48-slot flat wire stator winding and flat wire motor

Abstract

The invention discloses a 48-slot flat wire stator winding and a flat wire motor, the stator winding comprises three phases of phase windings, each phase winding comprises a plurality of groups of winding branches connected in parallel, each group of winding branches at least comprises one branch, and each branch comprises a plurality of coils which are sequentially arranged on circumferential iron core slots of a stator iron core and are connected in series; each branch takes a single coil located on the innermost layer of the groove bottom of the iron core groove as a winding starting point, a coil with the span being y is wound between the innermost layer of the groove bottom and the outermost layer of a groove opening, the coil with the span being y is used for conducting same-layer reversing on the outermost layer of the groove opening and the innermost layer of the groove bottom, and the process is repeated so that branch symmetry can be achieved; when the winding number of the coils of the branch in the iron core groove reaches a preset 1 / 2, the coils with the span being y + 1 are used for conducting same-layer reversing on the outermost layer of the groove opening or a single coil is used as a neutral point leading-out wire. The invention has the advantages of compact structure, balanced potential of each branch, no circulating current and the like, and eliminates a series of problems caused by asymmetry of each branch.

Description

Technical Field

[0001] The present invention belongs to the technical field of motors, and particularly relates to a 48-slot flat wire stator winding and a flat wire motor. Background Art

[0002] With the rapid development of new energy vehicle technology, as one of the key actuating components of electric vehicles, the performance requirements for drive motors are getting higher and higher. At present, high speed, light weight, and high efficiency have become the development trends of drive motors, and there are higher requirements for the power density, high-efficiency area, and heat dissipation capacity of motors.

[0003] Stator windings can be divided into round wires and flat wires. The difference between flat wire motors and round wire motors lies in the forming method of copper wires. Flat wires are beneficial to improving the slot fill factor. Generally, the slot fill factor of round wire motors is about 50%, while that of flat wire motors can reach more than 70%. The improvement of the slot fill factor means that more copper can be filled on the premise of unchanged space, the resistance of the motor decreases, and under the same current, the copper loss decreases. Compared with round wire motors, the contact area between copper conductors in the slots of flat wire motors is larger, and the heat dissipation effect is better.

[0004] When the motor runs at high speed, the AC copper loss of the motor increases significantly. To reduce the copper loss, generally, the number of conductor layers per slot in the stator is increased, such as 4 layers, 6 layers, 8 layers, etc. Since the conductors of each parallel branch are distributed at different positions in the stator slots, if the branches are asymmetric, it will lead to large differences in back electromotive force, resistance, and inductance, thus forming a circulating current, increasing the additional loss and reducing the efficiency. At the same time, it causes local overheating of the motor winding and reduces the service life of the motor. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to overcome the deficiencies of the prior art and provide a 48-slot flat wire stator winding and a flat wire motor with a compact structure, simple manufacturing, symmetric branches, and neat arrangement.

[0006] To solve the above technical problems, the present invention adopts the following technical solutions:

[0007] A 48-slot flat wire stator winding, comprising three-phase phase windings, each of the phase windings including multiple groups of parallel winding branches, each group of winding branches including at least one branch, the branch including multiple coils arranged in sequence and connected in series on the circumferential core slots of the stator core, the branch including single coils and coils with a span of y, the branch starting from a single coil at the innermost layer of the bottom of the core slot for winding, winding the coil with a span of y from the second innermost layer of the bottom of the core slot to the outermost layer of the slot opening, and performing in-layer commutation of the coil with a span of y at the outermost layer of the slot opening, then winding the coil with a span of y from the second outermost layer of the slot opening to the innermost layer of the bottom of the core slot, and performing in-layer commutation of the coil with a span of y at the innermost layer of the bottom of the core slot, and so on in a cycle to achieve branch symmetry; when the number of windings of the branch in the core slot reaches 1 / 2 of the preset number, using the coil with a span of y + 1 for in-layer commutation at the outermost layer of the slot opening or using a single coil as the neutral point lead-out wire.

[0008] As a further improvement of the present invention, the coil with a span of y includes a first coil, the first coil performing in-layer commutation at the outermost layer of the slot opening, the first coil including a first coil body and a first bending portion, the first coil body including two first struts arranged in parallel and a first head connecting one ends of the two first struts, and the other ends of the two first struts being provided with a first bending portion to form a welding end, the first bending portion being bent along one side in the width direction of the first coil body.

[0009] As a further improvement of the present invention, the coil with a span of y further includes a second coil, the second coil being wound from the second innermost layer of the bottom of the core slot to the second outermost layer of the slot opening, the second coil including a second coil body and a second bending portion, the second coil body including two second struts arranged in parallel and a second head connecting one ends of the two second struts, and the other ends of the two second struts being provided with a second bending portion to form a welding end, the second bending portion being bent along the width direction of the second coil body and away from the second coil body.

[0010] As a further improvement of the present invention, the coil with a span of y further includes a third coil, the third coil performing in-layer commutation at the innermost layer of the bottom of the core slot, the third coil including a third coil body and a third bending portion, the third coil body including two third struts arranged in parallel and a third head connecting one ends of the two third struts, and the other ends of the two third struts being provided with a third bending portion to form a welding end, the third bending portion being bent along the width direction of the third coil body and away from the third coil body; the bending direction of the third bending portion is opposite to the bending direction of the first bending portion.

[0011] As a further improvement of the present invention, the single coil includes a fifth coil, and the fifth coil is arranged at the innermost layer of the slot bottom as the starting point of winding. The fifth coil includes a fifth coil body and a fifth bending portion. The fifth coil body includes a fifth rod, and both ends of the fifth rod are respectively provided with a fifth head and a fifth bending portion. The fifth bending portion forms a welding end; the bending direction of the fifth head is the same as that of the fifth bending portion.

[0012] As a further improvement of the present invention, the coil with a span of y + 1 includes a fourth coil, and the fourth coil performs in-layer commutation at the innermost layer of the slot bottom. The fourth coil includes a fourth coil body and a fourth bending portion. The fourth coil body includes two fourth rods arranged in parallel and a fourth head connecting one end of the two fourth rods. The other ends of the two fourth rods are provided with fourth bending portions to form welding ends. The fourth bending portion bends along one side in the width direction of the fourth coil body; the bending direction of the third bending portion is the same as that of the fourth bending portion.

[0013] As a further improvement of the present invention, the single coil further includes a sixth coil, and the sixth coil is arranged at the innermost layer of the slot bottom as a neutral point lead-out wire. The sixth coil includes a sixth coil body and a sixth bending portion. The sixth coil body includes a sixth rod, and both ends of the sixth rod are respectively provided with a sixth head and a sixth bending portion. The sixth bending portion forms a welding end; the bending direction of the sixth head is opposite to that of the sixth bending portion.

[0014] As a further improvement of the present invention, the parallel form between each group of winding branches is star connection or delta connection.

[0015] As a further improvement of the present invention, the phase winding includes a group of winding branches. One branch in the winding branch includes single coils A0, a1 - A2, a3 - A4, a5 - A6, a7 - A8, a9 - A10, a11 - A12, a13 - A14, a15 - A16, a17 - A18, a19 - A20, a21 - A22, a23 - A24, a25 - A26, a27 - A28, a29 - A30, a31 - A32, ……, 61 - A62, a63;

[0016] The single coil A0 is located at the 4th layer along the slot bottom direction at the inner slot opening of the iron core slot;

[0017] The spans of a1 - A2, a9 - A10, a17 - A18, and a25 - A26 are all y. Their upper sides are located at the 3rd layer of the iron core slot, and their lower sides are located at the 2nd layer of the iron core slot;

[0018] The spans of a3 - A4, a11 - A12, a19 - A20, and a27 - A28 are all y, and their upper and lower sides are both located in the first layer of the iron core slot;

[0019] The spans of a5 - A6, a13 - A14, a21 - A22, and a29 - A30 are all y. Their upper sides are located in the second layer of the iron core slot, and their lower sides are located in the third layer of the iron core slot;

[0020] The spans of a7 - A8, a15 - A16, and a23 - A24 are all y. Their upper and lower sides are both located in the fourth layer of the iron core slot;

[0021] The span of a31 - A32 is y + 1, and its upper and lower sides are both located in the fourth layer of the iron core slot;

[0022] The spans of A33 - A34, a41 - A42, a49 - A50, and a57 - A58 are all y. Their upper sides are located in the third layer of the iron core slot, and their lower sides are located in the second layer of the iron core slot;

[0023] The spans of A35 - A36, a43 - A44, a51 - A52, and a59 - A60 are all y, and their upper and lower sides are both located in the first layer of the iron core slot;

[0024] The spans of A37 - A38, a45 - A46, a53 - A54, and a61 - A62 are all y. Their upper sides are located in the second layer of the iron core slot, and their lower sides are located in the third layer of the iron core slot;

[0025] In the winding branch, coil A0 is connected to coil a1 - A2 by a twist weld, coil a1 - A2 is connected to coil a3 - A4 by a twist weld, coil a3 - A4 is connected to coil a5 - A6 by a twist weld, coil a5 - A6 is connected to coil a7 - A8 by a twist weld, and so on; the coil sequence is from the fourth layer to the third layer, the third layer to the second layer and then to the first layer, and after finishing the same layer in the first layer, it returns to the second layer, from the first layer to the second layer and then to the third layer and the fourth layer, repeating in this way to complete the winding of the winding branch; the winding is transposed by the same - layer coils at the innermost layer of the slot bottom and the outermost layer of the slot opening to achieve symmetry of the three - phase winding.

[0026] As a further improvement of the present invention, the phase winding includes a set of winding branches. One branch of the winding branches includes a single coil A0, coils a1-A2, a3-A4, a5-A6, a7-A8, a9-A10, a11-A12, a13-A14, a15-A16, a17-A18, a19-A20, a21-A22, a23-A24, a25-A26, a27-A28, a29-A30, a31; the other branch includes a single coil B0, coils b1-B2, b3-B4, b5-B6, b7-B8, b9-B10, b11-B12, b13-B14, b15-B16, b17-B18, b19-B20, b21-B22, b23-B24, b25-B26, b27-B28, b29-B30, b31;

[0027] The two branches have the same winding method. The single coil A0 and the single coil B0 are both located in the 4th layer along the bottom direction of the inner slot opening of the iron core slot as the starting point of winding; the single coil a31 and the single coil b31 are both located in the 4th layer along the bottom direction of the inner slot opening of the iron core slot as the neutral point lead-out wire;

[0028] The spans of a1-A2, a9-A10, a17-A18, a25-A26, b1-B2, b9-B10, b17-B18 and b25-B26 are all y. Their upper sides are located in the 3rd layer of the iron core slot, and their lower sides are located in the 2nd layer of the iron core slot;

[0029] The spans of a3-A4, a11-A12, a19-A20, a27-A28, b3-B4, b11-B12, b19-B20 and b27-B28 are all y. Their upper sides and lower sides are both located in the 1st layer of the iron core slot;

[0030] The spans of a5-A6, a13-A14, a21-A22, a29-A30, b5-B6, b13-B14, b21-B22 and b29-B30 are all y. Their upper sides are located in the 2nd layer of the iron core slot, and their lower sides are located in the 3rd layer of the iron core slot;

[0031] The spans of a7-A8, a15-A16, a23-A24, b7-B8, b15-B16 and b23-B24 are all y. Their upper sides and lower sides are both located in the 4th layer of the iron core slot;

[0032] In the first branch, coil A0 is connected to coils a1 - A2 by twist welding, coils a1 - A2 are connected to coils a3 - A4 by twist welding, coils a3 - A4 are connected to coils a5 - A6 by twist welding, coil a5 - A6 is connected to coils a7 - A8 by twist welding, and so on; the coil sequence goes from the 4th layer to the 3rd layer, the 3rd layer to the 2nd layer and then to the 1st layer, after finishing the same layer in the 1st layer, it returns to the 2nd layer, from the 1st layer to the 2nd layer, then to the 3rd layer and the 4th layer, and so on in a cycle to complete the winding of the first branch, and the winding of the second branch is carried out in the same way; the windings are transposed through the innermost layer at the bottom of the slot and the outermost layer at the slot opening of the same layer of coils to achieve symmetry of the three - phase windings.

[0033] As a general technical concept, the present invention also provides a flat - wire motor, including the above - mentioned 48 - slot flat - wire stator winding.

[0034] Compared with the prior art, the advantages of the present invention are as follows:

[0035] 1. For the 48 - slot flat - wire stator winding of the present invention, in each winding branch, a winding arrangement method combining coils with different spans and different types is adopted, reducing the wire types and having no special - shaped wires, which is convenient for assembly and mass production; at the head end of each winding branch, a single - wire coil is used as the lead - out wire, the neutral point is connected through a Busbar, and the coil with a span of y is wound from the second - innermost layer at the bottom of the iron core slot to the outermost layer at the slot opening, the coil with a span of y makes a same - layer commutation at the outermost layer at the slot opening, then the coil with a span of y is wound from the second - outermost layer at the slot opening to the innermost layer at the bottom of the slot, and the coil with a span of y makes a same - layer commutation at the innermost layer at the bottom of the slot, and so on in a cycle to achieve branch symmetry; when the number of coils wound in the iron core slot of a branch reaches 1 / 2 of the preset number, a coil with a span of y + 1 makes a same - layer commutation at the outermost layer at the slot opening or a single - wire coil is used as the neutral - point lead - out wire. By combining coils with different spans and different types, by replacing 1 wire of a certain layer of the phase winding and keeping the welding ends consistent, different branch connection schemes are realized, and flexible conversion of different parallel - branch numbers can be achieved as needed. At the same time, it reduces the wire types, lowers the complexity of the manufacturing process, is convenient for production, and eliminates a series of problems caused by asymmetry of each branch, ensuring that each branch is symmetric both in the slot and in the layer, that is, each parallel branch is distributed in a circular - symmetric structure in the iron core slot, thereby realizing uniform and symmetric distribution of each phase winding, making the potential of each branch balanced, without circulating current, and canceling harmonics, greatly improving the performance of the motor. The present invention not only solves a series of problems caused by asymmetry of each branch, but also effectively reduces the problems of high difficulty in flat - wire winding process and high manufacturing cost of the motor due to the increase in the number of phases, effectively reducing the manufacturing cost of the vehicle.

[0036] 2. The stator winding and flat wire motor of the present invention achieve a winding that is compatible with different branch schemes without changing the welding end. It can flexibly switch different parallel branch numbers as needed, while reducing the manufacturing difficulty. The coil with different spans is used to form a commutated winding for commutation, making each branch completely symmetrical, avoiding the generation of circulating current, and reducing the motor temperature rise. The flat wire conductors in the same iron core slot of the stator winding are of the same phase, and no interphase insulation is required between the conductors in the slot, reducing the manufacturing difficulty and the motor insulation cost. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] Figure 1 It is a schematic structural principle diagram of the first coil in a specific embodiment of the present invention.

[0038] Figure 2 It is a schematic structural principle diagram of the second coil in a specific embodiment of the present invention.

[0039] Figure 3 It is a schematic structural principle diagram of the third coil in a specific embodiment of the present invention.

[0040] Figure 4 It is a schematic structural principle diagram of the fourth coil in a specific embodiment of the present invention.

[0041] Figure 5 It is a schematic structural principle diagram of the fifth coil in a specific embodiment of the present invention.

[0042] Figure 6 It is a schematic structural principle diagram of the sixth coil in a specific embodiment of the present invention.

[0043] Figure 7 It is a schematic structural principle diagram of the stator gantry end in Specific Embodiment 1 of the present invention.

[0044] Figure 8 It is a schematic structural principle diagram of the stator welding end in Specific Embodiment 1 of the present invention.

[0045] Figure 9 It is a phase arrangement schematic diagram of any one-phase winding in Specific Embodiment 1 of the present invention.

[0046] Figure 10 It is a schematic structural principle diagram of the stator gantry end in Specific Embodiment 2 of the present invention.

[0047] Figure 11 It is a schematic structural principle diagram of the stator welding end in Specific Embodiment 2 of the present invention.

[0048] Figure 12 It is a phase arrangement schematic diagram of any one-phase winding in Specific Embodiment 2 of the present invention.

[0049] Figure 13Schematic diagram of the star connection of the three-phase windings in a specific embodiment of the present invention.

[0050] Figure 14 Schematic diagram of the delta connection of the three-phase windings in a specific embodiment of the present invention.

[0051] Legend: 1. First coil; 11. First coil body; 111. First support rod; 112. First head; 12. First bending part; 2. Second coil; 21. Second coil body; 211. Second support rod; 212. Second head; 22. Second bending part; 3. Third coil; 31. Third coil body; 311. Third support rod; 312. Third head; 32. Third bending part; 4. Fourth coil; 41. Fourth coil body; 411. Fourth support rod; 412. Fourth head; 42. Fourth bending part; 5. Fifth coil; 51. Fifth coil body; 511. Fifth support rod; 512. Fifth head; 52. Fifth bending part; 6. Sixth coil; 61. Sixth coil body; 611. Sixth support rod; 612. Sixth head; 62. Sixth bending part; 7. Stator core; 71. Core slot. Detailed implementation mode

[0052] The present invention will be further described below in conjunction with the accompanying drawings of the specification and specific preferred embodiments, but the protection scope of the present invention is not limited thereby.

[0053] Embodiment 1

[0054] As Figures 1 to 9 , Figure 13 and Figure 14 shown, the stator winding of this embodiment includes three-phase windings. Each phase winding includes multiple groups of parallel winding branches. Each group of winding branches includes at least one branch. The branch includes multiple coils arranged in sequence and connected in series on the circumferential core slots 71 of the stator core 7. The branch includes a single coil and a coil with a span of y. The branch starts winding with a single coil located in the innermost layer at the bottom of the core slot 71 (the last first layer from the slot opening to the slot bottom), winds a coil with a span of y from the second innermost layer at the bottom of the core slot 71 to the outermost layer at the slot opening (the first layer from the slot opening to the slot bottom), and performs in-layer commutation of the coil with a span of y at the outermost layer at the slot opening. Then, wind a coil with a span of y from the second outermost layer at the slot opening to the innermost layer at the slot bottom, and perform in-layer commutation of the coil with a span of y at the innermost layer at the slot bottom. Repeat this cycle to achieve branch symmetry. When the number of coils wound in the core slot 71 of the branch reaches 1 / 2 of the preset number, use a coil with a span of y + 1 to perform in-layer commutation at the outermost layer at the slot opening. Different span U-shaped coils are used to form a commutation sequence winding for commutation, so that each branch is completely symmetrical, avoiding the generation of circulating current and reducing the temperature rise of the motor.

[0055] As Figure 1As shown, in this embodiment, the coil with a span of y includes a first coil 1. The first coil 1 performs in-layer commutation at the outermost layer of the slot opening. The first coil 1 includes a first coil body 11 and a first bending portion 12. The first coil body 11 includes two first support rods 111 arranged in parallel with each other and a first head 112 connecting one ends of the two first support rods 111. The other ends of the two first support rods 111 are provided with the first bending portion 12 to form a welding end. The first bending portion 12 bends along one side of the width direction of the first coil body 11.

[0056] As Figure 2 shown, in this embodiment, the coil with a span of y further includes a second coil 2. The second coil 2 is wound from the second innermost layer of the slot bottom to the second outermost layer of the slot opening. The second coil 2 includes a second coil body 21 and a second bending portion 22. The second coil body 21 includes two second support rods 211 arranged in parallel with each other and a second head 212 connecting one ends of the two second support rods 211. The other ends of the two second support rods 211 are provided with the second bending portion 22 to form a welding end. The second bending portion 22 bends along the width direction of the second coil body 21 and in a direction away from the second coil body 21.

[0057] As Figure 3 shown, in this embodiment, the coil with a span of y further includes a third coil 3. The third coil 3 performs in-layer commutation at the innermost layer of the slot bottom. The third coil 3 includes a third coil body 31 and a third bending portion 32. The third coil body 31 includes two third support rods 311 arranged in parallel with each other and a third head 312 connecting one ends of the two third support rods 311. The other ends of the two third support rods 311 are provided with the third bending portion 32 to form a welding end. The third bending portion 32 bends along the width direction of the third coil body 31 and in a direction away from the third coil body 31; the bending direction of the third bending portion 32 is opposite to the bending direction of the first bending portion 12.

[0058] As Figure 4 shown, in this embodiment, the coil with a span of y + 1 includes a fourth coil 4. The fourth coil 4 performs in-layer commutation at the innermost layer of the slot bottom. The fourth coil 4 includes a fourth coil body 41 and a fourth bending portion 42. The fourth coil body 41 includes two fourth support rods 411 arranged in parallel with each other and a fourth head 412 connecting one ends of the two fourth support rods 411. The other ends of the two fourth support rods 411 are provided with the fourth bending portion 42 to form a welding end. The fourth bending portion 42 bends along one side of the width direction of the fourth coil body 41; the bending direction of the third bending portion 32 is the same as the bending direction of the fourth bending portion 42.

[0059] As Figure 5As shown in the figure, in this embodiment, a single coil includes a fifth coil 5. The fifth coil 5 is arranged at the innermost layer of the slot bottom as the starting point of winding. The fifth coil 5 includes a fifth coil body 51 and a fifth bending part 52. The fifth coil body 51 includes a fifth rod 511. At both ends of the fifth rod 511, there are respectively a fifth head 512 and a fifth bending part 52. The fifth bending part 52 forms a welding end. The bending direction of the fifth head 512 is the same as that of the fifth bending part 52.

[0060] In this embodiment, the coils in each winding branch are wound along the direction from the inside to the outside. Each coil has the same span. The upper side and the lower side of the coil are respectively located in the iron core slots 71 of adjacent layers. Then, the coils are subjected to in-layer transposition through the innermost layer of the slot bottom or the outermost layer of the slot opening to eliminate the phase difference between different branches, ensuring that each branch is symmetric both in the slot and in the layer. That is, each parallel branch is distributed in a circular symmetric structure in the iron core slot, thereby realizing the uniform and symmetric distribution of each phase winding, making the potential of each branch balanced, without circulating current, and canceling harmonics, greatly improving the performance of the motor. Moreover, the flat wire conductors in the same iron core slot of the stator winding are of the same phase, and no inter-phase insulation is required between the conductors in the slot, reducing the manufacturing difficulty and the insulation cost of the motor.

[0061] In this embodiment, the heads of the first coil 1, the second coil 2, the third coil 3, and the fourth coil 4 are all in a V shape or an arc shape. Among them, the coil with a V-shaped head is called a V-shaped coil, and the coil with an arc-shaped head is called a U-shaped coil. In this embodiment, each coil can adopt a U-shaped coil or a V-shaped coil. Since each coil adopts the same shape, the special-shaped coils and the cross-connected coils are eliminated, which is convenient for assembly and mass production. Of course, in other embodiments, a combination of U-shaped coils and V-shaped coils can also be adopted.

[0062] As Figure 13 and Figure 14 shown, in this embodiment, the parallel form between each branch in each winding branch is star connection or delta connection.

[0063] In this embodiment, the neutral point of the coil (such as Figure 9 a63 in the figure) is connected through a Busbar. The structure is simple and the height is equivalent to that of the welding end, reducing the height of the winding end, thereby reducing the volume of the motor.

[0064] Specifically, taking a flat wire winding with 48 slots, 8 poles, 4 layers, and 1 branch as an example, the gate type end and the welding end of the motor stator are respectively as Figure 7 and Figure 8As shown, the neutral point of the motor is connected through a Busbar, with a simple structure. The number of coil layers increases successively from the slot opening to the slot bottom. U-phase branch: A-a. Since the number of slots per pole per phase is 2 and the number of branches is 1, to achieve branch symmetry, the first layer is a U-shaped coil with the same span, the second and third layers are U-shaped coils with the same span, and the fourth layer is a combination of U-shaped coils with two spans. Among them, the U-phase winding branch is represented by A, and a1-A2, a3-A4, a5-A6 form a U-shaped coil, and so on.

[0065] Specifically, in the first layer and the second to third layers, U-shaped coils with a span of 6 are used, and in the fourth layer, a combination of a U-shaped coil with a span of 6 and a U-shaped coil with a span of 7 is used.

[0066] In this embodiment, the phase winding includes a group of winding branches. One branch in the winding branch includes single coils A0, coils a1-A2, a3-A4, a5-A6, a7-A8, a9-A10, a11-A12, a13-A14, a15-A16, a17-A18, a19-A20, a21-A22, a23-A24, a25-A26, a27-A28, a29-A30, a31-A32... a59-A60, a61-A62, a63, and the phase winding is arranged as Figure 9 shown.

[0067] The single coil A0 is located in the fourth layer along the slot bottom direction at the slot opening of the iron core slot 71 and serves as the starting point for winding; it is a single coil shaped as Figure 5 shown. The single coil a63 is located in the fourth layer along the slot bottom direction at the slot opening of the iron core slot 71 and serves as the lead wire, and it is a single coil shaped as Figure 5 shown.

[0068] The spans of a1-A2, a9-A10, a17-A18, and a25-A26 are all 6. Their upper sides are located in the third layer of the iron core slot 71, and their lower sides are located in the second layer of the iron core slot 71; they are U-shaped coils shaped as Figure 2 shown.

[0069] The spans of a3-A4, a11-A12, a19-A20, and a27-A28 are all 6. Their upper sides and lower sides are both located in the first layer of the iron core slot 71; they are U-shaped coils shaped as Figure 1 shown.

[0070] The spans of a5-A6, a13-A14, a21-A22, and a29-A30 are all 6. Their upper sides are located in the second layer of the iron core slot 71, and their lower sides are located in the third layer of the iron core slot 71; they are U-shaped coils shaped as Figure 2 shown.

[0071] The spans of a7-A8, a15-A16, and a23-A24 are all 6, and their upper and lower sides are both located in the 4th layer of the iron core slot 71; in the shape of Figure 3 the U-shaped coil shown.

[0072] The span of a31-A32 is 7, and its upper and lower sides are both located in the 4th layer of the iron core slot 71, in the shape of Figure 4 the U-shaped coil shown.

[0073] The spans of A33-A34, a41-A42, a49-A50, and a57-A58 are all 6. Its upper side is located in the 3rd layer of the iron core slot 71, and the lower side is located in the 2nd layer of the iron core slot 71; in the shape of Figure 2 the U-shaped coil shown.

[0074] The spans of A35-A36, a43-A44, a51-A52, and a59-A60 are all 6. Its upper and lower sides are both located in the 1st layer of the iron core slot 71; in the shape of Figure 1 the U-shaped coil shown.

[0075] The spans of A37-A38, a45-A46, a53-A54, and a61-A62 are all 6. Its upper side is located in the 2nd layer of the iron core slot 71, and the lower side is located in the 3rd layer of the iron core slot 71; in the shape of Figure 2 the U-shaped coil shown.

[0076] In this embodiment, the coil A0 is connected to the coil a1-A2 by twist welding, the coil a1-A2 is connected to the coil a3-A4 by twist welding, the coil a3-A4 is connected to the coil a5-A6 by twist welding, and the a5-A6 coil is connected to the a7-A8 coil by twist welding, and so on. The coil sequence goes from the 4th layer to the 3rd layer, the 3rd layer to the 2nd layer and then to the 1st layer. After finishing the same layer in the 1st layer, it returns to the 2nd layer, from the 1st layer to the 2nd layer and then to the 3rd layer, the 4th layer, and so on in a cycle to complete the winding of the winding branch; the winding is transposed by the innermost coil at the bottom of the slot and the outermost coil at the slot opening of the same layer to achieve symmetry of the three-phase winding.

[0077] The coils are transposed by the coils of the same layer to eliminate the phase difference between different branches and ensure complete symmetry of each branch. In this embodiment, manufacturability is fully considered. The coil is composed of a U-shaped coil and a single wire, reducing the types of U-shaped coils. Most of the parts use cross-layer wires, reducing the manufacturing difficulty and facilitating mass production. In other embodiments, Bus-bar wire replacement can also be used.

[0078] In this embodiment, the stator winding is composed of 5 types of coils in total, as Figures 1 to 5As shown in the figure. The flat wire stator and the motor fully consider manufacturability. The coil is composed of U-shaped coils and a single wire, reducing the types of U-shaped coils, lowering the manufacturing difficulty, and facilitating mass production. By transposing the windings with the innermost and outermost coils of the same layer, the three-phase windings are ensured to be completely symmetrical, with fewer wire types and no special-shaped wires, greatly reducing the complexity of winding forming. Only by twisting and connecting the welding ends of the windings, it is convenient for production and can eliminate a series of problems caused by the asymmetry of each branch. The three-phase windings can be star-connected or delta-connected through Busbar or lead wires, with a compact structure.

[0079] As Figure 8 and Figure 9 shown, this embodiment also provides a stator, which includes a stator core 7 and the above-mentioned stator winding. 48 core slots 71 are circumferentially arranged on the inner wall of the stator core 7. Part of the phase winding in the stator winding is wound in the core slots 71, and part of the phase winding is located outside the core slots 71. Each core slot 71 has 4 layers of in-phase windings, and the number of winding layers in each core slot 71 is the same. It can be understood that in actual applications, the number of winding layers in each stator slot includes but is not limited to 4 layers, and can also be 2 layers, 6 layers, 8 layers, etc. The winding method can refer to the above-mentioned 4-layer winding method.

[0080] This embodiment also provides a flat wire motor including the above-mentioned stator winding. This motor can be applied to vehicles such as electric vehicles / electric cars (EV), pure electric vehicles (PEV / BEV), hybrid electric vehicles (HEV), range-extended electric vehicles (REEV), plug-in hybrid electric vehicles (PHEV), and new energy vehicles. In the flat wire wave-wound motor of this embodiment, the wave-wound flat wire does not need to be welded and has no welding points. At the same time, it has high design flexibility, reduces the processing procedures of the flat wire wave-wound motor, has a simple process, and reduces costs.

[0081] This embodiment also provides a vehicle including the above-mentioned motor. This vehicle can be an electric vehicle / electric car (EV), pure electric vehicle (PEV / BEV), hybrid electric vehicle (HEV), range-extended electric vehicle (REEV), plug-in hybrid electric vehicle (PHEV), new energy vehicle, etc.

[0082] In this embodiment, the motor is composed of a total of 5 types of coils. By transposing the windings with the innermost and outermost coils of the same layer, the phase difference between different branches is eliminated to ensure that each branch is completely symmetrical.

[0083] Embodiment 2

[0084] As Figures 1 to 3 , Figure 5 and Figure 6, Figures 10 to 14 As shown in the figure, the stator winding of this embodiment has a similar structural arrangement and working principle to that of Embodiment 1. The stator winding includes three-phase windings, and each phase winding includes multiple groups of parallel winding branches. Each group of winding branches includes at least one branch, and the branch includes multiple coils arranged in sequence and connected in series on the circumferential core slots 71 of the stator core 7. The branch includes a single coil and coils with a span of y. The branch starts winding with a single coil located in the innermost layer at the bottom of the core slot 71 (the last first layer from the slot opening to the slot bottom), and winds the coil with a span of y from the second innermost layer at the bottom of the core slot 71 to the outermost layer at the slot opening (the first layer from the slot opening to the slot bottom). Then, the coil with a span of y commutes on the same layer at the outermost layer of the slot opening, and then winds the coil with a span of y from the second outermost layer of the slot opening to the innermost layer at the slot bottom, and commutes on the same layer at the innermost layer at the slot bottom. This cycle is repeated to achieve branch symmetry. When the number of coils wound in the core slot 71 of the branch reaches 1 / 2 of the preset number, a single coil is used as the neutral point lead-out wire. By replacing the coil with a span of 7 in the fourth layer in Embodiment 1 with two identical single coils and keeping the welding ends unchanged, it can be changed into a flat wire winding with 48 slots, 4 layers, 8 poles, and 2 branch numbers.

[0085] As Figure 6 shown in the figure, in this embodiment, the single coil is the sixth coil 6, and the sixth coil 6 is arranged in the innermost layer at the bottom of the slot as the neutral point lead-out wire. The sixth coil 6 includes a sixth coil body 61 and a sixth bending part 62. The sixth coil body 61 includes a sixth branch rod 611, and the two ends of the sixth branch rod 611 are respectively provided with a sixth head 612 and a sixth bending part 62, and the sixth bending part 62 forms the welding end. The bending direction of the sixth head 612 is opposite to that of the sixth bending part 62.

[0086] Specifically, taking a flat wire winding with 48 slots, 8 poles, 4 layers, and 2 branch numbers as an example, the motor stator gantry end and the welding end are respectively as Figure 10 and Figure 11 shown in the figure. The motor neutral point is connected through a Busbar, and the structure is simple. The number of coil layers increases sequentially from the slot opening to the slot bottom. U-phase branch: A-a, B-b. Since the number of slots per pole per phase is 2 and the number of branch numbers is 2, in order to achieve branch symmetry, the first layer is a U-shaped coil with the same span on the same layer, the second and third layers are U-shaped coils with the same span, and the fourth layer is a combination of a U-shaped coil and two single coils. Among them, the U-phase winding branch is represented by A, a1-A2, a3-A4, a5-A6 form a U-shaped coil, and is represented by B, b1-B2, b3-B4, b5-B6 form a U-shaped coil, and so on.

[0087] The phase winding includes a set of winding branches. One of the winding branches includes a single coil A0, coils a1 - A2, a3 - A4, a5 - A6, a7 - A8, a9 - A10, a11 - A12, a13 - A14, a15 - A16, a17 - A18, a19 - A20, a21 - A22, a23 - A24, a25 - A26, a27 - A28, a29 - A30, a31; the other branch includes a single coil B0, coils b1 - B2, b3 - B4, b5 - B6, b7 - B8, b9 - B10, b11 - B12, b13 - B14, b15 - B16, b17 - B18, b19 - B20, b21 - B22, b23 - B24, b25 - B26, b27 - B28, b29 - B30, b31; the phase winding is arranged as Figure 12 shown.

[0088] The two branches have the same winding method. The single coil A0 and the single coil B0 are both located in the 4th layer along the bottom of the inner slot of the iron core 71, serving as the starting point of winding, and are single coils shaped as shown in Figure 5; the single coil a31 and the single coil b31 are both located in the 4th layer along the bottom of the inner slot of the iron core slot 71, serving as the neutral point lead - out wire, and are single coils shaped as shown in Figure 6.

[0089] The spans of a1 - A2, a9 - A10, a17 - A18, a25 - A26, b1 - B2, b9 - B10, b17 - B18, and b25 - B26 are all 6. Their upper sides are located in the 3rd layer of the iron core slot 71, and their lower sides are located in the 2nd layer of the iron core slot 71; they are U - shaped coils shaped as Figure 2 shown.

[0090] The spans of a3 - A4, a11 - A12, a19 - A20, a27 - A28, b3 - B4, b11 - B12, b19 - B20, and b27 - B28 are all 6. Their upper sides and lower sides are both located in the 1st layer of the iron core slot 71; they are U - shaped coils shaped as Figure 1 shown.

[0091] The spans of a5 - A6, a13 - A14, a21 - A22, a29 - A30, b5 - B6, b13 - B14, b21 - B22, and b29 - B30 are all 6. Their upper sides are located in the 2nd layer of the iron core slot 71, and their lower sides are located in the 3rd layer of the iron core slot 71; they are U - shaped coils shaped as Figure 2 shown.

[0092] The spans of a7 - A8, a15 - A16, a23 - A24, b7 - B8, b15 - B16, and b23 - B24 are all 6. Their upper sides and lower sides are both located in the 4th layer of the iron core slot 71; they are U - shaped coils shaped as Figure 3The U-shaped coil shown.

[0093] In the first branch, coil A0 is connected to coils a1 - A2 by a twist weld, coils a1 - A2 are connected to coils a3 - A4 by a twist weld, coils a3 - A4 are connected to coils a5 - A6 by a twist weld, coils a5 - A6 are connected to coils a7 - A8 by a twist weld, and so on; the coil sequence goes from the 4th layer to the 3rd layer, from the 3rd layer to the 2nd layer and then to the 1st layer. After finishing the same layer in the 1st layer, it returns to the 2nd layer, from the 1st layer to the 2nd layer, then to the 3rd layer and the 4th layer, and so on in a cycle to complete the winding of the first branch. The winding of the second branch is carried out in the same way; the windings are transposed by the innermost layer at the bottom of the slot and the outermost layer at the slot opening of the same layer of coils to achieve symmetry of the three-phase windings. In this embodiment, with the welding ends unchanged, a winding that is compatible with different branch schemes is achieved, and flexible conversion of different parallel branch numbers can be realized according to needs, while reducing the manufacturing difficulty.

[0094] Although the present invention has been disclosed above with preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make many possible changes and modifications to the technical solution of the present invention through the methods and technical content disclosed above, or modify it into equivalent embodiments with equivalent changes. Therefore, any simple modification, equivalent replacement, equivalent change and modification made to the above embodiments based on the technical essence of the present invention without departing from the technical solution of the present invention still fall within the scope of protection of the technical solution of the present invention.

Claims

1. A 48-slot flat wire stator winding, characterized in that, It includes three-phase phase windings. Each of the phase windings includes multiple groups of parallel winding branches. Each group of winding branches includes at least one branch. The branch includes multiple coils arranged in sequence and connected in series on the circumferential core slots (71) of the stator core (7). The branch includes single coils and coils with a span of y. The branch starts winding with a single coil at the innermost layer of the bottom of the core slot (71), winds the coil with a span of y from the second innermost layer of the bottom of the core slot (71) to the outermost layer of the slot opening, and performs in-layer commutation of the coil with a span of y at the outermost layer of the slot opening. Then, the coil with a span of y winds from the second outermost layer of the slot opening to the innermost layer of the bottom of the core slot, and performs in-layer commutation of the coil with a span of y at the innermost layer of the bottom of the core slot. This cycle is repeated to achieve branch symmetry. When the number of windings of the branch coils in the core slot (71) reaches 1 / 2 of the preset number, a coil with a span of y + 1 is used for in-layer commutation at the outermost layer of the slot opening or a single coil is used as the neutral point lead-out wire.

2. The 48-slot flat wire stator winding according to claim 1, wherein, The coil with a span of y includes a first coil (1). The first coil (1) performs in-layer commutation at the outermost layer of the slot opening. The first coil (1) includes a first coil body (11) and a first bending portion (12). The first coil body (11) includes two first struts (111) arranged in parallel and a first head (112) connecting one ends of the two first struts (111). The other ends of the two first struts (111) are provided with a first bending portion (12) to form a welding end. The first bending portion (12) bends along one side in the width direction of the first coil body (11).

3. The 48-slot flat wire stator winding according to claim 2, characterized in that, The coil with a span of y further includes a second coil (2). The second coil (2) winds from the second innermost layer of the bottom of the core slot to the second outermost layer of the slot opening. The second coil (2) includes a second coil body (21) and a second bending portion (22). The second coil body (21) includes two second struts (211) arranged in parallel and a second head (212) connecting one ends of the two second struts (211). The other ends of the two second struts (211) are provided with a second bending portion (22) to form a welding end. The second bending portion (22) bends along the width direction of the second coil body (21) and away from the second coil body (21).

4. The 48-slot flat wire stator winding according to claim 3, characterized in that, The coil with a span of y further includes a third coil (3). The third coil (3) performs in-layer commutation at the innermost layer of the bottom of the core slot. The third coil (3) includes a third coil body (31) and a third bending portion (32). The third coil body (31) includes two third struts (311) arranged in parallel and a third head (312) connecting one ends of the two third struts (311). The other ends of the two third struts (311) are provided with a third bending portion (32) to form a welding end. The third bending portion (32) bends along the width direction of the third coil body (31) and away from the third coil body (31). The bending direction of the third bending portion (32) is opposite to the bending direction of the first bending portion (12).

5. The 48-slot flat wire stator winding according to claim 4, characterized in that, The single coil includes a fifth coil (5), and the fifth coil (5) is arranged at the innermost layer of the slot bottom as the starting point of winding. The fifth coil (5) includes a fifth coil body (51) and a fifth bending part (52). The fifth coil body (51) includes a fifth rod (511), and both ends of the fifth rod (511) are respectively provided with a fifth head (512) and a fifth bending part (52). The fifth bending part (52) forms a welding end; the bending direction of the fifth head (512) is the same as that of the fifth bending part (52).

6. The 48-slot flat wire stator winding according to claim 5, wherein, The coil with a span of y + 1 includes a fourth coil (4), and the fourth coil (4) conducts commutation in the same layer at the innermost layer of the slot bottom. The fourth coil (4) includes a fourth coil body (41) and a fourth bending part (42). The fourth coil body (41) includes two fourth rods (411) arranged in parallel and a fourth head (412) connecting one end of the two fourth rods (411). The other ends of the two fourth rods (411) are provided with fourth bending parts (42) to form welding ends. The fourth bending part (42) bends along one side in the width direction of the fourth coil body (41); the bending direction of the third bending part (32) is the same as that of the fourth bending part (42).

7. The 48-slot flat wire stator winding according to claim 5, characterized in that, The single coil further includes a sixth coil (6), and the sixth coil (6) is arranged at the innermost layer of the slot bottom as the neutral point lead-out wire. The sixth coil (6) includes a sixth coil body (61) and a sixth bending part (62). The sixth coil body (61) includes a sixth rod (611), and both ends of the sixth rod (611) are respectively provided with a sixth head (612) and a sixth bending part (62). The sixth bending part (62) forms a welding end; the bending direction of the sixth head (612) is opposite to that of the sixth bending part (62).

8. The 48-slot flat wire stator winding according to any one of claims 1 to 7, characterized in that, The parallel form between each branch in each winding branch is star connection or delta connection.

9. The 48-slot flat wire stator winding according to claim 6, characterized in that, The phase winding includes a group of winding branches. One branch in the winding branch includes single coil A0, coils a1 - A2, a3 - A4, a5 - A6, a7 - A8, a9 - A10, a11 - A12, a13 - A14, a15 - A16, a17 - A18, a19 - A20, a21 - A22, a23 - A24, a25 - A26, a27 - A28, a29 - A30, a31 - A32, ……, a61 - A62, a63; The single coil A0 is located at the 4th layer along the slot bottom direction at the inner slot opening of the iron core slot (71); The spans of a1 - A2, a9 - A10, a17 - A18, and a25 - A26 are all y. Their upper sides are located at the 3rd layer of the iron core slot (71), and their lower sides are located at the 2nd layer of the iron core slot (71); The spans of a3 - A4, a11 - A12, a19 - A20, and a27 - A28 are all y. Their upper sides and lower sides are both located at the 1st layer of the iron core slot (71); The spans of a5 - A6, a13 - A14, a21 - A22, and a29 - A30 are all y. Their upper sides are located in the second layer of the iron core slot (71), and their lower sides are located in the third layer of the iron core slot (71). The spans of a7 - A8, a15 - A16, and a23 - A24 are all y. Their upper sides and lower sides are both located in the fourth layer of the iron core slot (71). The span of a31 - A32 is y + 1. Its upper side and lower side are both located in the fourth layer of the iron core slot (71). The spans of A33 - A34, a41 - A42, a49 - A50, and a57 - A58 are all y. Their upper sides are located in the third layer of the iron core slot (71), and their lower sides are located in the second layer of the iron core slot (71). The spans of A35 - A36, a43 - A44, a51 - A52, and a59 - A60 are all y. Their upper sides and lower sides are both located in the first layer of the iron core slot (71). The spans of A37 - A38, a45 - A46, a53 - A54, and a61 - A62 are all y. Their upper sides are located in the second layer of the iron core slot (71), and their lower sides are located in the third layer of the iron core slot (71). In the winding branch, coil A0 is connected to coil a1 - A2 by a twist weld, coil a1 - A2 is connected to coil a3 - A4 by a twist weld, coil a3 - A4 is connected to coil a5 - A6 by a twist weld, coil a5 - A6 is connected to coil a7 - A8 by a twist weld, and so on; the coil sequence goes from the fourth layer to the third layer, from the third layer to the second layer and then to the first layer, and after finishing the same layer in the first layer, it returns to the second layer, from the first layer to the second layer and then to the third layer, the fourth layer, and so on in a cycle to complete the winding of the winding branch; the winding is transposed by the innermost layer at the bottom of the slot and the outermost layer at the slot opening of the same - layer coils to achieve the symmetry of the three - phase winding.

10. The 48-slot flat wire stator winding according to claim 7, characterized in that, The phase winding includes a group of winding branches. One branch in the winding branch includes single - coil A0, coils a1 - A2, a3 - A4, a5 - A6, a7 - A8, a9 - A10, a11 - A12, a13 - A14, a15 - A16, a17 - A18, a19 - A20, a21 - A22, a23 - A24, a25 - A26, a27 - A28, a29 - A30, a31; the other branch includes single - coil B0, coils b1 - B2, b3 - B4, b5 - B6, b7 - B8, b9 - B10, b11 - B12, b13 - B14, b15 - B16, b17 - B18, b19 - B20, b21 - B22, b23 - B24, b25 - B26, b27 - B28, b29 - B30, b31. The two branches have the same winding method. Single - coil A0 and single - coil B0 are both located in the fourth layer along the bottom direction of the inner slot opening of the iron core slot (71) as the starting point of winding; single - coil a31 and single - coil b31 are both located in the fourth layer along the bottom direction of the inner slot opening of the iron core slot (71) as the neutral - point lead - out wire. The spans of a1-A2, a9-A10, a17-A18, a25-A26, b1-B2, b9-B10, b17-B18 and b25-B26 are all y. Their upper sides are located in the third layer of the iron core slot (71), and their lower sides are located in the second layer of the iron core slot (71); The spans of a3-A4, a11-A12, a19-A20, a27-A28, b3-B4, b11-B12, b19-B20 and b27-B28 are all y. Their upper sides and lower sides are both located in the first layer of the iron core slot (71); The spans of a5-A6, a13-A14, a21-A22, a29-A30, b5-B6, b13-B14, b21-B22 and b29-B30 are all y. Their upper sides are located in the second layer of the iron core slot (71), and their lower sides are located in the third layer of the iron core slot (71); The spans of a7-A8, a15-A16, a23-A24, b7-B8, b15-B16 and b23-B24 are all y. Their upper sides and lower sides are both located in the fourth layer of the iron core slot (71); In the first branch, the coil A0 is connected to the coil a1-A2 by a twist welding, the coil a1-A2 is connected to the coil a3-A4 by a twist welding, the coil a3-A4 is connected to the coil a5-A6 by a twist welding, the coil a5-A6 is connected to the coil a7-A8 by a twist welding, and so on; The coil sequence is from the fourth layer to the third layer, the third layer to the second layer and then to the first layer. After finishing the same layer in the first layer, it returns to the second layer, from the first layer to the second layer and then to the third layer and the fourth layer, and so on in a cycle to complete the winding of the first branch. The winding of the second branch is carried out in the same way; The windings are transposed by the same-layer coils at the innermost layer of the slot bottom and the outermost layer of the slot opening to achieve the symmetry of the three-phase windings.

11. A flat wire motor, characterized in that, It includes the 48-slot flat wire stator winding described in any one of claims 1 to 10.

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