Stator assembly and motor

Abstract

The invention discloses a stator assembly and a motor, and belongs to the technical field of motors, the stator assembly comprises a stator core and an S-phase stator winding, and the stator core is provided with N stator slots; the S-phase stator winding is formed by winding a plurality of U-shaped hairpin coils in a stator slot to form an M-layer winding, and two adjacent layers of windings form a region, including a plurality of regions; the M layers of windings in any stator slot belong to the same phase, and the stator windings of each pole and each phase are arranged in the adjacent three stator slots; each phase of stator winding comprises a parallel branches, a = 1, 2, 3 or 4, and each branch comprises a first coil group which shares one flat wire twisting process and is located in the same area and a second coil group which shares the other flat wire twisting process and is located in two adjacent areas. The problems that different windings of the flat wire motor are complex to prepare and the production cost is increased are solved, and the effects that the stator winding connection mode can be compatible with multiple different branches at the same time and the production efficiency of the motor is improved are achieved.

Description

Technical Field

[0001] The present application relates to the field of motor technology, and in particular to a stator assembly and a motor. Background Art

[0002] As new energy vehicles increase their space utilization requirements, the demand for motor power density is also gradually increasing. Compared with round wire motors, flat wire motors are more suitable as drive motors for new energy vehicles. To best adapt to different motor performance requirements, the winding structure of flat wire motors can be adjusted to achieve different numbers of series turns per phase, thereby achieving different torque and power. The number of series turns per phase of the motor depends on the number of pole pairs, number of slots, number of flat wire layers, and number of parallel branches.

[0003] Currently, different vehicle models have varying requirements for low-speed, high-torque and high-speed, high-power output, requiring motors with varying numbers of series turns per phase to match these requirements. However, since most flat wire winding types cannot accommodate multiple parallel branches simultaneously, the number of series turns per phase must be changed by varying both the number of flat wire layers and the number of parallel branches. This approach presents a problem: in actual production, different flat wire winding types require different wire types and different forming, insertion, and twisting processes, complicating the motor winding process and increasing production costs. Summary of the Invention

[0004] The main purpose of this application is to provide a stator assembly and a motor, aiming to solve the technical problem in the related art that different windings of flat wire motors require different wire types and different processes, which leads to complex preparation and increased production costs.

[0005] To achieve the above objectives, this application adopts the following technical solutions:

[0006] In a first aspect, the present application provides a stator assembly for an S-phase motor, wherein the number of rotor poles of the S-phase motor is 2p, where S and p are positive integers; the stator assembly comprises:

[0007] A stator core, wherein the inner periphery of the stator core has N stator slots arranged at intervals and extending in the radial direction of the stator core;

[0008] The S-phase stator winding is formed by winding a plurality of U-shaped hairpin coils in the stator slots to form an M-layer winding. The M-layer windings are arranged in order from the 1st layer to the Mth layer along the radial direction of the stator core toward the center of the circle, where M is a positive integer and is an even number greater than or equal to 4;

[0009] In the M-layer winding, two adjacent layers of windings constitute an area. The M-layer winding includes regions;

[0010] The M layers of windings in any stator slot belong to the same phase, and the stator windings of each pole and each phase are placed in three adjacent stator slots;

[0011] Each phase stator winding includes a parallel branches, a = 1, 2, 3 or 4;

[0012] Each branch includes a first coil group located in the same area and A second coil group located in two adjacent areas; wherein, The first coil groups share a flat wire twisting process, The second coil group shares another flat wire twisting process.

[0013] Optionally, in the above-mentioned stator assembly, the U-shaped hairpin coil includes two straight segments and a head connected to one end of the two straight segments, and the two straight segments are respectively placed in two stator slots;

[0014] Each first coil group includes a plurality of first hairpin coils whose two straight segments are respectively located in adjacent layers of two stator slots, and the first hairpin coils include full-pitch U-shaped hairpin coils and / or long-pitch U-shaped hairpin coils;

[0015] Each second coil group includes one or more second hairpin coils whose two straight segments are respectively located in adjacent layers of two stator slots. The second hairpin coils include short-distance U-shaped hairpin coils, full-distance U-shaped hairpin coils and / or long-distance U-shaped hairpin coils.

[0016] The short-distance U-shaped hairpin coil includes a span of and / or U-shaped hairpin coil;

[0017] The full-spacing U-shaped hairpin coil includes a span of U-shaped hairpin coil;

[0018] Long distance U-shaped hairpin coil includes a span of and / or U-shaped hairpin coil.

[0019] Optionally, in the above-mentioned stator assembly, a bending portion is provided at each end of the two straight segments of the U-shaped hairpin coil away from the head;

[0020] When a=1, a=2 or a=3, the voltage lead wire and the neutral lead wire of each branch are located at the same layer of the stator slots. The first coil group in each region further includes a return crossover wire, which is a U-shaped hairpin coil with two bending parts having the same bending direction, and the return crossover wire is located at the Mth layer of the stator slot.

[0021] Optionally, in the above stator assembly, when S=3, M=8, N=72, p=4, a=3,

[0022] Each first coil group includes 6 full-span U-shaped hairpin coils with a span of 9, and the return span includes a short-span U-shaped hairpin coil with a span of 8 or a long-span U-shaped hairpin coil with a span of 11;

[0023] Each second coil group includes two short-distance U-shaped hairpin coils with a span of 8 or one short-distance U-shaped hairpin coil with a span of 8 and one long-distance U-shaped hairpin coil with a span of 11.

[0024] Optionally, in the above stator assembly, when S=3, M=8, N=72, p=4, a=2,

[0025] Each first coil group includes 8 full-span U-shaped hairpin coils with a span of 9 and 2 long-span U-shaped hairpin coils with a span of 10, and the return span includes a full-span U-shaped hairpin coil with a span of 9;

[0026] Each second coil group includes two short-distance U-shaped hairpin coils with a span of 7 or two full-distance U-shaped hairpin coils with a span of 9.

[0027] Optionally, in the above stator assembly, when S=3, M=8, N=72, p=4, a=1,

[0028] Each first coil group includes 18 full-span U-shaped hairpin coils with a span of 9 and 4 long-span U-shaped hairpin coils with a span of 10. The return span includes a full-span U-shaped hairpin coil with a span of 9.

[0029] Each second coil group includes two short-distance U-shaped hairpin coils with a span of 7.

[0030] Optionally, in the above stator assembly, when a=2 or a=4, the voltage lead of each branch is located at the 1st layer and the neutral lead is located at the Mth layer, or the voltage lead is located at the Mth layer and the neutral lead is located at the 1st layer.

[0031] Optionally, in the above stator assembly, when S=3, M=8, N=72, p=4, a=2,

[0032] Each first coil group includes 9 full-span U-shaped hairpin coils with a span of 9 and 2 long-span U-shaped hairpin coils with a span of 10;

[0033] Each second coil group includes a short-distance U-shaped hairpin coil with a span of 7.

[0034] Optionally, in the above stator assembly, when S=3, M=8, N=72, p=4, a=4,

[0035] Each first coil group includes 4 full-span U-shaped hairpin coils with a span of 9 and 1 long-span U-shaped hairpin coil with a span of 10;

[0036] Each second coil group includes a short-distance U-shaped hairpin coil with a span of 7 or a full-distance U-shaped hairpin coil with a span of 9.

[0037] In a second aspect, the present application further proposes a motor, comprising the stator assembly and rotor assembly as described above.

[0038] The above one or more technical solutions provided by this application may have the following advantages or at least achieve the following technical effects:

[0039] The present application proposes a stator assembly and a motor, which uses a plurality of U-shaped hairpin coils to form an M-layer winding in the stator slot, and divides the M-layer winding into The stator windings of each phase are placed in three adjacent stator slots, and each phase of the stator winding includes a parallel branch, each branch includes a branch located at The first coil group in the same area and A second coil group is located in two adjacent areas, thereby constructing an S-phase motor. The S-phase motor is a full-pitch motor. While meeting the motor performance, no matter each phase stator winding is set to 1, 2, 3 or 4 parallel branches, the first coil groups of a branches in each phase stator winding can share a flat wire twisting process, and the second coil groups share another flat wire twisting process, so that the stator winding connection method is simple, and it can be compatible with multiple different branches at the same time, and the torque-power curve of the motor can be flexibly adjusted to meet more motor requirements; compared with the existing flat wire motor, when it is necessary to change the number of series turns per phase of the motor, the flat wire shape and flat wire twisting process can be shared, and the types of wire shapes and molds used are few, which reduces the types of wire shapes and process complexity in actual production, reduces production costs and improves the production efficiency of the motor. BRIEF DESCRIPTION OF THE DRAWINGS

[0040] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the following briefly introduces the drawings required for use in the description of the embodiments. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on the structures shown in these drawings without any creative work.

[0041] Figure 1 This is a schematic structural diagram of a stator assembly in an embodiment of the present application;

[0042] Figure 2 for Figure 1 Schematic diagram of the structure of the S-phase stator winding;

[0043] Figure 3 Schematic diagram of the winding distribution of the U-phase winding 3 branches in the second embodiment of the present application;

[0044] Figure 4 Schematic diagram of the winding distribution of the U-phase winding 2 branch in the second embodiment of the present application;

[0045] Figure 5 Schematic diagram of the winding distribution of the U-phase winding 1 branch in the second embodiment of the present application;

[0046] Figure 6 Schematic diagram of the winding distribution of the U-phase winding 2 branch in the third embodiment of the present application;

[0047] Figure 7 This is a schematic diagram of the winding distribution of the four branches of the U-phase winding in Example 3 of the present application.

[0048] Description of Figure Numbers:

[0049] Label name Label name 10 stator assembly 11 stator core 12 stator winding 13 stator slots 14 Slot insulation paper 15 U-shaped hairpin coil 151 head 152 Bending part

[0050] The realization of the objectives, functional features and advantages of this application will be further explained in conjunction with embodiments and with reference to the accompanying drawings. DETAILED DESCRIPTION

[0051] To make the purpose, technical solutions, and advantages of this application more clear, the technical solutions in the embodiments of this application will be clearly and completely described below in conjunction with the drawings in the embodiments of this application. Obviously, the described embodiments are only part of the embodiments of this application, not all of the embodiments. Based on the embodiments in this application, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of this application.

[0052] It should be noted that in the embodiments of the present application, all directional indications (such as up, down, left, right, front, back, etc.) are only used to explain the relative position relationship, movement, etc. between the components under a specific posture (as shown in the accompanying drawings). If the specific posture changes, the directional indication will also change accordingly. In the present application, the terms "include", "comprise" or any other variations thereof are intended to cover non-exclusive inclusion, so that a device or system including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such a device or system. In the absence of further restrictions, the elements defined by the sentence "include..." do not exclude the presence of other identical elements in the device or system including the element. In the present application, unless otherwise clearly specified and limited, the terms "connect", "fixed", etc. should be understood in a broad sense. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be the internal communication of two elements or the interaction relationship between two elements. In this application, if there are descriptions involving "first", "second", etc., the descriptions of "first", "second", etc. are only used for descriptive purposes and cannot be understood as indicating or suggesting their relative importance or implicitly indicating the number of technical features indicated. Therefore, the features defined as "first" and "second" may explicitly or implicitly include at least one of such features. For ordinary technicians in this field, the specific meanings of the above terms in this application can be understood according to the specific circumstances. In addition, the technical solutions of each embodiment can be combined with each other, but it must be based on the ability of ordinary technicians in this field to implement. When the combination of technical solutions is contradictory or cannot be implemented, it should be deemed that such combination of technical solutions does not exist and is not within the scope of protection required by this application.

[0053] As new energy vehicles increase their space utilization requirements, the demand for motor power density is also gradually increasing. Compared with round wire motors, flat wire motors offer advantages such as higher slot fill rate, shorter winding ends, higher power density, and stronger heat dissipation. They are suitable as drive motors for new energy vehicles, achieving increased power density and meeting the application requirements of miniaturization and lightweighting of automotive drive motors.

[0054] An analysis of relevant technologies found that with the extensive use and platform construction of flat wire motors, in order to adapt to different motor performance requirements as much as possible, on the same platform, in addition to adjusting the stacking height parameters of the motor, the winding form of the flat wire motor can also be adjusted to obtain different numbers of series turns per phase of the motor to obtain different torques and powers. A small number of turns can output small torque, high power, and a high turning speed, while a large number of turns can output large torque, but a low turning speed.

[0055] The number of series turns per phase of a motor depends on the number of pole pairs, number of slots, number of flat wire layers, and number of parallel branches of the motor. Currently, different vehicle models have different requirements for low-speed high torque and high-speed high power output, requiring the motor to have different numbers of series turns per phase to match. Since most flat wire winding designs cannot accommodate multiple numbers of parallel branches at the same time, the number of series turns per phase must be changed by changing both the number of flat wire layers and the number of parallel branches. The problem with this approach is that, due to slot fill rate limitations and thermal load requirements for motors, designs with different numbers of flat wire layers for the same motor will result in flat wire sizes that cannot be shared, requiring different wire types, resulting in an increase in flat wire types, which is not conducive to the construction of a flat wire platform. Furthermore, different flat wire winding forms require corresponding different processes such as forming, wire insertion, and twisting, which will make the winding process of the motor winding more complicated in actual production, increasing the cost of motor production.

[0056] In view of the technical problem that different windings of flat wire motors in the related art require different wire types and different processes, resulting in complex preparation and increased production costs, the present application provides a stator assembly and a motor, and specific embodiments and implementation methods are as follows:

[0057] Example 1

[0058] This embodiment provides a stator assembly for an S-phase motor with a rotor pole number of 2p, where p and S are positive integers, and S can be an integer multiple of 3. For example, in this embodiment, the stator assembly is used for a three-phase motor, i.e., S=3.

[0059] In this embodiment, the S-phase motor is composed of a rotor assembly in the shape of a ring and a stator assembly 10 in the shape of a ring.

[0060] The rotor assembly includes a rotor core and a rotating shaft made of stacked silicon steel sheets. Various rotor magnetic circuit structures can be applied to the hairpin stator of this embodiment, such as squirrel-cage asynchronous rotors, surface-mount rotors, internal radial rotors (I-type), internal tangential rotors (Spoke-type), multi-layer magnetic steel rotors, hybrid magnetic circuit rotors, and Halbach array rotors.

[0061] The stator assembly 10 includes a stator core 11 and an S-phase stator winding 12;

[0062] The inner periphery of the stator core 11 has N stator slots 13 arranged at intervals and extending radially along the stator core 11;

[0063] The S-phase stator winding 12 can be formed into an M-layer winding by winding a plurality of U-shaped hairpin coils 15 in the stator slot 13. The M-layer windings are sequentially arranged from the 1st layer to the Mth layer along the radial direction toward the center of the stator core 11, where M is a positive integer and M is an even number greater than or equal to 4.

[0064] like Figure 1 Schematic diagram of the structure of the stator assembly in this embodiment is shown. The stator assembly 10 includes a stator core 11 and a three-phase stator winding 12 arranged on the stator core 11 .

[0065] The stator core 11 includes N stator teeth, which are evenly distributed along the circumferential direction and extend radially from the outside to the inside along the stator core 11. Two adjacent stator teeth form a stator slot 13, that is, each stator slot 13 is formed between two adjacent stator teeth, and the slot opening is semi-closed, thereby forming a total of N stator slots 13 along the circumference of the stator core 11, where N is a positive integer and can be a multiple of 3, so that the number of slots per pole and per phase of the motor is 3.

[0066] Optionally, slot insulation paper 14 is inserted along the inner wall of the stator slot 13. The slot insulation paper 14 extends beyond the two end surfaces of the stator core 11. One slot insulation paper 14 is arranged in each stator slot 13, for a total of N slot insulation papers 14. The slot insulation paper 14 is used to insulate the inner wall of the stator slot 13 or the stator teeth from the stator winding 12. The three-phase stator winding 12 can be inserted into the area defined by the slot insulation paper 14 within the stator slot 13.

[0067] The three-phase stator windings 12 are arranged in each stator slot 13, and the windings in each stator slot 13 are arranged in multiple layers along the radial direction of the stator core 11 toward the center. That is, M layers of windings are arranged in each stator slot 13 along the radial direction of the stator core 11 toward the center. The layers of the M layers of windings can be designated as the 1st to the Mth layers from the outside to the inside of the stator core 11, or as the 1st to the Mth layers from the inside to the outside of the stator core 11, depending on the needs.

[0068] In this embodiment, the S-phase motor is a three-phase motor with a rotor pole number of 2p. The stator core 11 has N stator slots 13, where p is a positive integer and N is an even multiple of 3. Each stator slot 13 has M layers of windings, where M is an even number greater than or equal to 4. Taking N=72, M=8, and 2p=8 as an example, the stator core 11 has 72 stator slots 13, each of which has eight layers of windings. The eight layers of windings are arranged radially inward from the outside of the stator core 11, from the first layer to the eighth layer. Each layer of each stator slot 13 is a straight segment of a U-shaped hairpin coil 15. The U-shaped hairpin coil 15 is described in detail below.

[0069] Furthermore, in the S-phase stator winding, based on the M layers of windings corresponding to the N stator slots 13, the following conditions are met:

[0070] In the M-layer winding, two adjacent layers of windings constitute an area. The M-layer winding includes regions;

[0071] The M layers of windings in any stator slot 13 belong to the same phase, and the stator windings of each pole and each phase are placed in three adjacent stator slots 13;

[0072] Each phase stator winding can include a parallel branches, a=1, 2, 3 or 4, that is, the number of parallel branches of each phase in the S-phase stator winding can be 1 branch, 2 branches, 3 branches or 4 branches; the phases of the S-phase stator winding can be connected in star or triangle.

[0073] In this embodiment, taking a three-phase motor with N=72, M=8, and 2p=8 as an example, the eight layers of the three-phase stator winding comprise four regions: layers 1 and 2 constitute the first region, layers 3 and 4 constitute the second region, layers 5 and 6 constitute the third region, and layers 7 and 8 constitute the fourth region. The eight layers of winding within any stator slot 13 belong to the same phase. Each phase of the stator winding per pole is placed in three adjacent stator slots 13. Each three-phase stator winding per pole comprises nine adjacent stator slots 13, and an eight-pole three-phase stator winding corresponds to exactly 72 stator slots 13.

[0074] For this three-phase motor, the three phases are U phase, V phase and W phase, and the stator winding of each phase can be set to 1 branch, 2 branches, 3 branches or 4 branches. For example, when the number of branches of each phase stator winding is 1, the U-phase winding can include a branch u1, and the u1 branch can specifically include a voltage lead line u1+ and a neutral lead line u1-, and a plurality of U-shaped hairpin coils 15 connected between the voltage lead line u1+ and the neutral lead line u1-; when the number of branches of each phase stator winding is 2, the U-phase winding can include two branches u1 and u2, wherein the u1 branch can specifically include a voltage lead line u1+ and a neutral lead line u1-, and a plurality of U-shaped hairpin coils 15 connected between the voltage lead line u1+ and the neutral lead line u1-, and the u2 branch can specifically include a voltage lead line u2+ and a neutral lead line u2-, and a plurality of U-shaped hairpin coils 15 connected between the voltage lead line u2+ and the neutral lead line u2-, and so on, which will not be repeated here.

[0075] Furthermore, each branch may include a first coil group located in the same area and A second coil group located in two adjacent areas; wherein, The first coil groups share a flat wire twisting process, The second coil group shares another flat wire twisting process.

[0076] In this embodiment, each branch of each phase stator winding can be configured to include The first coil group and Taking the aforementioned three-phase motor as an example, each branch of the U-phase winding can include four first coil groups and three second coil groups. The four first coil groups share a flat wire twisting process, while the three second coil groups share another flat wire twisting process. Regardless of the number of parallel branches in each phase of the stator winding, each branch can be configured in this manner.

[0077] The stator assembly 10 provided in this embodiment has a simple stator winding connection method, a small number of wire types and mold types, and can be compatible with 1 branch, 2 branches, 3 branches, and 4 branches at the same time, so as to flexibly adjust the torque-power curve to match different application requirements.

[0078] Furthermore, the U-shaped hairpin coil 15 includes two straight segments and a head 151 connected to one end of the two straight segments, and the two straight segments are respectively placed in two stator slots 13; the two straight segments of the U-shaped hairpin coil 15 are each provided with a bending portion 152 at one end away from the head 151, and the bending directions of the two bending portions 152 of the U-shaped hairpin coil 15 can be set to the same or opposite.

[0079] Specifically, the U-shaped hairpin coil can be made of flat copper wire. The U-shaped hairpin coil 15 is generally U-shaped, comprising two straight segments and a connecting portion, or head 151, connecting one end of the two straight segments, also known as a crown end. In practice, the two straight segments pass through the stator slots 13 and are located within the slot insulation paper 14. The two straight segments of the U-shaped hairpin coil 15 can be inserted into adjacent layers of two stator slots, or into the same layer of two stator slots, depending on the needs.

[0080] The two straight segments of the U-shaped hairpin coil 15 are each provided with a bending portion 152, namely a left bending portion and a right bending portion, at one end away from the head 151. In actual application, on the side opposite to the insertion side of the stator core 11, the left bending portion and the right bending portion of a U-shaped hairpin coil 15 can be connected to the bending portion of other U-shaped hairpin coils 15 by welding. The left bending portion and the right bending portion can be bent in the same direction or in opposite directions, which can be selected according to specific needs.

[0081] According to the distance between the two stator slots 13 into which each U-shaped hairpin coil 15 is inserted, i.e., the slot spacing, also called the span, the U-shaped hairpin coil 15 can be divided into short-distance U-shaped hairpin coils, full-distance U-shaped hairpin coils, and long-distance U-shaped hairpin coils.

[0082] Furthermore, each first coil group includes a plurality of first hairpin coils whose two straight segments are respectively located in adjacent layers of two stator slots, and the first hairpin coils include full-pitch U-shaped hairpin coils and / or long-pitch U-shaped hairpin coils;

[0083] Each second coil group includes one or more second hairpin coils whose two straight segments are respectively located in adjacent layers of two stator slots. The second hairpin coils include short-distance U-shaped hairpin coils, full-distance U-shaped hairpin coils and / or long-distance U-shaped hairpin coils.

[0084] Furthermore, the short-distance U-shaped hairpin coil includes a span of and / or U-shaped hairpin coil;

[0085] The full-spacing U-shaped hairpin coil includes a span of U-shaped hairpin coil;

[0086] Long distance U-shaped hairpin coil includes a span of and / or U-shaped hairpin coil.

[0087] Specifically, each first coil group includes multiple first hairpin coils located in the same area, and the two adjacent layers where the two straight line segments of the first hairpin coils are located belong to the same area; each second coil group includes one or more second hairpin coils located in two adjacent areas, and the two adjacent layers where the two straight line segments of the second hairpin coils are located belong to different areas, but belong to two adjacent areas.

[0088] Each phase stator winding consists of a parallel branches, each branch consists of a first coil assembly and The first coil group includes multiple first hairpin coils, and the second coil group includes one or more second hairpin coils. Each phase of the stator winding is formed by connecting multiple U-shaped hairpin coils. This eliminates radial and circumferential interference between the hairpin coils in each phase of the motor's stator windings. The lead wires of each phase are arranged compactly, reducing resistance imbalance.

[0089] It should be noted that each branch contains the same number of first and second coil groups, and the same total number of hairpin coils in each branch. Correspondingly, each phase of the stator winding also contains the same number of hairpin coils. This allows the positions of the branches within the stator slots to correspond, resulting in identical back EMF, resistance, and inductance, as well as the same current through each branch. This prevents circulating currents between branches, significantly reducing parasitic energy consumption at high frequencies, improving motor efficiency at high speeds, preventing localized winding overheating, extending motor life, and suppressing electromagnetic noise.

[0090] The stator assembly of this embodiment is formed into M-layer windings by using multiple U-shaped hairpin coils in the stator slots. The M-layer windings are divided into The stator windings of each phase are placed in three adjacent stator slots, and each phase of the stator winding includes a parallel branch, each branch includes a parallel branch located in the same area. A first coil group and two adjacent areas A second coil group is formed to construct an S-phase motor. The S-phase motor is a full-pitch motor. While meeting the motor performance, no matter each phase stator winding is set to 1, 2, 3 or 4 parallel branches, the first coil groups of a branches in each phase stator winding can share a flat wire twisting process, and the second coil groups share another flat wire twisting process, so that the stator winding connection method is simple, and it can be compatible with multiple different branches at the same time, and the torque-power curve of the motor can be flexibly adjusted to meet more motor requirements; compared with the existing flat wire motor, when it is necessary to change the number of series turns per phase of the motor, the flat wire line shape and flat wire twisting process can be shared, and the types of line shapes and molds used are few, which reduces the types of line shapes and process complexity in actual production, reduces production costs and improves the production efficiency of the motor.

[0091] Example 2

[0092] Based on the same technical concept, on the basis of embodiment 1, refer to Figure 3-Figure 5 , a second embodiment of the stator assembly of the present application is proposed. In this embodiment, the stator assembly is used for a three-phase motor as an example for explanation. Figure 3 Schematic diagram of the winding distribution of the three branches of the U-phase winding in this embodiment. Figure 4 Schematic diagram of the winding distribution of the U-phase winding 2 branch in this embodiment. Figure 5 Schematic diagram of the winding distribution of the U-phase winding 1 branch in this embodiment.

[0093] Furthermore, when a=1, a=2 or a=3, the voltage lead wire and the neutral lead wire of each branch are located at the same layer of the stator slots, and the voltage lead wire and the neutral lead wire of each branch are located at the same layer of the stator slots. The first coil group in each region further includes a return crossover wire, which is a U-shaped hairpin coil with two bending parts having the same bending direction, and the return crossover wire is located at the Mth layer of the stator slot.

[0094] Specifically, the motor input and output wires of each branch in each phase of the S-phase stator winding, including the voltage lead wire and the neutral lead wire, can be set on any side of the stator assembly in the axial direction, such as Figure 1It is set at the top of the stator assembly, at the head end of the stator winding. It can also be set at the bottom of the stator assembly, at the welding end of the hairpin coil. When the voltage lead wire and the neutral lead wire are on the non-welding side of the hairpin coil, an I-type hairpin coil must be used. When on the welding side of the hairpin coil, the I-type hairpin coil can be cancelled and a U-type hairpin coil can be used. It can also be set at any layer of any stator slot, such as Figure 1 The first layer of windings is set in the stator slots. In fact, it can also be set in other layers of windings in other stator slots according to actual needs. When the voltage lead is adjusted, the neutral lead changes accordingly according to the rules. An offset line can also be added at the actual lead position to facilitate the connection of the lead with other components, such as Figure 1 based on Figure 3 The winding connection method shown offsets the nine voltage leads or nine neutral leads corresponding to the three branches of the three-phase stator winding; specific adjustments can be made based on actual structural requirements.

[0095] Specifically, a U-shaped hairpin coil 15 is also used for the return crossover. Specifically, the U-shaped hairpin coil 15 has two straight segments inserted into the same layer of two stator slots 13, and two bent portions bent in the same direction. The return crossover is located in the Mth layer of the stator slots, which means that the two straight segments are located in the Mth layer of two different stator slots.

[0096] The following is an example of a stator assembly for a three-phase motor with 72 slots and 8 poles. Set S=3, M=8, N=72, and p=4. Figure 3-Figure 5 This embodiment is described in detail. Figure 3-Figure 5 In the figure, the horizontal marks 1-72 indicate the stator slot numbers, and the vertical marks 1-8 indicate the winding layer numbers in the stator slots; the solid line indicates the connecting part between the two straight segments of the U-shaped hairpin coil, namely the head 151, and the dotted line indicates the welding part of the U-shaped hairpin coil at one end away from the head 151, namely the bending part 152.

[0097] In the first optional implementation of this embodiment, when S=3, M=8, N=72, p=4, a=3,

[0098] Each first coil group includes 6 full-span U-shaped hairpin coils with a span of 9, and the return span includes a short-span U-shaped hairpin coil with a span of 8 or a long-span U-shaped hairpin coil with a span of 11;

[0099] Each second coil group includes two short-distance U-shaped hairpin coils with a span of 8 or one short-distance U-shaped hairpin coil with a span of 8 and one long-distance U-shaped hairpin coil with a span of 11.

[0100] like Figure 3The U-phase stator winding shown includes three branches u1, u2 and u3, and the voltage lead wire and neutral lead wire of each branch are located in the first layer of the stator slot; the first coil group located in the fourth area of ​​each branch also includes a return cross-wire, which is located in the eighth layer of the stator slot.

[0101] The u1 branch includes four first coil groups U11, U12, U13, and U14, U11 is located in the first area, U12 is located in the second area, U13 is located in the third area, and U14 is located in the fourth area; it also includes three second coil groups U21, U22, and U23, U21 is located in the second and third layers of the stator slot between the first and second areas, U22 is located in the fourth and fifth layers of the stator slot between the second and third areas, and U23 is located in the sixth and seventh layers of the stator slot between the third and fourth areas.

[0102] like Figure 3 As shown, in branch u1, U11, U12, U13, and U14 each include six full-span U-shaped hairpin coils with a span of 9. The return line in U14, located on the eighth layer of the stator slot, uses a short-span U-shaped hairpin coil with a span of 8. U21 includes two short-span U-shaped hairpin coils with a span of 8. U22 includes one long-span U-shaped hairpin coil with a span of 11 and one short-span U-shaped hairpin coil with a span of 8. U23 includes one short-span U-shaped hairpin coil with a span of 8 and one long-span U-shaped hairpin coil with a span of 11. The voltage lead u1+ of branch u1 is located on the first layer of the first stator slot, and the neutral lead u1- is located on the first layer of the 65th stator slot. Both the voltage lead u1+ and the neutral lead u1- can use I-type coils.

[0103] The structure of branch U2 is similar to that of branch U1, differing only in that branch U21 includes a long U-shaped hairpin coil with a span of 11 and a short U-shaped hairpin coil with a span of 8. U22 includes a short U-shaped hairpin coil with a span of 8 and a long U-shaped hairpin coil with a span of 11. U23 includes two short U-shaped hairpin coils with a span of 8. The voltage lead u2+ of branch U2 is located in the first layer of the second stator slot, and the neutral lead u2- is located in the first layer of the 66th stator slot.

[0104] The structure of branch U3 is similar to that of branch U1, differing only in that the return line of branch U14 uses a long U-shaped hairpin coil with a span of 11. In branch U3, branch U21 includes a short U-shaped hairpin coil with a span of 8 and a long U-shaped hairpin coil with a span of 11. U22 also includes a short U-shaped hairpin coil with a span of 8. U23 includes a long U-shaped hairpin coil with a span of 11 and a short U-shaped hairpin coil with a span of 8. The voltage lead u3+ of branch U3 is located in the first layer of the third stator slot, and the neutral lead u3- is located in the first layer of the 65th stator slot.

[0105] In a specific application, the three branches of each pole and each phase winding are located in three adjacent slots. Each branch is first introduced from the first layer and then led out from the same layer. They are spirally connected from the stator outer diameter to the stator inner diameter in the order of U11, U21, U12, U22, U13, U23, and U14, and then spirally connected from the stator inner diameter to the stator outer diameter in the order of U14, U23, U13, U22, U12, U21, and U11. For example, the connection method of branch u1 in this embodiment is:

[0106] In the first area, the voltage lead line u1+ of the I-type coil is introduced into the first layer of the first stator slot, and then the three coils of U11 continuously cross the layers to bridge one circle of the stator, and then enter the second area through one coil of U21;

[0107] In the second area, the three coils of U12 continuously cross the number of layers to bridge one circle of the stator, and then enter the third area through one coil of U22;

[0108] In the third area, the three coils of U13 continuously cross the stator for one circle, and then enter the fourth area through one coil of U23;

[0109] In the fourth area, the three coils of U14 are continuously crossed to cross the stator for one circle, and then the return line of U14 is connected. It continues to stay in the fourth area, and the three coils of U14 are continuously crossed to cross the stator for one circle in the reverse direction, and then it enters the third area through one coil of U23.

[0110] In the third area, the three coils of U13 continuously cross the layers and cross the stator in the opposite direction for one circle, and then enter the second area through one coil of U22;

[0111] In the second area, the three coils of U12 continuously cross the layers and cross the stator in the opposite direction for one circle, and then enter the first area through one coil of U21;

[0112] In the first area, the three coils of U11 continuously cross the layers and reversely cross the stator for one circle, and then the neutral line u1- of the I-type coil is led out at the first layer of the 65th stator slot.

[0113] Correspondingly, the connection method of branches u2 and u3 is similar to that of u1. The only difference is that different coils are used for the cross-connection between the two areas. The same coils are used in other areas, and the corresponding processes are also the same.

[0114] Need to explain, Figure 3 Only the connection method of the U-phase winding among the U, V, and W three-phase windings is shown. The three-phase winding structures are completely consistent. The connection method of the V-phase and W-phase windings is the same as the connection method of the U-phase winding. The only difference is that the stator slots corresponding to the V-phase winding are shifted by 3 slots parallel to the U-phase winding. For example, the voltage lead wires of the V-phase 3 branches correspond to the 4th, 5th, and 6th slots, and the stator slots corresponding to the W-phase winding can be shifted by 6 slots parallel to the U-phase winding. For example, the voltage lead wires of the W-phase 3 branches correspond to the 7th, 8th, and 9th slots. In this way, a complete three-phase winding can be formed.

[0115] In current motor winding connection schemes, the number of parallel branches per phase stator winding must generally be a multiple of the number of poles, 2p, to achieve a design without circulating winding current. For example, an 8-pole, 72-slot motor can achieve a 2-branch or 4-branch design without circulating current, but a 3-branch design is theoretically impossible to achieve completely without circulating current. However, in this embodiment, for different motors with different numbers of parallel branches, while reusing the same linear configuration, the circulating current in the 3-branch design can be minimized, ensuring motor performance.

[0116] In the second optional implementation of this embodiment, when S=3, M=8, N=72, p=4, a=2,

[0117] Each first coil group includes 8 full-span U-shaped hairpin coils with a span of 9 and 2 long-span U-shaped hairpin coils with a span of 10, and the return span includes a full-span U-shaped hairpin coil with a span of 9;

[0118] Each second coil group includes two short-distance U-shaped hairpin coils with a span of 7 or two full-distance U-shaped hairpin coils with a span of 9.

[0119] like Figure 4 The U-phase stator winding shown includes two branches u1 and u2, and the voltage lead wire and neutral lead wire of each branch are located in the first layer of the stator slot; the first coil group located in the fourth area of ​​each branch also includes a return cross-wire, which is located in the eighth layer of the stator slot.

[0120] The u1 branch includes four first coil groups U11, U12, U13, and U14, U11 is located in the first area, U12 is located in the second area, U13 is located in the third area, and U14 is located in the fourth area; it also includes three second coil groups U21, U22, and U23, U21 is located in the second and third layers of the stator slot between the first and second areas, U22 is located in the fourth and fifth layers of the stator slot between the second and third areas, and U23 is located in the sixth and seventh layers of the stator slot between the third and fourth areas.

[0121] like Figure 4 As shown, in branch u1, U11, U12, U13, and U14 each include eight U-shaped hairpin coils with a span of 9 and two long U-shaped hairpin coils with a span of 10. The return line in U14, located on the eighth layer of the stator slot, uses a U-shaped hairpin coil with a span of 9. U21 includes two U-shaped hairpin coils with a span of 9, U22 includes two short U-shaped hairpin coils with a span of 7, and U23 includes two U-shaped hairpin coils with a span of 9. The voltage lead u1+ of branch u1 is located on the first layer of the third stator slot, and the neutral lead u1- is located on the first layer of the 66th stator slot. Both the voltage lead u1+ and the neutral lead u1- can use I-type coils.

[0122] The structure of branch U2 is similar to that of branch U1, differing only in that branch U21 includes two short-span U-shaped hairpin coils with a span of 7, branch U22 includes two full-span U-shaped hairpin coils with a span of 9, and branch U23 includes two short-span U-shaped hairpin coils with a span of 7. The voltage lead u2+ of branch U2 is located in the first layer of the 38th stator slot, and the neutral lead u2- is located in the first layer of the 29th stator slot.

[0123] In a specific application, the two branches of each pole and each phase winding are located in three adjacent slots. Each branch is first introduced from the first layer and then led out from the same layer. They are spirally connected from the stator outer diameter to the stator inner diameter in the order of U11, U21, U12, U22, U13, U23, and U14, and then spirally connected from the stator inner diameter to the stator outer diameter in the order of U14, U23, U13, U22, U12, U21, and U11. For example, the connection method of branch u1 in this embodiment is:

[0124] In the first area, the voltage lead u1+ of the I-type coil is introduced into the first layer of the third stator slot, and then passes through three coils with a span of 9, one coil with a span of 10, and one coil with a span of 9 of U11, continuously crossing the layers to span one and a half turns of the stator, and then enters the second area through a coil with a span of 9 of U21;

[0125] In the second area, it passes through one coil with a span of 9, one coil with a span of 10, and three coils with a span of 9 in U12, and then crosses the stator for one and a half turns. Then, it enters the third area through one coil with a span of 7 in U22.

[0126] In the third area, it passes through three coils with a span of 9, one coil with a span of 10, and one coil with a span of 9 of U13, and then crosses the stator for one and a half turns. Then, it enters the fourth area through one coil with a span of 9 of U23.

[0127] In the fourth area, after continuously crossing the layers of a coil with a span of 9, a coil with a span of 10, and three coils with a span of 9 of U14 to bridge the stator for one and a half turns, it is immediately connected to the return line of U14 and continues to stay in the fourth area. After continuously crossing the layers of the five coils of U14 to bridge the stator for one and a half turns in the opposite direction, it enters the third area through a coil of U23.

[0128] In the third area, the five coils of U13 are continuously crossed in layers and connected in the opposite direction for one and a half turns of the stator, and then enter the second area through one coil of U22;

[0129] In the second area, the five coils of U12 continuously cross the layers and cross the stator in the opposite direction for one and a half turns, and then enter the first area through one coil of U21;

[0130] In the first area, the five coils of U11 continuously cross the layers and reversely cross the stator for one and a half turns, and then the neutral line u1- of the I-type coil is led out at the first layer of the 66th stator slot.

[0131] Correspondingly, the connection method of branch u2 is similar to that of u1. The only difference is that the coils used for bridging between the two areas are different. The same coils are used in other areas, and the corresponding processes are also the same.

[0132] In the third optional implementation of this embodiment, when S=3, M=8, N=72, p=4, a=1,

[0133] Each first coil group includes 18 full-span U-shaped hairpin coils with a span of 9 and 4 long-span U-shaped hairpin coils with a span of 10. The return span includes a full-span U-shaped hairpin coil with a span of 9.

[0134] Each second coil group includes two short-distance U-shaped hairpin coils with a span of 7.

[0135] like Figure 5The U-phase stator winding shown includes a branch u1, the voltage lead wire and the neutral lead wire of the branch are both located in the first layer of the stator slot; the first coil group located in the fourth area of ​​the branch also includes a return cross-wire, which is located in the eighth layer of the stator slot.

[0136] The u1 branch includes four first coil groups U11, U12, U13, and U14, U11 is located in the first area, U12 is located in the second area, U13 is located in the third area, and U14 is located in the fourth area; it also includes three second coil groups U21, U22, and U23, U21 is located in the second and third layers of the stator slot between the first and second areas, U22 is located in the fourth and fifth layers of the stator slot between the second and third areas, and U23 is located in the sixth and seventh layers of the stator slot between the third and fourth areas.

[0137] like Figure 5 As shown, in branch u1, U11, U12, U13, and U14 each include 18 full-span U-shaped hairpin coils with a span of 9 and four long-span U-shaped hairpin coils with a span of 10. The return line in U14, located on the eighth layer of the stator slot, uses a full-span U-shaped hairpin coil with a span of 9. U21, U22, and U23 each include two short-span U-shaped hairpin coils with a span of 7. The voltage lead u1+ of branch u1 is located on the first layer of the third stator slot, and the neutral lead u1- is located on the first layer of the 66th stator slot. Both voltage lead u1+ and neutral lead u1- can use I-type coils.

[0138] In a specific application, one branch of each pole and phase winding is located in three adjacent slots. The branch is first introduced from the first layer and then led out from the same layer. It is spirally connected from the stator outer diameter to the stator inner diameter in the order of U11, U21, U12, U22, U13, U23, and U14, and then spirally connected from the stator inner diameter to the stator outer diameter in the order of U14, U23, U13, U22, U12, U21, and U11. For example, the connection method of branch u1 in this embodiment is:

[0139] In the first area, the voltage lead u1+ of the I-type coil is introduced into the first layer of the third stator slot, and then passes through three coils with a span of 9, one coil with a span of 10, three coils with a span of 9, one coil with a span of 10, and three coils with a span of 9 in U11, continuously crossing the layers to cross the stator three times, and then enters the second area through a coil with a span of 7 in U21;

[0140] In the second area, the coils are connected through three coils with a span of 9, one coil with a span of 10, three coils with a span of 9, one coil with a span of 10, and three coils with a span of 9, crossing the stator three times, and then entering the third area through one coil with a span of 7 of U22.

[0141] In the third area, the coils are connected through three coils with a span of 9, one coil with a span of 10, three coils with a span of 9, one coil with a span of 10, and three coils with a span of 9, crossing the stator three times, and then entering the fourth area through one coil with a span of 7 of U23.

[0142] In the fourth area, it passes through U13's three coils with a span of 9, one coil with a span of 10, three coils with a span of 9, one coil with a span of 10, and three coils with a span of 9, continuously crossing the layers and bridging the stator three times, then immediately connects to the return crossover line of U14, continues to stay in the fourth area, and passes through U14's 11 coils, continuously crossing the layers and bridging the stator three times in the opposite direction, and then enters the third area through U23's one coil;

[0143] In the third area, the 11 coils of U13 are continuously crossed in reverse order to cross the stator three turns, and then enter the second area through one coil of U22;

[0144] In the second area, the 11 coils of U12 continuously cross the layers and cross the stator three times in the opposite direction, and then enter the first area through one coil of U21;

[0145] In the first area, the 11 coils of U11 continuously cross the layers and reversely cross the stator three times, and then the neutral line u1- of the I-type coil is led out at the first layer of the 66th stator slot.

[0146] In the above three embodiments, the U-shaped hairpin coils required for winding the U-phase stator winding of 3 branches include five different types and processes of coils, namely, the same-region cross-layer wire with a span of 9, the same-layer wire with a span of 8, the same-layer wire with a span of 11, the cross-region cross-layer wire with a span of 8, and the cross-region cross-layer wire with a span of 11; the U-shaped hairpin coils required for winding the U-phase stator winding of 2 branches include five different types and processes of coils, namely, the same-region cross-layer wire with a span of 9, the same-layer wire with a span of 10, the same-layer wire with a span of 9, the cross-region cross-layer wire with a span of 7, and the cross-region cross-layer wire with a span of 9; the U-shaped hairpin coils required for winding the U-phase stator winding of 1 branch include four different types and processes of coils, namely, the same-region cross-layer wire with a span of 9, the same-region cross-layer wire with a span of 10, the same-layer wire with a span of 9, and the cross-region cross-layer wire with a span of 7. From this, it can be seen that the same-area cross-layer wire with a span of 9 can be used to wind the stator winding of the above-mentioned 1, 2 or 3 branches, and the same-area cross-layer wire with a span of 9, the same-area cross-layer wire with a span of 10, the same-layer wire with a span of 9, and the cross-area cross-layer wire with a span of 7 can be used to wind the stator winding of the above-mentioned 1 or 2 branches, which is sufficient to show that the winding connection method of this embodiment can be compatible with different parallel branches.

[0147] The stator assembly proposed in this embodiment has a winding connection method that is not only compatible with different parallel branches, but also compatible with different numbers of flat wire layers. 8 layers are used as an example here, but it can actually be applied to 4 layers, 6 layers, etc., thereby expanding the adaptability in practical applications.

[0148] Example 3

[0149] Based on the same technical concept, on the basis of embodiment 1, refer to Figure 6-Figure 7 , a third embodiment of the stator assembly of the present application is proposed. In this embodiment, the stator assembly is used for a three-phase motor as an example for explanation. Figure 6 Schematic diagram of the winding distribution of the U-phase winding 2 branch in this embodiment; Figure 7 Schematic diagram of the winding distribution of the four branches of the U-phase winding in this embodiment.

[0150] Furthermore, when a=2 or a=4, the voltage lead wire of each branch is located at the 1st layer and the neutral lead wire is located at the Mth layer, or the voltage lead wire is located at the Mth layer and the neutral lead wire is located at the 1st layer.

[0151] Specifically, the voltage lead wire and the neutral lead wire of each branch in each phase of the S-phase stator winding can be set on any side of the stator assembly in the axial direction, such as Figure 1 It is set at the top of the stator assembly, at the head end of the stator winding. In fact, it can also be set at the bottom of the stator assembly, at the welding end of the stator winding. The voltage lead can also be set at the 1st or Mth layer of any stator slot, such as Figure 6 The voltage lead of one branch is set at the first winding layer of the stator slot, and the voltage lead of the other branch is set at the Mth winding layer of the stator slot. Correspondingly, the neutral line lead is set at the Mth or 1st layer of any stator slot, such as Figure 6 The neutral line lead-out line of one branch is set in the Mth layer winding of the stator slot, and the electrical neutral line lead-out line of the other branch is set in the 1st layer winding of the stator slot.

[0152] The following is an example of a stator assembly for a three-phase motor with 72 slots and 8 poles. Set S=3, M=8, N=72, and p=4. Figure 6-Figure 7 This embodiment is described in detail. Figure 6-Figure 7 In the figure, the horizontal marks 1-72 indicate the stator slot numbers, and the vertical marks 1-8 indicate the winding layer numbers in the stator slots; the solid line indicates the connecting part between the two straight segments of the U-shaped hairpin coil, namely the head 151, and the dotted line indicates the welding part of the U-shaped hairpin coil at one end away from the head 151, namely the bending part 152.

[0153] In an optional implementation of this embodiment, when S=3, M=8, N=72, p=4, a=2,

[0154] Each first coil group includes 9 full-span U-shaped hairpin coils with a span of 9 and 2 long-span U-shaped hairpin coils with a span of 10;

[0155] Each second coil group includes a short-distance U-shaped hairpin coil with a span of 7.

[0156] like Figure 6 The U-phase stator winding shown includes two branches u1 and u2. The voltage lead wire of branch u1 is located at the first layer of the stator slot, and the neutral lead wire is located at the Mth layer of the stator slot. The voltage lead wire of branch u2 is located at the Mth layer of the stator slot, and the neutral lead wire is located at the first layer of the stator slot.

[0157] The u1 branch includes four first coil groups U11, U12, U13, and U14, U11 is located in the first area, U12 is located in the second area, U13 is located in the third area, and U14 is located in the fourth area; it also includes three second coil groups U21, U22, and U23, U21 is located in the second and third layers of the stator slot between the first and second areas, U22 is located in the fourth and fifth layers of the stator slot between the second and third areas, and U23 is located in the sixth and seventh layers of the stator slot between the third and fourth areas.

[0158] like Figure 6 As shown, in branch u1, U11, U12, U13, and U14 each include nine full-span U-shaped hairpin coils with a span of 9 and two long-span U-shaped hairpin coils with a span of 10. U21, U22, and U23 each include one short-span U-shaped hairpin coil with a span of 7. The voltage lead u1+ of branch u1 is located in the first layer of the third stator slot, and the neutral lead u1- is located in the eighth layer of the tenth stator slot. Both voltage lead u1+ and neutral lead u1- can use I-type coils.

[0159] The structure of the u2 branch is similar to that of the u1 branch, with the only difference being that the voltage lead wire u2+ of the u2 branch is located at the 8th layer of the 1st stator slot, and the neutral line lead wire u2- is located at the 1st layer of the 66th stator slot.

[0160] In a specific application, the two branches of each phase winding are located in three adjacent slots and are staggered in each layer in a region. One of the two branches is first introduced from the first layer, and is spirally connected from the outer diameter of the stator to the inner diameter of the stator in the order of U11, U21, U12, U22, U13, U23, and U14, and is then led out from the eighth layer. For example, the connection method of branch u1 in this embodiment is:

[0161] In the first area, the voltage lead wire u1+ of the I-type coil is introduced into the first layer of the third stator slot, and then the three coils with a span of 9 of U11 are continuously crossed over the number of layers to bridge the stator circle, and then a coil with a span of 10 is bridged to the left adjacent slot of the third stator slot, that is, the first layer of the second stator slot. Then, the three coils with a span of 9 of U11 are continuously crossed over the number of layers to bridge the stator circle, and then a coil with a span of 10 is bridged to the left adjacent slot of the second stator slot, that is, the first layer. 1st layer of the stator slot, then through the three coils with a span of 9 of U11, continuously cross the layers to bridge the stator for one circle, and then through the one coil with a span of 7 of U21 to enter the second area; that is, through the three coils with a span of 9 of U11, one coil with a span of 10, three coils with a span of 9, one coil with a span of 10, and three coils with a span of 9, continuously cross the layers to bridge the stator for three circles, and then through the one coil with a span of 7 of U21 to enter the second area;

[0162] In the second area, the coils are connected through three coils with a span of 9, one coil with a span of 10, three coils with a span of 9, one coil with a span of 10, and three coils with a span of 9, crossing the stator three times, and then entering the third area through one coil with a span of 7 of U22.

[0163] In the third area, the coils are connected through three coils with a span of 9, one coil with a span of 10, three coils with a span of 9, one coil with a span of 10, and three coils with a span of 9, crossing the stator three times, and then entering the fourth area through one coil with a span of 7 of U23.

[0164] In the 4th area, the three coils with a span of 9, one coil with a span of 10, three coils with a span of 9, one coil with a span of 10, and three coils with a span of 9 of U14 are crossed in layers to bridge three turns of the stator, and then the neutral line u1- of the I-type coil is led out at the 8th layer of the 10th stator slot.

[0165] Correspondingly, the other branch of the two branches is introduced from the 8th layer and spirally connected from the inner diameter of the stator to the outer diameter of the stator in the order of U14, U23, U13, U22, U12, U21, and U11, and then led out from the 1st layer. For example, the connection method of branch u2 in this embodiment is similar to that of u1 and will not be repeated here. In the above two branches u1 and u2, each area uses the same coil and the corresponding process is also the same. The cross-layer wires and their processes used between areas are also the same, and the types of coils involved are relatively small.

[0166] In another optional implementation of this embodiment, when S=3, M=8, N=72, p=4, a=4,

[0167] Each first coil group includes 4 full-span U-shaped hairpin coils with a span of 9 and 1 long-span U-shaped hairpin coil with a span of 10;

[0168] Each second coil group includes a short-distance U-shaped hairpin coil with a span of 7 or a full-distance U-shaped hairpin coil with a span of 9.

[0169] like Figure 7 The U-phase stator winding shown includes four branches u1, u2, u3 and u4. The voltage lead wires of branches u1 and u3 are located at the first layer of the stator slots, and the neutral lead wire is located at the Mth layer of the stator slots. The voltage lead wires of branches u2 and u4 are located at the Mth layer of the stator slots, and the neutral lead wire is located at the first layer of the stator slots.

[0170] The u1 branch includes four first coil groups U11, U12, U13, and U14, U11 is located in the first area, U12 is located in the second area, U13 is located in the third area, and U14 is located in the fourth area; it also includes three second coil groups U21, U22, and U23, U21 is located in the second and third layers of the stator slot between the first and second areas, U22 is located in the fourth and fifth layers of the stator slot between the second and third areas, and U23 is located in the sixth and seventh layers of the stator slot between the third and fourth areas.

[0171] like Figure 7 As shown, in branch u1, U11, U12, U13, and U14 each include four full-span U-shaped hairpin coils with a span of 9 and one long-span U-shaped hairpin coil with a span of 10. U21 includes one full-span U-shaped hairpin coil with a span of 9, U22 includes one short-span U-shaped hairpin coil with a span of 7, and U23 includes one full-span U-shaped hairpin coil with a span of 9. The voltage lead u1+ of branch u1 is located in the first layer of the third stator slot, and the neutral lead u1- is located in the eighth layer of the tenth stator slot. Both voltage lead u1+ and neutral lead u1- can use I-type coils.

[0172] The structure of the u2 branch is similar to that of the u1 branch, with the only difference being that the voltage lead wire u2+ of the u2 branch is located at the 8th layer of the 1st stator slot, and the neutral line lead wire u2- is located at the 1st layer of the 66th stator slot.

[0173] The structure of branch U3 is similar to that of branch U1, differing only in that branch U21 includes a short-span U-shaped hairpin coil with a span of 7, U22 includes a full-span U-shaped hairpin coil with a span of 9, and U23 includes a short-span U-shaped hairpin coil with a span of 7. The voltage lead u3+ of branch U3 is located in the first layer of the 38th stator slot, and the neutral lead u3- is located in the eighth layer of the 47th stator slot.

[0174] The structure of the u4 branch is similar to that of the u3 branch, with the only difference being that the voltage lead wire u2+ of the u4 branch is located at the 8th layer of the 38th stator slot, and the neutral line lead wire u4- is located at the 1st layer of the 29th stator slot.

[0175] In a specific application, the four branches of each phase winding are located in three adjacent slots and are staggered in layers within a region. Two of the four branches are introduced from the first layer, and are spirally connected from the outer diameter of the stator to the inner diameter of the stator in the order of U11, U21, U12, U22, U13, U23, and U14, and are then led out from the eighth layer. For example, the connection method of branch u1 in this embodiment is:

[0176] In the first area, the voltage lead u1+ of the I-type coil is introduced into the first layer of the third stator slot, and then the three coils with a span of 9 of U11 are continuously crossed over the layers to bridge the stator for one circle, and then the coil with a span of 10 is bridged to the first layer of the second stator slot, which is the adjacent slot on the left side of the third stator slot, and then the coil with a span of 9 of U11 is bridged to the second layer of the 47th stator slot, and then the coil with a span of 7 of U21 is bridged into the second area; that is, the three coils with a span of 9, the coil with a span of 10, and the coil with a span of 9 of U11 are continuously crossed over the layers to bridge the stator for one and a half circles, and then the coil with a span of 9 of U21 is bridged into the second area;

[0177] In the second area, it passes through three coils with a span of 9, one coil with a span of 10, and one coil with a span of 9 of U12, and then crosses the stator for one and a half turns. Then, it enters the third area through one coil with a span of 7 of U22.

[0178] In the third area, it passes through three coils with a span of 9, one coil with a span of 10, and one coil with a span of 9 of U13, and then crosses the stator for one and a half turns. Then, it enters the fourth area through one coil with a span of 9 of U23.

[0179] In the 4th area, three coils with a span of 9, one coil with a span of 10, and one coil with a span of 9 of U14 are crossed in turn to bridge one and a half turns of the stator, and then the neutral line u1- of the I-type coil is led out at the 8th layer of the 10th stator slot.

[0180] Correspondingly, the other two of the four branches are introduced from layer 8, spirally connected from the inner diameter of the stator to the outer diameter of the stator in the order of U14, U23, U13, U22, U12, U21, and U11, and then exit from layer 1. For example, branch u2 in this embodiment is connected in a similar manner to u1, differing only in the use of different coils for the crossover between the two regions. The same coils are used in all other regions, and the corresponding processes are also the same. The four branches u1, u2, u3, and u4 mentioned above all use the same coils in each region.

[0181] In the above two embodiments, the U-shaped hairpin coils required for winding the U-phase stator winding of 2 branches include three different types and processes of coils: the same-area cross-layer wire with a span of 9, the same-area cross-layer wire with a span of 10, and the cross-area cross-layer wire with a span of 7; the U-shaped hairpin coils required for winding the U-phase stator winding of 4 branches include four different types and processes of coils: the same-area cross-layer wire with a span of 9, the same-area cross-layer wire with a span of 10, the cross-area cross-layer wire with a span of 7, and the cross-area cross-layer wire with a span of 9.

[0182] From this, it can be seen that the same-area cross-layer wire with a span of 9, the same-area cross-layer wire with a span of 10, and the cross-area cross-layer wire with a span of 7 can be used to wind the above-mentioned 2-branch and 4-branch stator windings. Furthermore, the same-area cross-layer wire with a span of 9 can also be used to wind the stator windings of 1, 2 or 3 branches in the above-mentioned embodiment 2, which is sufficient to illustrate that the winding connection method of this embodiment is compatible with different parallel branches.

[0183] Based on the multiple implementation methods of the above-mentioned Examples 2 and 3, when a motor production scenario includes coils of all the above-mentioned different types and processes, specifically including nine types of U-shaped hairpin coils, including same-region cross-layer lines with a span of 9, same-region cross-layer lines with a span of 10, same-layer lines with a span of 8, same-layer lines with a span of 11, same-layer lines with a span of 9, cross-region cross-layer lines with a span of 8, cross-region cross-layer lines with a span of 11, cross-region cross-layer lines with a span of 7, and cross-region cross-layer lines with a span of 9, a three-phase motor with 1 branch, 2 branches, 3 branches or 4 branches per phase stator winding can be obtained.

[0184] Optionally, in the above-mentioned various embodiments, the three-phase stator winding is on the welding side of the stator core ( Figure 3-Figure 7 The structure of the middle dotted line part) can be exactly the same to ensure the same torsional welding process after wire insertion, realize common production line production, and further improve the production efficiency of the motor.

[0185] It should be noted that the above-mentioned various implementations only take the 8-pole 72-slot motor as an example. In actual applications, the winding connection method of the stator assembly in this embodiment can also be applied to other motors with 3 slots per pole and per phase, such as 6-pole 54 slots, 10-pole 90 slots, 12-pole 108 slots, etc. The above-mentioned stator winding connection method is simple, with a small number of wire types and mold types, and can be compatible with the actual production of 1 branch, 2 branches, 3 branches, and 4 branches at the same time. The connection of the U-shaped hairpin coil is simple and easy to process, and the position of the input and output lines can be changed according to actual needs, so that it can be compatible with a variety of flat wire layers, such as 4 layers, 6 layers, etc. In the above-mentioned implementation, the motor input and output lines are simultaneously in the 1st layer or respectively in the 1st layer and the Mth layer as an example. In actual applications, it can also be adjusted to other layers.

[0186] The stator assembly proposed in this embodiment provides a variety of options for the number of parallel branches, while being able to share actual production processes such as torsion. The number of flat wire layers can also be changed accordingly, thereby changing the number of series turns per phase of the motor, thereby facilitating the improvement of the matching between the low-speed torque and high-speed power of the motor.

[0187] Example 4

[0188] This embodiment provides a motor, which may include:

[0189] The stator assembly 10 of any implementation manner of the above embodiment 1; and the rotor assembly.

[0190] The rotor assembly includes a rotor core made of stacked silicon steel sheets and a rotating shaft. The stator assembly 10 includes a stator core 11 and an S-phase stator winding 12. The stator core 11 includes stator teeth and stator slots 13, and the S-phase stator winding 12 includes a U-shaped hairpin coil 15. The specific connection method can be found in the description of the above embodiments and will not be repeated here.

[0191] It should be noted that the specific structure of the stator assembly can refer to the above embodiments. Since this embodiment adopts all the technical solutions of all the above embodiments, it has at least all the beneficial effects brought by the technical solutions of the above embodiments, which will not be described one by one here.

[0192] It should be noted that the serial numbers of the embodiments of the present application are for descriptive purposes only and do not represent the superiority or inferiority of the embodiments. The above are only optional embodiments of the present application and do not limit the scope of the patent of the present application. All equivalent structural transformations made based on the content of the present application description and drawings, or directly or indirectly applied to other related technical fields, are included in the scope of patent protection of the present application.

Claims

1. A stator assembly, characterized in that: For an S-phase motor, the number of rotor poles of the S-phase motor is 2p, where S and p are positive integers; the stator assembly comprises: A stator core, wherein the inner periphery of the stator core has N stator slots arranged at intervals and extending radially along the stator core; An S-phase stator winding, wherein the S-phase stator winding is wound into M layers of windings by a plurality of U-shaped hairpin coils in the stator slots, and the M layers of windings are sequentially arranged from the first layer to the Mth layer along the radial direction of the stator core toward the center of the circle, where M is a positive integer and is an even number greater than or equal to 4; In the M-layer winding, two adjacent layers of winding constitute one area, and the M-layer winding includes regions; The M layers of windings in any stator slot belong to the same phase, and the stator windings of each pole and each phase are placed in three adjacent stator slots; Each phase of the stator winding includes a parallel branches, a=1, 2, 3 or 4; Each of the branches includes a first coil group located in the same area and A second coil group located in two adjacent areas; wherein, The first coil groups share a flat wire twisting process, The second coil groups share another flat wire twisting process.

2. The stator assembly according to claim 1, wherein The U-shaped hairpin coil includes two straight segments and a head connected to one end of the two straight segments, and the two straight segments are respectively placed in the two stator slots; Each of the first coil groups includes a plurality of first hairpin coils whose two straight segments are respectively located in adjacent layers of two stator slots, and the first hairpin coils include full-pitch U-shaped hairpin coils and / or long-pitch U-shaped hairpin coils; Each of the second coil groups includes one or more second hairpin coils whose two straight segments are respectively located in adjacent layers of two stator slots, and the second hairpin coils include short-distance U-shaped hairpin coils, full-distance U-shaped hairpin coils and / or long-distance U-shaped hairpin coils; The short-distance U-shaped hairpin coil includes a span of and / or U-shaped hairpin coil; The full-spacing U-shaped hairpin coil includes a span of U-shaped hairpin coil; The long distance U-shaped hairpin coil includes a span of and / or U-shaped hairpin coil.

3. The stator assembly according to claim 2, wherein: The two straight segments of the U-shaped hairpin coil are each provided with a bending portion at one end away from the head; When a=1, a=2 or a=3, the voltage lead wire and the neutral lead wire of each branch are located at the same layer of the stator slots, and the voltage lead wire and the neutral lead wire of each branch are located at the same layer of the stator slots. The first coil group in each region further includes a return crossover wire, which is a U-shaped hairpin coil with two bending parts having the same bending direction, and the return crossover wire is located in the Mth layer of the stator slot.

4. The stator assembly according to claim 3, wherein: When S=3, M=8, N=72, p=4, a=3, Each of the first coil groups includes 6 full-span U-shaped hairpin coils with a span of 9, and the return crossover includes a short-span U-shaped hairpin coil with a span of 8 or a long-span U-shaped hairpin coil with a span of 11; Each of the second coil groups includes two short-distance U-shaped hairpin coils with a span of 8 or one short-distance U-shaped hairpin coil with a span of 8 and one long-distance U-shaped hairpin coil with a span of 11.

5. The stator assembly according to claim 3, wherein: When S=3, M=8, N=72, p=4, a=2, Each of the first coil groups includes 8 full-span U-shaped hairpin coils with a span of 9 and 2 long-span U-shaped hairpin coils with a span of 10, and the return span includes a full-span U-shaped hairpin coil with a span of 9; Each of the second coil groups includes two short-span U-shaped hairpin coils with a span of 7 or two full-span U-shaped hairpin coils with a span of 9.

6. The stator assembly according to claim 3, wherein: When S=3, M=8, N=72, p=4, a=1, Each of the first coil groups includes 18 full-span U-shaped hairpin coils with a span of 9 and 4 long-span U-shaped hairpin coils with a span of 10, and the return span includes a full-span U-shaped hairpin coil with a span of 9; Each of the second coil groups includes two short-distance U-shaped hairpin coils with a span of 7.

7. The stator assembly according to claim 2, wherein: When a=2 or a=4, the voltage lead wire of each branch is located at the 1st layer and the neutral lead wire is located at the Mth layer, or the voltage lead wire is located at the Mth layer and the neutral lead wire is located at the 1st layer.

8. The stator assembly according to claim 7, wherein: When S=3, M=8, N=72, p=4, a=2, Each of the first coil groups includes 9 full-span U-shaped hairpin coils with a span of 9 and 2 long-span U-shaped hairpin coils with a span of 10; Each of the second coil groups includes a short-span U-shaped hairpin coil with a span of 7.

9. The stator assembly according to claim 7, wherein: When S=3, M=8, N=72, p=4, a=4, Each of the first coil groups includes four full-span U-shaped hairpin coils with a span of 9 and one long-span U-shaped hairpin coil with a span of 10; Each of the second coil groups includes a short-span U-shaped hairpin coil with a span of 7 or a full-span U-shaped hairpin coil with a span of 9.

10. A motor, characterized in that: The invention comprises a stator assembly and a rotor assembly according to any one of claims 1 to 9.

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