1 neutral line 601, the W1 neutral line 602, the U2 neutral line 7, the V2 neutral line 701, and the W2 neutral line 702 are arranged in the slots 802 on one side of the stator slot 801 close to or far from the center hole 803; the U1 neutral line 6 and the U2 neutral line 7 are arranged in the same stator slot 801; the V1 neutral line 601 and the V2 neutral line 701 are arranged in the same stator slot 801; the W1 neutral line 602 and the W2 neutral line 702 are arranged in the same stator slot 801.

[0067] The U1 neutral line 6 and the U2 neutral line 7 are arranged in the same stator slot 801, and they are respectively arranged in the innermost layer and the outermost layer of the stator slot 801; the V1 neutral line 601 and the V2 neutral line 701 are arranged in the same stator slot 801, and they are respectively arranged in the innermost layer and the outermost layer of the stator slot 801; the W1 neutral line 602 and the W2 neutral line 702 are arranged in the same stator slot 801, and they are respectively arranged in the innermost layer and the outermost layer of the stator slot 801; thus, the positions and spans of the neutral lines are the same; the three-phase relative positions of any neutral point are basically the same, making the process feasibility of neutral line welding stronger and the degree of process standardization higher.

[0068] In this embodiment, the neutral line 6 of U1 is arranged in the slot 802 of the first layer or the sixth layer, and the neutral line 7 of U2 is arranged in the slot 802 of the sixth layer or the first layer in the same stator slot 801; the neutral line 601 of V1 is arranged in the slot 802 of the first layer or the sixth layer, and the neutral line 701 of V2 is arranged in the slot 802 of the sixth layer or the first layer in the same stator slot 801; the neutral line 602 of W1 is arranged in the slot 802 of the first layer or the sixth layer, and the neutral line 702 of W2 is arranged in the slot 802 of the sixth layer or the first layer in the same stator slot 801.

[0069] The number of stator slots 801 spanned between the neutral line 602 of W1 and the neutral line 6 of U1 is the same as the number of stator slots 801 spanned between the neutral line 602 of W1 and the neutral line 601 of V1; the number of stator slots 801 spanned between the neutral line 702 of W2 and the neutral line 7 of U2 is the same as the number of stator slots 801 spanned between the neutral line 702 of W2 and the neutral line 701 of V2.

[0070] The slot pitch spanned between the neutral line 602 of W1 and the neutral line 6 of U1 is equal to the slot pitch spanned between the neutral line 602 of W1 and the neutral line 601 of V1; the slot pitch spanned between the neutral line 702 of W2 and the neutral line 7 of U2 is equal to the slot pitch spanned between the neutral line 702 of W2 and the neutral line 701 of V2; this can make the phase resistance more balanced and reduce the abnormal heating problem caused by the phase balance problem.

[0071] In this embodiment, the neutral line 602 of W1 and the neutral line 702 of W2 are arranged in the same stator slot 801, and both are arranged in the ninth stator slot 801; the neutral line 6 of U1 and the neutral line 7 of U2 are arranged in the same stator slot 801, and both are arranged in the first stator slot 801; the neutral line 601 of V1 and the neutral line 701 of V2 are both arranged in the same stator slot 801, and they are respectively arranged in the seventeenth stator slot 801.

[0072] As Figure 6 and Figure 7 shown, each single-phase branch in the first three-phase branch 2 and / or the second three-phase branch 3 includes a wave-wound coil 9; the wave-wound coil 9 is connected with a cross-layer wire 901; each cross-layer wire 901 includes a first pin 905 and a second pin 906; the lead wire in the single-phase branch where each cross-layer wire 901 is located is in the same stator slot 801 as the first pin 905 in this cross-layer wire 901; the neutral line in the single-phase branch where each cross-layer wire 901 is located is in the same stator slot 801 as the second pin 906 in this cross-layer wire 901.

[0073] Each wave-wound coil 9 includes a U-pin wire 902; the lead wire and the neutral line of each single-phase branch are both I-Pin wires 903.

[0074] The U-pin wire 902 is a hairpin wire; the wave-wound coil 9 includes a plurality of U-pin wires 902, and the cross-layer wire 901 is also a U-pin wire 902. The cross-layer wire 901 of the single-phase branch is connected between two adjacent wave-wound coils 9 of the single-phase branch to achieve cross-layer connection of the wave-wound coils 9; the U-pin wire 902 includes two pins 904, and the pins 904 are respectively inserted into different stator slots 801; the cross-layer wire 901 includes a first pin 905 and a second pin 906; the first pins 905 of the cross-layer wire 901 and the lead wires of each single-phase branch of the U1 branch 4, V1 branch 401, W1 branch 402, U2 branch 5, V2 branch 501 and W2 branch 502 are arranged in the same stator slot 801, and the second pins 906 of the cross-layer wire 901 and the neutral wires of each single-phase branch of the U1 branch 4, V1 branch 401, W1 branch 402, U2 branch 5, V2 branch 501 and W2 branch 502 are arranged in the same stator slot 801; so that the lead wire I-pin and the cross-layer wire U-pin are located in the same slot and have the same span, and the lead wire I-pin does not need to be bent into a U shape, leaving space for the layout of the cross-layer wire, so that the cross-layer wire and other U-pin wires can be at the same height;

[0075] In this embodiment, the U1 branch 4, V1 branch 401, W1 branch 402, U2 branch 5, V2 branch 501 and W2 branch 502 each include three wave-wound coils 9 and 2 cross-layer wires 901; the wave-wound coil 9 includes 16 consecutive U-pin wires 902 connected at a specified slot pitch; the first pin 905 of the first cross-layer wire 901 is arranged in the second-layer slot 802 of the stator slot 801 where the neutral wire of each single-phase branch of the U1 branch 4, V1 branch 401, W1 branch 402, U2 branch 5, V2 branch 501 and W2 branch 502 is located, and the second pin 906 of the first cross-layer wire 901 is arranged in the third-layer slot 802 of the stator slot 801 where the lead wire of each single-phase branch is located; the first pin 905 of the second cross-layer wire 901 is arranged in the fourth-layer slot 802 of the stator slot 801 where the neutral wire of each single-phase branch is located, and the second pin 906 of the second cross-layer wire 901 is arranged in the fifth-layer slot 802 of the stator slot 801 where the lead wire of each single-phase branch is located.

[0076] A winding method for a flat wire stator assembly includes the following steps:

[0077] S1: Wind the first three-phase total winding 1 and the second three-phase total winding 101 on the stator structure 8;

[0078] S2: Connect the first three-phase branch 2 and the second three-phase branch 3 in a Y shape respectively; connect the first three-phase branch 2 and the second three-phase branch 3 in parallel.

[0079] In S1, both the first three-phase main winding 1 and the second three-phase main winding 101 are wound around the stator structure 8; in S2, the first three-phase branch 2 and the second three-phase branch 3 are Y-connected and the single-phase branches are connected in parallel.

[0080] As Figures 9 - 13 shown, in S1, the first three-phase main winding 1 is arranged in the (2L - 1)-th stator slot 801 of the stator structure 8, where L = 1, 2, 3, …… 48; the second three-phase main winding 101 is arranged in the 2L-th stator slot 801 of the stator structure 8, where L = 1, 2, 3, …… 48;

[0081] The first three-phase branch 2 is arranged in the (2N - 1)-th layer of the slot 802 in the stator slot 801, where N = 1, 2, 3, ……; the second three-phase branch 3 is arranged in the 2N-th layer of the slot 802; the U1 lead wire 403, V1 lead wire 404, W1 lead wire 405, U2 lead wire 503, V2 lead wire 504 and W2 lead wire 505 are arranged in the slot 802 on one side of the stator slot 801 close to or far from the central hole 803;

[0082] The U1 neutral wire 6, V1 neutral wire 601, W1 neutral wire 602, U2 neutral wire 7, V2 neutral wire 701 and W2 neutral wire 702 are arranged in the slot 802 on one side of the stator slot 801 close to or far from the central hole 803; the U1 neutral wire 6 and U2 neutral wire 7 are arranged in the same stator slot 801; the V1 neutral wire 601 and V2 neutral wire 701 are arranged in the same stator slot 801; the W1 neutral wire 602 and W2 neutral wire 702 are arranged in the same stator slot 801.

[0083] In this embodiment, the first three-phase main winding 1 and the second three-phase main winding 101 are independent three-phase main windings; wound around the same stator structure 8, the first three-phase main winding 1 occupies the odd slots and the second three-phase main winding 101 occupies the even slots;

[0084] The U1 branch 4 and U2 branch 5 of the first three-phase main winding 1 are arranged in the same stator slot 801, and are arranged in the (6X - 5)-th stator slot 801 of the stator structure 8, where X = 1, 2, 3, …… 16; the V1 branch 401 and V2 branch 501 are arranged in the same stator slot 801, and are arranged in the (6X - 3)-th stator slot 801 of the stator structure 8, where X = 1, 2, 3, …… 16; the W1 branch 402 and W2 branch 502 are arranged in the same stator slot 801, and are arranged in the (6X - 1)-th stator slot 801 of the stator structure 8, where X = 1, 2, 3, …… 16; after winding, by connecting the first three-phase branch 2 and the second three-phase branch 3 in parallel, the winding of the first three-phase main winding 1 is realized;

[0085] The U1 branch 4 and the U2 branch 5 of the second three-phase main winding 101 are arranged in the same stator slot 801 and in the 6X - 4 stator slot 801 of the stator structure 8, where X is 1, 2, 3, …… 16; the V1 branch 401 and the V2 branch 501 are arranged in the same stator slot 801 and in the 6X - 2 stator slot 801 of the stator structure 8, where X is 1, 2, 3, …… 16; the W1 branch 402 and the W2 branch 502 are arranged in the same stator slot 801 and in the 6X stator slot 801 of the stator structure 8, where X is 1, 2, 3, …… 16; after winding is completed, the second three-phase main winding 101 is wound by paralleling the first three-phase branch 2 and the second three-phase branch 3.

[0086] In S1, the first pin 905 of the cross-layer wire 901 and the lead wire of the single-phase branch where the cross-layer wire 901 is located are arranged in the same stator slot 801; the second pin 906 of the cross-layer wire 901 and the neutral wire of the single-phase branch where the cross-layer wire 901 is located are arranged in the same stator slot 801.

[0087] The lead wires and neutral wires of the single-phase branches of the first three-phase branch 2 and the second three-phase branch 3 share the I-Pin wire 903. The first three-phase branch 2 and the second three-phase branch 3 adopt the full-pitch U-pin wire 902. The cross-layer wire 901 and the lead wire are located in the same slot, further reducing the types of cross-layer wires 901 and lead wires. The U-pin wire type of the general wire adopts an equal span scheme, and the wire type is simple; thus, the overall number of wire types in the scheme is small, there are no irregular wires, the process is simple, and the production cost is lower.

[0088] In S2, the number of stator slots 801 spanned between the W1 neutral wire 602 and the U1 neutral wire 6 is the same as the number of stator slots 801 spanned between the W1 neutral wire 602 and the V1 neutral wire 601, both being 7; the number of stator slots 801 spanned between the W2 neutral wire 702 and the U2 neutral wire 7 is the same as the number of stator slots 801 spanned between the W2 neutral wire 702 and the V2 neutral wire 701, both being 7.

[0089] As Figure 14 shown, the present invention can ensure that the stator phase balance is less than 1%. At the same time, through the branch parallel connection method, using the characteristics of the parallel resistance, the stator phase balance of the branches after parallel connection is further reduced to 0.5%, far lower than the industry standard requirement of 3%. In this way, the optimal stator temperature rise, the minimum ripple voltage, and the optimal NVH (Noise, Vibration, Harshness) performance are realized.

[0090] The specific working process of the present invention is as follows:

[0091] A winding method for a flat wire stator assembly includes the following steps:

[0092] S1: Wind the first three-phase main winding 1 and the second three-phase main winding 101 on the stator structure 8;

[0093] S2: Connect the first three-phase branch 2 and the second three-phase branch 3 in a Y shape respectively; Connect the first three-phase branch 2 and the second three-phase branch 3 in parallel.

[0094] The present invention has been described exemplarily in conjunction with the accompanying drawings. Obviously, the specific implementation of the present invention is not limited by the above methods. As long as various non-substantive improvements are made by adopting the method concept and technical solution of the present invention; or without improvement, and the above concept and technical solution of the present invention are directly applied to other occasions, they are all within the protection scope of the present invention.

Claims

1. A coil structure, characterized in that: The invention comprises a first three-phase total winding (1) and a second three-phase total winding (101); the first three-phase total winding (1) and the second three-phase total winding (101) both comprise a first three-phase branch (2) and a second three-phase branch (3); the first three-phase branch (2) and the second three-phase branch (3) are connected in parallel.

2. A coil structure according to claim 1, characterized in that: The first three-phase branch (2) comprises three single-phase branches, which are respectively: a U1 branch (4), a V1 branch (401) and a W1 branch (402); the U1 branch (4), the V1 branch (401) and the W1 branch (402) in the first three-phase branch (2) are connected in a Y shape; the second three-phase branch (3) comprises three single-phase branches, which are respectively: a U2 branch (5), a V2 branch (501) and a W2 branch (502); the U2 branch (5), the V2 branch (501) and the W2 branch (502) in the second three-phase branch (3) are connected in a Y shape.

3. A coil structure according to claim 2, characterized in that: The U1 branch (4) includes a U1 lead wire (403) and a U1 neutral wire (6); the V1 branch (401) includes a V1 lead wire (404) and a V1 neutral wire (601); the W1 branch (402) includes a W1 lead wire (405) and a W1 neutral wire (602); the U2 branch (5) includes a U2 lead wire (503) and a U2 neutral wire (7); the V2 branch (501) includes a V2 lead wire (504) and a V2 neutral wire (701); the W2 branch (502) includes The W2 lead wire (505) and the W2 neutral wire (702) are connected; the U1 lead wire (403) and the U2 lead wire (503) are connected; the V1 lead wire (404) and the V2 lead wire (504) are connected; the W1 lead wire (405) and the W2 lead wire (505) are connected; the U1 neutral wire (6) and the V1 neutral wire (601) and the W1 neutral wire (602) are connected respectively; the U2 neutral wire (7) and the V2 neutral wire (701) and the W2 neutral wire (702) are connected respectively.

4. A flat wire stator assembly, characterized in that: It comprises a stator structure (8) and a coil structure as claimed in any one of claims 1 to 3; the first three-phase total winding (1) and the second three-phase total winding (101) in the coil structure are both arranged on the stator structure (8).

5. A flat wire stator assembly according to claim 4, characterized in that: The stator structure (8) comprises a stator slot (801); 2N layers of slots (802) are arranged in the stator slot (801), N is 1, 2, 3, ...; the first three-phase branch (2) is arranged in the 2N-1 layer of slots (802); the second three-phase branch (3) is arranged in the 2N layer of slots (802); The stator structure (8) comprises a stator core; a center hole (803) is provided on the stator core; the center hole (803) is coaxially arranged with the stator core; the U1 lead wire (403), the V1 lead wire (404), the W1 lead wire (405), the U2 lead wire (503), the V2 lead wire (504) and the W2 lead wire (505) are arranged in a slot (802) on one side of the stator slot (801) close to or away from the center hole (803).

6. A flat wire stator assembly according to claim 5, characterized in that: The U1 neutral line (6), the V1 neutral line (601), the W1 neutral line (602), the U2 neutral line (7), the V2 neutral line (701) and the W2 neutral line (702) are arranged in a slot (802) on a side of the stator slot (801) close to or far from the central hole (803); the U1 neutral line (6) and the U2 neutral line (7) are arranged in the same stator slot (801); the V1 neutral line (601) and the V2 neutral line (701) are arranged in the same stator slot (801); and the W1 neutral line (602) and the W2 neutral line (702) are arranged in the same stator slot (801).

7. A flat wire stator assembly according to any one of claims 5-6, characterized in that: The number of stator slots (801) spanning between the W1 neutral line (602) and the U1 neutral line (6) is the same as the number of stator slots (801) spanning between the W1 neutral line (602) and the V1 neutral line (601); the number of stator slots (801) spanning between the W2 neutral line (702) and the U2 neutral line (7) is the same as the number of stator slots (801) spanning between the W2 neutral line (702) and the V2 neutral line (701).

8. A flat wire stator assembly according to claim 7, characterized in that: Each single-phase branch in the first three-phase branch (2) and / or the second three-phase branch (3) comprises a wave-wound coil (9); the wave-wound coil (9) is connected to a cross-layer wire (901); each cross-layer wire (901) comprises a first pin (905) and a second pin (906); the lead wire in the single-phase branch where each cross-layer wire (901) is located and the first pin (905) in the cross-layer wire (901) are located in the same stator slot (801); the neutral wire in the single-phase branch where each cross-layer wire (901) is located and the second pin (906) in the cross-layer wire (901) are located in the same stator slot (801); Each of the wave-wound coils (9) comprises a U-pin line (902); the lead-out line and the neutral line of each single-phase branch are both I-Pin lines (903).

9. A method for winding a flat wire stator assembly according to any one of claims 4 to 8, characterized in that: The following steps are involved: S1: Winding a first three-phase total winding (1) and a second three-phase total winding (101) on a stator structure (8); S2: connecting the first three-phase branch (2) and the second three-phase branch (3) in a Y shape respectively; connecting the first three-phase branch (2) and the second three-phase branch (3) in parallel.

10. A winding method according to claim 9, characterized in that: In S1, the first three-phase total winding (1) is arranged in the 2L-1 stator slot (801) of the stator structure (8), and L is 1, 2, 3, ... 48; the second three-phase total winding (101) is arranged in the 2L stator slot (801) of the stator structure (8), and L is 1, 2, 3, ... 48; The first three-phase branch (2) is arranged in a slot (802) of the 2N-1 layer of the stator slot (801), where N is 1, 2, 3, ...; the second three-phase branch (3) is arranged in a slot (802) of the 2N layer; the U1 lead wire (403), the V1 lead wire (404), the W1 lead wire (405), the U2 lead wire (503), the V2 lead wire (504) and the W2 lead wire (505) are arranged in the slot (802) of the stator slot (801) close to or far from the central hole (803); The U1 neutral line (6), the V1 neutral line (601), the W1 neutral line (602), the U2 neutral line (7), the V2 neutral line (701) and the W2 neutral line (702) are arranged in a slot (802) on a side of the stator slot (801) close to or far from the center hole (803); the U1 neutral line (6) and the U2 neutral line (7) are arranged in the same stator slot (801); the V1 neutral line (601) and the V2 neutral line (701) are arranged in the same stator slot (801); and the W1 neutral line (602) and the W2 neutral line (702) are arranged in the same stator slot (801).

11. A winding method according to claim 10, characterized in that: In S1, a first pin (905) of a cross-layer wire (901) and a lead-out line of a single-phase branch where the cross-layer wire (901) is located are arranged in the same stator slot (801); and a second pin (906) of the cross-layer wire (901) and a neutral line of a single-phase branch where the cross-layer wire (901) is located are arranged in the same stator slot (801).

12. A winding method according to any one of claims 10-11, characterized in that: In S2, the number of stator slots (801) spanned between the W1 neutral line (602) and the U1 neutral line (6) is the same as the number of stator slots (801) spanned between the W1 neutral line (602) and the V1 neutral line (601), both of which are 7; the number of stator slots (801) spanned between the W2 neutral line (702) and the U2 neutral line (7) is the same as the number of stator slots (801) spanned between the W2 neutral line (702) and the V2 neutral line (701), both of which are 7.

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