Flat wire winding stator with centralized outgoing lines and flat wire motor

Abstract

The invention relates to a flat wire winding stator with centralized outgoing lines and a flat wire motor, the flat wire winding stator comprises a stator core, flat wire windings and copper bus bars, the flat wire windings are arranged in 2n layers along the radial direction of a stator groove, n is greater than or equal to 2 and is a natural number, the copper bus bars comprise a first copper bar and a second copper bar, the flat wire winding comprises a plurality of first leading-out wires, second leading-out wires, first-type flat wires and second-type flat wires; the first-type flat wires are located on the first layer, the second-type flat wires are located on the 2k-th layer, and one ends of the first-type flat wires are connected with the second-type flat wires; the first lead-out wires and the second lead-out wires are located on the 2n layer and the 2n-1 layer, the first lead-out wires and the second lead-out wires on the same layer are arranged alternately, the first lead-out wires on different layers are located in the same stator groove, the first lead-out wires are connected with the first copper bar, and the second lead-out wires are connected with the second copper bar. Compared with the prior art, the lead-out wires are arranged in a centralized mode, sufficient space is provided for installation of the copper bar, and the structure of the copper bar is optimized.

Description

Technical Field

[0001] The present invention relates to the technical field of motors, and in particular to a flat wire winding stator with centralized lead wires and a flat wire motor. Background Art

[0002] Conventional flat-wire motors require the required flat copper wire to be bent into U- and I-shaped configurations, known as Upin and Ipin wires. These wires are then inserted into the stator core from the hairpin ends. The flat copper wires are then connected at the stator core welding ends to ensure circuit continuity across all branches. Finally, a large number of three-phase copper busbars, neutral copper busbars, and bridge copper busbars are used to connect each branch to ensure safe motor operation.

[0003] However, the following problems or defects still exist: (1) The flat wire stator winding is composed of rectangular flat copper wires of various sizes and specifications. When the flat wire stator winding involves more types of wires, the process of inserting the flat copper wires into the stator becomes more complicated, and the risk of inserting the wrong wire type increases; (2) If the flat wire stator has Ipin wire types at both the slot and the slot bottom, it is necessary to consider the space for the flat copper wires at the slot position and the flat copper wires at the slot bottom position at the same time, which makes the copper busbar design difficult.

[0004] Chinese patent CN114400812A discloses a winding structure for a flat wire motor, which includes a stator core, several special-shaped flat wires I, three-phase lead wires, a neutral point connection copper busbar, several special-shaped flat wires II, and several special-shaped flat wires III; wherein the special-shaped flat wires I, II, and III are respectively assembled in the stator core, and form a hairpin end on one side of the stator core and a welding end on the other side; the special-shaped flat wire II adopts an integrated structure, which can be connected across phases; the three-phase lead wires are welded to a portion of the special-shaped flat wires III at the hairpin end; and the neutral point connection copper busbar is welded to another portion of the special-shaped flat wires III at the hairpin end.

[0005] However, the flat-wire motor stator in the aforementioned prior art requires multiple, heterogeneous busbars to connect to the stator windings. A large number of these busbars significantly increases procurement costs, diminishing the performance advantages of the flat-wire stator and even making mass production difficult. Furthermore, some flat copper wires require specialized three-dimensional structures, which can cause them to occupy the inner diameter of the stator core. This forces the rotor to be assembled in only one direction, limiting the flexibility of flat-wire stators. Summary of the Invention

[0006] The purpose of the present invention is to overcome the defects of the prior art that the lead wires of the flat wire winding are relatively scattered, the installation space of the busbar is small, and the installation of the busbar is inconvenient, and to provide a flat wire winding stator and a flat wire motor with centralized lead wires.

[0007] The purpose of the present invention can be achieved by the following technical solutions:

[0008] This solution provides a flat wire winding stator with centralized lead wires, comprising a stator core, a flat wire winding, and a busbar. The stator core is provided with a plurality of stator slots. The flat wire winding is provided with 2n layers radially along the stator slots, where n ≥ 2 and n is a natural number. The busbar comprises a first copper bar and a second copper bar. The flat wire winding comprises a plurality of first lead wires, a second lead wire, a first type of flat wire, and a second type of flat wire.

[0009] The first type of flat wire is located in the first layer, the second type of flat wire is located in the 2k layer, and one end of the first type of flat wire located at the hairpin end of the stator core is bent toward the second type of flat wire and connected to the second type of flat wire;

[0010] The first lead wire and the second lead wire are located at the 2nth layer and the 2n-1th layer, the first lead wire and the second lead wire located at the same layer are arranged alternately, the first lead wires located at different layers are located in the same stator slot, one end of the first lead wire located at the hairpin end of the stator core is connected to the first copper bar, and one end of the second lead wire located at the hairpin end of the stator core is connected to the second copper bar.

[0011] Furthermore, the second copper bar includes a first neutral copper bar and a second neutral copper bar, the first neutral copper bar is connected to the second lead wire located at the 2nth layer, and the second neutral copper bar is connected to the second lead wire located at the 2n-1th layer.

[0012] Furthermore, the first lead wire and the second lead wire are deflected in the same direction and at the same angle.

[0013] Furthermore, the flat wire winding further comprises a plurality of first U-shaped flat wires with a span of 5, a second U-shaped flat wire with a span of 7, and a third U-shaped flat wire with a span of 6;

[0014] One end of the first U-shaped flat wire and the second U-shaped flat wire are located at the 2k-1 layer, and the other end is located at the 2k layer. The first U-shaped flat wire and the second U-shaped flat wire are alternately and cross-distributed. The second U-shaped flat wire is located on the first U-shaped flat wire. One end of the third U-shaped flat wire is located at the 2k layer, and the other end is located at the 2k+1 layer. k≥1 and k≤n, and k is a natural number.

[0015] Furthermore, two ends of the third U-shaped flat wire are respectively arranged in adjacent stator slots.

[0016] Furthermore, one end of the first U-shaped flat wire and the third U-shaped flat wire located at the hairpin end of the stator core has a pointed top structure, and one end of the second U-shaped flat wire located at the hairpin end of the stator core has a flat top structure.

[0017] Furthermore, the flat wire winding passes through the stator slots and is led out from the welding end of the stator core. The 2k-1 layer of flat wire led out from the welding end of the flat wire winding is deflected in the first direction by a first angle, and the 2k layer of flat wire led out from the welding end of the flat wire winding is deflected in the second direction by a second angle, and the first direction is opposite to the second direction.

[0018] Furthermore, the first direction is a counterclockwise direction facing the welding end of the stator core, and the second direction is a clockwise direction facing the welding end of the stator core.

[0019] Furthermore, the sum of the first angle and the second angle is in the range of 40-50°.

[0020] This solution also provides a flat wire motor, including the above-mentioned flat wire winding stator with centralized lead wires.

[0021] Compared with the prior art, the present invention has the following advantages:

[0022] (1) This solution deflects the first type of flat wire located on the 1st layer toward the second type of flat wire located on the 2nth layer, and connects the two, so that the flat wires that previously served as the current input and output ends of each branch are closed; the first lead wire and the second lead wire are arranged on the 2nth and 2n-1th layers, away from the central axis of the stator core, and the first lead wires of each branch of the same phase are arranged adjacent to each other, connected in parallel through the first copper busbar, and the second lead wires of each phase are connected in series through the second copper busbar, thereby realizing the arrangement of the flat wire winding.

[0023] Through the first lead-out wire and the second lead-out wire, the current output ends and output ends of the existing relatively dispersed branches are transferred to two layers of centralized lead-out away from the center of the stator core, thereby increasing the space for copper bus bar wiring and achieving connection with a copper bus bar with a simple structure; the structure of the bus bar is simplified, the difficulty of bus bar design is reduced, and the use of flat wires with anisotropic structures is avoided. The first lead-out wire and the second lead-out wire have a simple structure and are easy to manufacture, and the connection between the bus bar and the flat wire winding is achieved by avoiding radial deflection of the flat wire, which will not interfere with the inner diameter of the stator core and improve the flexibility of the flat wire stator application.

[0024] (2) For the distributed lead wires, using a single busbar to connect them will waste copper and increase costs. In this solution, the second lead wires, i.e., the current lead terminals of each branch, are located on two layers. Two copper buses are used to connect the second lead wires of the two layers in parallel, which reduces the use of unnecessary copper busbars, reduces copper busbar waste, and does not affect the current of each branch, effectively reducing manufacturing costs.

[0025] (3) Existing flat wire windings have a variety of flat wire specifications. The process of inserting the flat wire into the stator slot is relatively complicated, increasing the risk of linear insertion errors. The multiple wire types also increase the cost of flat wire forming. In this solution, only three U-shaped flat wires with different spans are used. The first and second U-shaped flat wires are alternately inserted into the stator slots at a time, and the third U-shaped flat wires are arranged adjacent to each other. This provides a stronger regularity, makes wire insertion more convenient, and reduces the risk of wire insertion errors. In addition, the reduction in flat wire specifications reduces the need for customization of flat wire forming molds, thereby reducing the production cost of flat wires. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 A schematic structural diagram of the flat wire winding stator provided by the present invention;

[0027] Figure 2 A cross-sectional view of a flat wire winding stator provided by the present invention;

[0028] Figure 3 A schematic structural diagram of the flat wire winding stator welding end provided by the present invention;

[0029] Figure 4 A schematic structural diagram of the card issuing terminal provided by the present invention;

[0030] Figure 5 for Figure 4 A magnified view of the local structure at point A;

[0031] Figure 6 A schematic structural diagram of a flat wire provided by the present invention with its two ends located at the first layer and the second layer respectively;

[0032] Figure 7 A schematic structural diagram of a flat wire provided by the present invention with its two ends located at the second layer and the third layer respectively;

[0033] Figure 8 A schematic structural diagram of a flat wire provided by the present invention with its two ends located at the third layer and the fourth layer respectively;

[0034] Figure 9 A schematic structural diagram of a flat wire provided by the present invention with its two ends located at the 4th layer and the 5th layer respectively;

[0035] Figure 10 A schematic structural diagram of a flat wire provided by the present invention with its two ends located at the 5th and 6th layers respectively;

[0036] Figure 11 A schematic structural diagram of a flat wire provided by the present invention with its two ends located at the 6th and 7th layers respectively;

[0037] Figure 12 A schematic structural diagram of a flat wire provided by the present invention with its two ends located at the 7th and 8th layers respectively;

[0038] Figure 13 A schematic diagram of the connection structure of the first type of flat wire and the second type of flat wire provided by the present invention;

[0039] Figure 14 A schematic structural diagram of the first lead wire and the second lead wire provided by the present invention;

[0040] Figure: 1. Stator core, 2. Flat wire winding, 3. Busbar, 11. Stator slot, 12. Welding end, 13. Hairpin end, 21. First lead wire, 22. Second lead wire, 23. First type flat wire, 24. Second type flat wire, 31. First copper bar, 32. Second copper bar, 33. First neutral copper bar, 34. Second neutral copper bar, 201. Upin-1-2-7 flat copper wire, 202. Upin-1-2-5 flat copper wire, 203. Upin-2-3-6 flat copper wire, 204. Upin-3-4-7 flat copper wire, 205. Upin-3-4-5 flat copper wire , 206, Upin-4-5-6 flat copper wire, 207, Upin-5-6-7 flat copper wire, 208, Upin-5-6-5 flat copper wire, 209, Upin-6-7-6 flat copper wire, 210, Upin-7-8-7 flat copper wire, 211, Upin-7-8-5 flat copper wire, 212, Ipin-1-1 flat copper wire, 213, Ipin-8-1 flat copper wire, 214, Ipin-7-1 flat copper wire, 215, Ipin-8-2; 301, W-phase terminal, 302, V-terminal, 303, U-phase terminal, 304, neutral copper busbar. DETAILED DESCRIPTION

[0041] To make the objectives, technical solutions, and advantages of the embodiments of the present invention more clear, the technical solutions of the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Generally, the components of the embodiments of the present invention described and shown in the drawings herein can be arranged and designed in various different configurations.

[0042] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the invention as claimed, but rather merely represents selected embodiments of the present invention. All other embodiments derived by persons of ordinary skill in the art based on the embodiments of the present invention without creative effort shall fall within the scope of protection of the present invention.

[0043] It should be noted that similar reference numerals and letters denote similar items in the following drawings, and therefore, once an item is defined in one drawing, it does not need to be further defined or explained in subsequent drawings.

[0044] In the description of the present invention, it should be noted that the terms "center", "up", "down", "left", "right", "vertical", "horizontal", "inside", "outside", etc., indicating the orientation or position relationship, are based on the orientation or position relationship shown in the accompanying drawings, or are the orientation or position relationship in which the product of the invention is usually placed when in use. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation. Therefore, they should not be understood as limiting the present invention.

[0045] It should be noted that the terms "first" and "second" are used for descriptive purposes only and should not be understood to indicate or imply relative importance or implicitly specify the number of the technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of the features. In the description of this application, "plurality" means two or more, unless otherwise specifically defined.

[0046] Furthermore, terms such as "horizontal" and "vertical" do not necessarily mean that a component must be absolutely horizontal or overhanging, but rather that it can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal than "vertical," and does not mean that the structure must be completely horizontal, but rather that it can be slightly tilted.

[0047] Example 1

[0048] like Figure 1 and Figure 2 As shown, this embodiment provides a flat wire winding stator with centralized lead wires, including a stator core 1, a flat wire winding 2, and a bus bar 3. The stator core 1 is provided with a plurality of stator slots 11. The flat wire winding 2 is radially arranged in 2n layers along the stator slots 11, where n ≥ 2 and n is a natural number. The bus bar 3 includes a first copper bar 31 and a second copper bar 32. The flat wire winding 2 includes a plurality of first lead wires 21, a second lead wire 22, a first type of flat wire 23, and a second type of flat wire 24.

[0049] The first type flat wire 23 is located in the 1st layer, and the second type flat wire 24 is located in the 2kth layer. One end of the first type flat wire 23 located at the hairpin end of the stator core 1 is bent toward the second type flat wire 24 and connected to the second type flat wire 24.

[0050] The first lead wire 21 and the second lead wire 22 are located on the 2nth layer and the 2n-1th layer. The first lead wire 21 and the second lead wire 22 located on the same layer are arranged alternately. The first lead wire 21 located on different layers is located in the same stator slot 11. The end of the first lead wire 21 located at the hairpin end of the stator core 1 is connected to the first copper bus 31, and the end of the second lead wire 22 located at the hairpin end of the stator core 1 is connected to the second copper bus 32.

[0051] This solution deflects the first type of flat wire 23 located on the 1st layer toward the second type of flat wire 24 located on the 2nth layer, and connects the two, so that the flat wires previously serving as the current input and current output ends of each branch are closed; the first lead wire 21 and the second lead wire 22 are arranged on the 2nth and 2n-1th layers, away from the central axis of the stator core 1, and the first lead wires 21 of each branch of the same phase are arranged adjacent to each other and connected in parallel through the first copper busbar 31, and the second lead wires 22 of each phase are connected in series through the second copper busbar 32 to realize the arrangement of the flat wire winding.

[0052] Through the first lead-out wire 21 and the second lead-out wire 22, the current output ends and output ends of the existing relatively scattered branches are transferred to two layers of centralized lead-out away from the center of the stator core 1, and the connection can be achieved with a copper bus with a simple structure; the structure of the bus bar is simplified, the difficulty of designing the bus bar 3 is reduced, and the use of flat wires with anisotropic structures is avoided. The first lead-out wire 21 and the second lead-out wire have a simple structure and are easy to manufacture, and the connection between the bus bar 3 and the flat wire winding 2 is achieved by avoiding radial deflection of the flat wire, which will not interfere with the inner diameter of the stator core 1, thereby improving the flexibility of the flat wire stator application.

[0053] As a preferred embodiment, the second copper bar 32 includes a first neutral copper bar 33 and a second neutral copper bar 34. The first neutral copper bar 33 is connected to the second lead wire 22 located on the 2nth layer, and the second neutral copper bar 34 is connected to the second lead wire 22 located on the 2n-1th layer.

[0054] By optimizing the lead-out structure, all three-phase branch current input wires are gathered in one place, thus achieving three-phase connection of the three-phase flat wire winding with a simple terminal structure. Furthermore, since the current output wires of each branch are distributed on the two outer layers, the neutral copper busbar is split into two equal-sized ones to reduce copper busbar consumption, thereby reducing costs.

[0055] Furthermore, the first lead wire 21 and the second lead wire 22 are deflected in the same direction and at the same angle. Deflecting the branches of the same phase located on different layers in the same direction, and arranging the first lead wires 21 located on different layers in the same stator slot 11 adjacent to each other, can simplify the structure of the first copper busbar 31 and facilitate the connection between the first copper busbar 31 and the first lead wire 21.

[0056] As another preferred embodiment, the flat wire winding 2 further includes a plurality of first U-shaped flat wires with a span of 5, a second U-shaped flat wire with a span of 7, and a third U-shaped flat wire with a span of 6;

[0057] One end of the first U-shaped flat wire and the second U-shaped flat wire are located at the 2k-1 layer, and the other end is located at the 2k layer. The first U-shaped flat wire and the second U-shaped flat wire are alternately and cross-distributed. The second U-shaped flat wire is located on the first U-shaped flat wire. One end of the third U-shaped flat wire is located at the 2k layer, and the other end is located at the 2k+1 layer. k≥1 and k≤n, where k is a natural number.

[0058] Only three types of U-shaped flat wires with different spans are used. The first and second U-shaped flat wires are alternately and cross-inserted into the stator slots, and the third U-shaped flat wires are distributed adjacently. This provides a stronger regularity and makes insertion more convenient, reducing the risk of insertion errors. In addition, the reduction in flat wire specifications reduces the need for customization of flat wire forming molds and reduces the production cost of the flat wires.

[0059] Both ends of the third U-shaped rectangular wire are respectively arranged in adjacent stator slots 11 .

[0060] Specifically, the ends of the first and third U-shaped flat wires located at the hairpin end of the stator core 1 have pointed top structures, and the end of the second U-shaped flat wire located at the hairpin end of the stator core 1 has a flat top structure.

[0061] The flat wire winding 2 passes through the stator slots 11 and is led out from the welding end of the stator core 1. The 2k-1 layer of flat wires of the flat wire winding 2 led out from the welding end is deflected in a first direction by a first angle. The 2k layer of flat wires of the flat wire winding 2 led out from the welding end is deflected in a second direction by a second angle. The first direction is opposite to the second direction.

[0062] The first direction is the counterclockwise direction facing the welding end of the stator core 1, and the second direction is the clockwise direction facing the welding end of the stator core 1. The sum of the first angle and the second angle is in the range of 40-50 degrees.

[0063] In combination with the above preferred embodiments, this embodiment also provides a more specific wiring structure of a flat wire winding stator with centralized lead wires: Figure 1 As shown, a flat wire motor stator includes a stator core 1, a flat wire winding 2, and a busbar 3.

[0064] In this embodiment, the stator core 1 has 48 slots (S), with the stator slots 11 increasing in number counterclockwise from the weld end. The number of poles (Q) is 8. The flat wire winding 2 comprises 2N (8) layers. The first and second angles of twist at the weld end are both 22.5°. The flat wire winding 2 has four branches. The three-phase U, V, and W windings consist of 3*(N-1)+2 sizes of Upin wire and 4 types of Ipin wire.

[0065] like Figure 2 、 3As shown in FIG4 and FIG5 , the flat wire winding 2 is composed of a number of Upin-1-2-7 flat copper wires 201, Upin-1-2-5 flat copper wires 202, Upin-2-3-6 flat copper wires 203, Upin-3-4-7 flat copper wires 204, Upin-3-4-5 flat copper wires 205, Upin-4-5-6 flat copper wires 206, Upin-5-6-7 flat copper wires 207, Upin-5-6-5 flat copper wires 208, U The pin-6-7-6 flat copper wire 209, Upin-7-8-7 flat copper wire 210, Upin-7-8-5 flat copper wire 211, Ipin-1-1 flat copper wire 213, Ipin-8-1 flat copper wire 213, Ipin-7-1 flat copper wire 214, and Ipin-8-2 flat copper wire 215 are collectively composed; the busbar 3 is composed of a W-phase terminal 301, a V-direction terminal 302, a U-phase terminal 303, and a neutral copper bar 304.

[0066] like Figure 6 As shown, 18 Upin-1-2-5 flat copper wires are used, and the two ends of the flat copper wires are respectively inserted into the L1 layer S3 core slot and the L2 layer S46 core slot, the L1 layer S1 core slot and the L2 layer S44 core slot, the L1 layer S47 core slot and the L2 layer S42 core slot, the L1 layer S45 core slot and the L2 layer S40 core slot, the L1 layer S43 core slot and the L2 layer S38 core slot, the L1 layer S41 core slot and the L2 layer S36 core slot, the L1 layer S39 core slot and the L2 layer S34 core slot, the L1 layer S37 core slot and the L2 layer S32 core slot, and the L1 The L1 layer S35 core slot and the L2 layer S30 core slot, the L1 layer S33 core slot and the L2 layer S28 core slot, the L1 layer S31 core slot and the L2 layer S26 core slot, the L1 layer S29 core slot and the L2 layer S24 core slot, the L1 layer S27 core slot and the L2 layer S22 core slot, the L1 layer S25 core slot and the L2 layer S20 core slot, the L1 layer S23 core slot and the L2 layer S18 core slot, the L1 layer S21 core slot and the L2 layer S16 core slot, the L1 layer S19 core slot and the L2 layer S14 core slot, the L1 layer S17 core slot and the L2 layer S12 core slot.

[0067] At the same time, use 18 Upin-1-2-7 flat copper wires and insert the two ends of the flat copper wire into the stator core L1 layer S4 core slot and L2 layer S45 core slot, L1 layer S2 core slot and L2 layer S43 core slot, L1 layer S48 core slot and L2 layer S41 core slot, L1 layer S46 core slot and L2 layer S39 core slot, L1 layer S44 core slot and L2 layer S37 core slot, L1 layer S42 core slot and L2 layer S35 core slot, L1 layer S40 core slot and L2 layer S33 core slot, L1 layer S38 core slot and L2 layer S31 core slot, L1 The L1 layer S36 core slot and the L2 layer S29 core slot, the L1 layer S34 core slot and the L2 layer S27 core slot, the L1 layer S32 core slot and the L2 layer S25 core slot, the L1 layer S30 core slot and the L2 layer S23 core slot, the L1 layer S28 core slot and the L2 layer S21 core slot, the L1 layer S26 core slot and the L2 layer S19 core slot, the L1 layer S24 core slot and the L2 layer S17 core slot, the L1 layer S22 core slot and the L2 layer S15 core slot, the L1 layer S20 core slot and the L2 layer S13 core slot, the L1 layer S18 core slot and the L2 layer S11 core slot.

[0068] The 18 Upin-1-2-7 flat copper wires are respectively pressed on the 18 Upin-1-2-5 flat copper wires in the axial direction of the stator.

[0069] like Figure 7 As shown, 12 Upin-2-3-6 flat copper wires are used, and the two ends of the flat copper wires are respectively inserted into the stator core L2 layer S10 core slot and L3 layer S16 core slot, L2 layer S9 core slot and L3 layer S15 core slot, L2 layer S8 core slot and L3 layer S14 core slot, L2 layer S7 core slot and L3 layer S13 core slot, L2 layer S6 core slot and L3 layer S12 core slot. slot, L2 layer S5 core slot and L3 layer S11 core slot, L2 layer S4 core slot and L3 layer S10 core slot, L2 layer S3 core slot and L3 layer S9 core slot, L2 layer S2 core slot and L3 layer S8 core slot, L2 layer S1 core slot and L3 layer S7 core slot, L2 layer S48 core slot and L3 layer S6 core slot, L2 layer S47 core slot and L3 layer S5 core slot.

[0070] At this point, the stator winding L2 layer is fully inserted.

[0071] like Figure 8As shown, 18 Upin-3-4-5 flat copper wires are used, and the two ends of the flat copper wires are respectively inserted into the L3 layer S3 core slot and the L4 layer S46 core slot, the L3 layer S1 core slot and the L4 layer S44 core slot, the L3 layer S47 core slot and the L4 layer S42 core slot, the L3 layer S45 core slot and the L4 layer S40 core slot, the L3 layer S43 core slot and the L4 layer S38 core slot, the L3 layer S41 core slot and the L4 layer S36 core slot, the L3 layer S39 core slot and the L4 layer S34 core slot, the L3 layer S37 core slot and the L4 layer S32 core slot, and the L3 The L3 layer S35 core slot and the L4 layer S30 core slot, the L3 layer S33 core slot and the L4 layer S28 core slot, the L3 layer S31 core slot and the L4 layer S26 core slot, the L3 layer S29 core slot and the L4 layer S24 core slot, the L3 layer S27 core slot and the L4 layer S22 core slot, the L3 layer S25 core slot and the L4 layer S20 core slot, the L3 layer S23 core slot and the L4 layer S18 core slot, the L3 layer S21 core slot and the L4 layer S16 core slot, the L3 layer S19 core slot and the L4 layer S14 core slot, and the L3 layer S17 core slot and the L4 layer S12 core slot.

[0072] At the same time, use 18 Upin-3-4-7 flat copper wires and insert the two ends of the flat copper wire into the stator core's L3 layer S4 core slot and L4 layer S45 core slot, L3 layer S2 core slot and L4 layer S43 core slot, L3 layer S48 core slot and L4 layer S41 core slot, L3 layer S46 core slot and L4 layer S39 core slot, L3 layer S44 core slot and L4 layer S37 core slot, L3 layer S42 core slot and L4 layer S35 core slot, L3 layer S40 core slot and L4 layer S33 core slot, L3 layer S38 core slot and L4 layer S31 core slot, L3 The L3 layer S36 core slot and the L4 layer S29 core slot, the L3 layer S34 core slot and the L4 layer S27 core slot, the L3 layer S32 core slot and the L4 layer S25 core slot, the L3 layer S30 core slot and the L4 layer S23 core slot, the L3 layer S28 core slot and the L4 layer S21 core slot, the L3 layer S26 core slot and the L4 layer S19 core slot, the L3 layer S24 core slot and the L4 layer S17 core slot, the L3 layer S22 core slot and the L4 layer S15 core slot, the L3 layer S20 core slot and the L4 layer S13 core slot, and the L3 layer S18 core slot and the L4 layer S11 core slot.

[0073] The 18 Upin-3-4-7 flat copper wires are respectively pressed on the 18 Upin-3-4-5 flat copper wires in the axial direction of the stator.

[0074] At this point, the stator winding L3 layer is fully inserted.

[0075] like Figure 9As shown, 12 Upin-4-5-6 flat copper wires are used, and the two ends of the flat copper wires are respectively inserted into the stator core L4 layer S10 core slot and L5 layer S16 core slot, L4 layer S9 core slot and L5 layer S15 core slot, L4 layer S8 core slot and L5 layer S14 core slot, L4 layer S7 core slot and L5 layer S13 core slot, L4 layer S6 core slot and L5 layer S12 core slot. slots, L4 layer S5 core slots and L5 layer S11 core slots, L4 layer S4 core slots and L5 layer S10 core slots, L4 layer S3 core slots and L5 layer S9 core slots, L4 layer S2 core slots and L5 layer S8 core slots, L4 layer S1 core slots and L5 layer S7 core slots, L4 layer S48 core slots and L5 layer S6 core slots, L4 layer S47 core slots and L5 layer S5 core slots.

[0076] At this point, the stator winding L4 layer is fully inserted.

[0077] like Figure 10 As shown, 18 Upin-5-6-5 flat copper wires are used, and the two ends of the flat copper wires are respectively inserted into the L5 layer S3 core slot and the L6 layer S46 core slot, the L5 layer S1 core slot and the L6 layer S44 core slot, the L5 layer S47 core slot and the L6 layer S42 core slot, the L5 layer S45 core slot and the L6 layer S40 core slot, the L5 layer S43 core slot and the L6 layer S38 core slot, the L5 layer S41 core slot and the L6 layer S36 core slot, the L5 layer S39 core slot and the L6 layer S34 core slot, the L5 layer S37 core slot and the L6 layer S32 core slot, and the L5 layer S38 core slot. The L5 layer S35 core slot and the L6 layer S30 core slot, the L5 layer S33 core slot and the L6 layer S28 core slot, the L5 layer S31 core slot and the L6 layer S26 core slot, the L5 layer S29 core slot and the L6 layer S24 core slot, the L5 layer S27 core slot and the L6 layer S22 core slot, the L5 layer S25 core slot and the L6 layer S20 core slot, the L5 layer S23 core slot and the L6 layer S18 core slot, the L5 layer S21 core slot and the L6 layer S16 core slot, the L5 layer S19 core slot and the L6 layer S14 core slot, the L5 layer S17 core slot and the L6 layer S12 core slot.

[0078] At the same time, use 18 Upin-5-6-7 flat copper wires and insert the two ends of the flat copper wire into the stator core L5 layer S4 core slot and L6 layer S45 core slot, L5 layer S2 core slot and L6 layer S43 core slot, L5 layer S48 core slot and L6 layer S41 core slot, L5 layer S46 core slot and L6 layer S39 core slot, L5 layer S44 core slot and L6 layer S37 core slot, L5 layer S42 core slot and L6 layer S35 core slot, L5 layer S40 core slot and L6 layer S33 core slot, L5 layer S38 core slot and L6 layer S31 core slot, L5 The L5 layer S36 core slot and the L6 layer S29 core slot, the L5 layer S34 core slot and the L6 layer S27 core slot, the L5 layer S32 core slot and the L6 layer S25 core slot, the L5 layer S30 core slot and the L6 layer S23 core slot, the L5 layer S28 core slot and the L6 layer S21 core slot, the L5 layer S26 core slot and the L6 layer S19 core slot, the L5 layer S24 core slot and the L6 layer S17 core slot, the L5 layer S22 core slot and the L6 layer S15 core slot, the L5 layer S20 core slot and the L6 layer S13 core slot, the L5 layer S18 core slot and the L6 layer S11 core slot.

[0079] The 18 Upin-5-6-7 flat copper wires are respectively pressed on the 18 Upin-5-6-5 flat copper wires in the axial direction of the stator.

[0080] At this point, the stator winding L5 layer is fully inserted.

[0081] like Figure 11 As shown, 12 Upin-6-7-6 flat copper wires are used, and the two ends of the flat copper wires are respectively inserted into the stator core L6 layer S10 core slot and L7 layer S16 core slot, L6 layer S9 core slot and L7 layer S15 core slot, L6 layer S8 core slot and L7 layer S14 core slot, L6 layer S7 core slot and L7 layer S13 core slot, L6 layer S6 core slot and L7 layer S12 core slot. slots, L6 layer S5 core slots and L7 layer S11 core slots, L6 layer S4 core slots and L7 layer S10 core slots, L6 layer S3 core slots and L7 layer S9 core slots, L6 layer S2 core slots and L7 layer S8 core slots, L6 layer S1 core slots and L7 layer S7 core slots, L6 layer S48 core slots and L7 layer S6 core slots, L6 layer S47 core slots and L7 layer S5 core slots.

[0082] At this point, the stator winding L6 layer is fully inserted.

[0083] like Figure 12As shown, 18 Upin-7-8-5 flat copper wires are used, and the two ends of the flat copper wires are respectively inserted into the stator core L7 layer S3 core slot and L8 layer S46 core slot, L7 layer S1 core slot and L8 layer S44 core slot, L7 layer S47 core slot and L8 layer S42 core slot, L7 layer S45 core slot and L8 layer S40 core slot, L7 layer S43 core slot and L8 layer S38 core slot, L7 The core slots of layer S41 and layer S36, the core slots of layer S37 and layer S32, the core slots of layer S27 and layer S22, the core slots of layer S23 and layer S18, the core slots of layer S21 and layer S16, the core slots of layer S19 and layer S14, and the core slots of layer S17 and layer S12.

[0084] At the same time, use 18 Upin-7-8-7 flat copper wires and insert the two ends of the flat copper wire into the stator core L7 layer S4 core slot and L8 layer S45 core slot, L7 layer S2 core slot and L8 layer S43 core slot, L7 layer S48 core slot and L8 layer S41 core slot, L7 layer S46 core slot and L8 layer S39 core slot, L7 layer S44 core slot and L8 layer S37 core slot, L7 layer S42 core slot and L8 core slot. The L7 layer S35 core slot, the L7 layer S38 core slot and the L8 layer S31 core slot, the L7 layer S30 core slot and the L8 layer S23 core slot, the L7 layer S28 core slot and the L8 layer S21 core slot, the L7 layer S24 core slot and the L8 layer S17 core slot, the L7 layer S22 core slot and the L8 layer S15 core slot, the L7 layer S20 core slot and the L8 layer S13 core slot, the L7 layer S18 core slot and the L8 layer S11 core slot.

[0085] The 18 Upin-7-8-7 flat copper wires are respectively pressed on the 18 Upin-7-8-5 flat copper wires in the stator axial direction.

[0086] like Figure 13 As shown, 12 Ipin-1-1 flat copper wires are used, and both ends of the flat copper wires are respectively inserted into the L1 layer S16 core slot, L1 layer S15 core slot, L1 layer S14 core slot, L1 layer S13 core slot, L1 layer S12 core slot, L1 layer S11 core slot, L1 layer S10 core slot, L1 layer S9 core slot, L1 layer S8 core slot, L1 layer S7 core slot, L1 layer S6 core slot, and L1 layer S5 core slot of the stator core.

[0087] At this point, the first L6 layers of the stator winding are fully inserted.

[0088] Use 12 Ipin-8-1 flat copper wires and insert both ends of the flat copper wires into the L8 layer S10 core slot, L8 layer S9 core slot, L8 layer S8 core slot, L8 layer S7 core slot, L8 layer S6 core slot, L8 layer S5 core slot, L8 layer S4 core slot, L8 layer S3 core slot, L8 layer S2 core slot, L8 layer S1 core slot, L8 layer S48 core slot, and L8 layer S47 core slot of the stator core.

[0089] like Figure 14 As shown, 12 Ipin-7-1 flat copper wires are used, and both ends of the flat copper wires are respectively inserted into the L7 layer S40 core slot, L7 layer S39 core slot, L7 layer S36 core slot, L7 layer S35 core slot, L7 layer S34 core slot, L7 layer S33 core slot, L7 layer S32 core slot, L7 layer S31 core slot, L7 layer S30 core slot, L7 layer S29 core slot, L7 layer S26 core slot, and L7 layer S25 core slot of the stator core.

[0090] At this point, the stator winding L7 layer is fully inserted.

[0091] Use 12 Ipin-8-2 flat copper wires and insert both ends of the flat copper wires into the L8 layer S34 core slot, L8 layer S33 core slot, L8 layer S30 core slot, L8 layer S29 core slot, L8 layer S28 core slot, L8 layer S27 core slot, L8 layer S26 core slot, L8 layer S25 core slot, L8 layer S24 core slot, L8 layer S23 core slot, L8 layer S20 core slot, and L8 layer S19 core slot of the stator core.

[0092] At this point, the stator winding L8 layer is fully inserted.

[0093] The flat copper wires for the L2, L4, L6, and 8 layers, extending from the stator core weld ends, are twisted 22.5° in the direction of decreasing stator core slot numbers. The flat copper wires for the L1, L3, L5, and L7 layers, extending from the stator core weld ends, are twisted 22.5° in the direction of increasing stator core slot numbers. By connecting these twisted flat copper wires, electrical connections are established between the L1 and L2 layers, the L3 and L4 layers, the L5 and L6 layers, and the L7 and L8 layers.

[0094] The original winding arrangement, which routed the wires from the slot opening L1 and slot bottom L8, has been changed to route the wires from the slot bottom L7 and L8, increasing the space available for the copper busbars. This eliminates the need to force the copper busbars into the narrow gap between L1 and L8, or to create special shapes for the Ipin wires to accommodate them.

[0095] The flat copper wires Upin-1-2-7, Upin-3-4-7, Upin-5-6-7, and Upin-7-8-7 have the same spatial arrangement sequence; Upin-1-2-5, Upin-3-4-5, Upin-5-6-5, and Upin-7-8-5 have the same spatial arrangement sequence; Upin-2-3-6, Upin-4-5-6, and Upin-6-7-6 have the same spatial arrangement sequence; and the Ipin-1-1, Ipin-7-1, Ipin-8-1, and Ipin-8-2 flat copper wires are arranged in an overlapping pattern, facilitating wire insertion. This regular pattern simplifies the wire insertion process for the flat wire motor stator and reduces the risk of operational errors.

[0096] It is easy to imagine that the above-mentioned wire insertion method for the stator core with 48 slots and 4 branches can be achieved by reducing the number of layers or changing the number of adjacent first lead wires 21 for 48 slots, 2 branches or 6 branches, 54 slots, 2 branches or 6 branches, 72 slots, 2 branches, 4 branches or 6 branches.

[0097] This embodiment further provides a flat wire motor, including the above-mentioned flat wire winding stator with concentrated lead wires.

[0098] The above describes in detail the preferred embodiments of the present invention. It should be understood that those skilled in the art can make numerous modifications and variations based on the concepts of the present invention without inventive effort. Therefore, any technical solutions that can be derived by those skilled in the art through logical analysis, reasoning, or limited experimentation based on the concepts of the present invention and the prior art should be within the scope of protection defined by the claims.

Claims

1. A flat wire winding stator with concentrated lead wires, comprising a stator core (1), a flat wire winding (2) and a busbar (3), wherein the stator core (1) is provided with a plurality of stator slots (11), and is characterized in that: The flat wire winding (2) is provided with 2n layers radially along the stator slot (11), where n≥2 and n is a natural number; the busbar (3) comprises a first copper bar (31) and a second copper bar (32); and the flat wire winding (2) comprises a plurality of first lead wires (21), second lead wires (22), first-type flat wires (23), and second-type flat wires (24); The first type of flat wire (23) is located in the first layer, the second type of flat wire (24) is located in the 2kth layer, and one end of the first type of flat wire (23) located at the hairpin end of the stator core (1) is bent toward the second type of flat wire (24) and connected to the second type of flat wire (24); The first lead wire (21) and the second lead wire (22) are located at the 2nth layer and the 2n-1th layer, the first lead wire (21) and the second lead wire (22) located at the same layer are arranged alternately, the first lead wires (21) located at different layers are located in the same stator slot (11), one end of the first lead wire (21) located at the hairpin end of the stator core (1) is connected to the first copper bar (31), and one end of the second lead wire (22) located at the hairpin end of the stator core (1) is connected to the second copper bar (32).

2. The flat wire winding stator with centralized lead wires according to claim 1, characterized in that: The second copper bar (32) comprises a first neutral copper bar (33) and a second neutral copper bar (34), wherein the first neutral copper bar (33) is connected to the second lead-out line (22) located at the 2nth layer, and the second neutral copper bar (34) is connected to the second lead-out line (22) located at the 2n-1th layer.

3. The flat wire winding stator with centralized lead wires according to claim 1, characterized in that: The first lead wire (21) and the second lead wire (22) are deflected in the same direction and at the same angle.

4. The flat wire winding stator with centralized lead wires according to claim 1, characterized in that: The flat wire winding (2) further comprises a plurality of first U-shaped flat wires with a span of 5, a second U-shaped flat wire with a span of 7, and a third U-shaped flat wire with a span of 6; One end of the first U-shaped flat wire and the second U-shaped flat wire are located at the 2k-1 layer, and the other end is located at the 2k layer. The first U-shaped flat wire and the second U-shaped flat wire are alternately and cross-distributed. The second U-shaped flat wire is located on the first U-shaped flat wire. One end of the third U-shaped flat wire is located at the 2k layer, and the other end is located at the 2k+1 layer. k≥1 and k≤n, and k is a natural number.

5. The flat wire winding stator with centralized lead wires according to claim 4, characterized in that: Both ends of the third U-shaped flat wire are respectively arranged in adjacent stator slots (11).

6. The flat wire winding stator with centralized lead wires according to claim 4, characterized in that: The ends of the first U-shaped flat wire and the third U-shaped flat wire located at the hairpin end of the stator core (1) are of pointed top structure, and the end of the second U-shaped flat wire located at the hairpin end of the stator core (1) is of flat top structure.

7. The flat wire winding stator with centralized lead wires according to claim 1, characterized in that: The flat wire winding (2) passes through the stator slot (11) and is led out from the welding end of the stator core (1); the 2k-1th layer of flat wire of the flat wire winding (2) led out from the welding end is deflected in a first direction by a first angle; the 2kth layer of flat wire of the flat wire winding (2) led out from the welding end is deflected in a second direction by a second angle; the first direction is opposite to the second direction.

8. The flat wire winding stator with centralized lead wires according to claim 7, characterized in that: The first direction is the counterclockwise direction facing the welding end of the stator core (1), and the second direction is the clockwise direction facing the welding end of the stator core (1).

9. The flat wire winding stator with centralized lead wires according to claim 7, characterized in that: The sum of the first angle and the second angle is in the range of 40-50°.

10. A flat wire motor, characterized in that: It comprises a flat wire winding stator with concentrated lead wires as described in any one of claims 1-9.

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