Motor electromagnetic driving structure using continuous waves to wind copper wires and stacked in multiple layers

Abstract

The invention discloses a motor electromagnetic driving structure using continuous waves to wind copper wires and stacked in multiple layers. Comprising a stator shell and a continuous wave winding copper wire group wound outside the stator shell, stator grooves are formed in the periphery of the stator shell, the continuous wave winding copper wire group is wound in the stator grooves, and the continuous wave winding copper wire group is formed by continuous wave winding of a plurality of groups of copper wire windings with different lengths and different distribution positions. And a three-phase interface is output through specific wiring connection among different copper wire windings. The defect that the motor performance is improved by purely increasing the use amount of copper wires is overcome, a brand new idea is developed for designing an electromagnetic scheme in a narrow space, an electromagnetic scheme is newly designed, the electromagnetic performance of a system is improved, and the use amount of the copper wires is greatly reduced.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of two-wheeled electric vehicle parts manufacturing, and particularly relates to a motor electromagnetic drive structure design using continuous wave winding copper wire and multi-layer stacking. BACKGROUND

[0002] Currently on the market, two-wheeled electric vehicles using 12-inch rims all use multi-strand concentrated winding motors. Such motors have low copper wire slot filling rate, high magnetic leakage, and it is difficult to improve motor efficiency. Torque fluctuation is obvious, and running stability is poor, which is not suitable for high-precision and high-stability occasions. In this case, continuing to improve the performance of the motor often means increasing the use of copper wire, expanding the number of windings, and increasing the volume of the magnet. However, the performance improvement is not obvious, and it becomes a situation of half the work and twice the effort.

[0003] Due to the small space of 12-inch rims, how to select, weave and embed the wire so that the three form an excellent three-phase circuit and form a stronger magnetic field has become a new problem. The continuous wave winding scheme of existing large motors is not suitable for this, and after scaling down, its performance is much weaker than the multi-strand concentrated winding electromagnetic scheme, so improvement in this regard seems meaningless.

[0004] How to design a continuous wave winding electromagnetic scheme that is different from others and has excellent performance for 12-inch and other small-sized two-wheeled electric vehicle hub motors, and arrange it in the small space of a 12-inch rim while having better performance than the current multi-strand concentrated winding scheme, has become a problem that needs to be solved by the present application. SUMMARY

[0005] In view of the problems and defects of the above background technology, the present application designs a continuous wave winding electromagnetic scheme for 12-inch and other small-sized two-wheeled electric vehicle hub motors, which abandons the multi-strand concentrated winding electromagnetic scheme of the prior art and adopts a different special design.

[0006] That is, in view of the problems existing in the above background technology, the present application develops an electromagnetic drive structure using continuous wave winding copper wire and multi-layer stacking and applies it to motor production. The motor using this scheme is arranged in a 12-inch rim and has better performance than the multi-strand concentrated winding electromagnetic scheme commonly used in the industry. At the same time, the multi-strand concentrated winding electromagnetic scheme is optimized in view of the large amount of copper wire used, and the amount of copper wire used is reduced in this scheme and used in a small space.

[0007] To achieve the above purpose, the present application adopts the following technical scheme:

[0008] It comprises a stator shell.

[0009] The continuous wave winding copper wire group is formed by continuously winding a plurality of copper wire groups with different lengths and different distribution positions.

[0010] The three-phase interface includes three-phase wires, and the continuous wave winding copper wire group is connected by specific wiring between different copper wire groups.

[0011] A rotor housing is further arranged outside the stator housing, and a permanent magnet is arranged on the inner circumferential surface of the rotor housing for cooperation with the continuous wave winding copper wire group.

[0012] The outer circumferential surface of the stator housing is circumferentially spaced apart to form N stator slots, and the stator teeth are formed between adjacent stator slots. Each copper wire group of the continuous wave winding copper wire group is embedded into the stator slots from the outside to the inside.

[0013] The continuous wave winding copper wire group is divided into a plurality of copper wire groups, and each copper wire group is continuously wound in an S-shaped path with two stator slots as a period, that is, each copper wire group is continuously wound in an S-shaped path on a plurality of stator slots spaced apart by two stator slots.

[0014] The adjacent copper wire groups are wound in a staggered manner with a preset hourglass direction interval of k stator slots along the circumferential direction of the stator housing, and k is usually equal to 1. The preset hourglass direction is one of clockwise or counterclockwise.

[0015] Each stator slot is basically axially arranged along the main shaft of the motor and is obliquely parallel through, so that the copper wire of the copper wire group wound in the stator slot is also obliquely arranged to the main shaft of the motor.

[0016] Each stator slot of the stator housing is not completely axially arranged along the main shaft, but is obliquely inclined by an angle of 4.75°-5.3° to the tangential direction on the basis of being parallel to the axial direction, so that the copper wire of the copper wire group wound in the stator slot is arranged obliquely by an angle of 4.75°-5.3° to the tangential direction on the basis of being parallel to the axial direction.

[0017] The continuous wave winding copper wire group includes four copper wire groups with different lengths, and the four copper wire groups with different lengths are respectively wound in continuous stator slots covering 1 / 4, 2 / 4, 3 / 4, and 4 / 4 of the entire circumferential direction of the stator housing.

[0018] Alternatively / and the continuous wave winding copper wire group includes four copper wire groups with different starting points, and the starting points of the four copper wire groups with different starting points are respectively from the stator slots at the middle of the upper side, the middle of the left side, the middle of the lower side, and the middle of the right side of the stator housing.

[0019] Or / and the continuous wave winding copper wire group includes four kinds of terminal different copper wire winding, and the terminal ends of the four kinds of terminal different copper wire winding are respectively wound to the middle of the upper side, the middle of the left side, the middle of the lower side and the middle of the right side of the stator shell.

[0020] The present application forms simple and effective winding and wiring through the special design of different groups, wiring and connection in the continuous wave winding copper wire group, the whole copper amount is significantly reduced, and the performance and efficiency of motor control can be significantly improved.

[0021] The continuous wave winding copper wire group includes seven kinds of copper wire winding with different lengths and distribution positions, each copper wire winding includes three copper wire windings, and a total of 21 copper wire windings;

[0022] The first copper wire winding includes three copper wire windings covering 1 / 4 of the complete circumference of the stator shell, wherein each two adjacent copper wire windings are arranged by being staggered by one stator slot in the preset clockwise direction, and the starting ends of the three copper wire windings are respectively wound from the three stator slots near the upper side of the stator shell, and the terminal ends are respectively wound to the three stator slots near the upper side of the stator shell.

[0023] The second copper wire winding includes three copper wire windings covering 2 / 4 of the complete circumference of the stator shell, wherein each two adjacent copper wire windings are arranged by being staggered by one stator slot in the preset clockwise direction, and the starting ends of the three copper wire windings are respectively wound from the three stator slots near the upper side of the stator shell, and the terminal ends are respectively wound to the three stator slots near the upper side of the stator shell.

[0024] The third copper wire winding includes three copper wire windings covering 3 / 4 of the complete circumference of the stator shell, wherein each two adjacent copper wire windings are arranged by being staggered by one stator slot in the preset clockwise direction, and the starting ends of the three copper wire windings are respectively wound from the three stator slots near the upper side of the stator shell, and the terminal ends are respectively wound to the three stator slots near the upper side of the stator shell.

[0025] The fourth copper wire winding includes three copper wire windings covering 4 / 4 of the complete circumference of the stator shell, wherein each two adjacent copper wire windings are arranged by being staggered by one stator slot in the preset clockwise direction, and the starting ends of the three copper wire windings are respectively wound from the three stator slots near the upper side of the stator shell, and the terminal ends are respectively wound to the three stator slots near the upper side of the stator shell.

[0026] The fifth copper wire winding includes three copper wire windings each covering 3 / 4 of the complete circumference of the stator slots, wherein each two adjacent copper wire windings are arranged in a staggered manner along the circumference with one stator slot in the preset clockwise direction, and the starting ends of the three copper wire windings are respectively wound from the three stator slots near the left middle of the stator shell, and the ending ends are respectively wound to the three stator slots near the upper middle of the stator shell.

[0027] The sixth copper wire winding includes three copper wire windings each covering 2 / 4 of the complete circumference of the stator slots, wherein each two adjacent copper wire windings are arranged in a staggered manner along the circumference with one stator slot in the preset clockwise direction, and the starting ends of the three copper wire windings are respectively wound from the three stator slots near the lower middle of the stator shell, and the ending ends are respectively wound to the three stator slots near the upper middle of the stator shell.

[0028] The seventh copper wire winding includes three copper wire windings each covering 1 / 4 of the complete circumference of the stator slots, wherein each two adjacent copper wire windings are arranged in a staggered manner along the circumference with one stator slot in the preset clockwise direction, and the starting ends of the three copper wire windings are respectively wound from the three stator slots near the right middle of the stator shell, and the ending ends are respectively wound to the three stator slots near the upper middle of the stator shell.

[0029] Among the 21 copper wire windings of the seven different lengths and different distribution positions:

[0030] On the left side of the stator shell, the ending ends of the three copper wire windings of the first copper wire winding are respectively connected to the starting ends of the three copper wire windings of the fifth copper wire winding.

[0031] On the lower side of the stator shell, the ending ends of the three copper wire windings of the second copper wire winding are respectively connected to the starting ends of the three copper wire windings of the sixth copper wire winding.

[0032] On the right side of the stator shell, the ending ends of the three copper wire windings of the third copper wire winding are respectively connected to the starting ends of the three copper wire windings of the seventh copper wire winding.

[0033] On the upper side of the stator shell:

[0034] The starting first end of the first copper wire winding and the starting first end of the last copper wire winding of the third copper wire winding are correspondingly connected, the starting first end of the first copper wire winding and the starting first end of the last copper wire winding of the sixth copper wire winding are correspondingly connected, and the starting first end of the middle one of the second copper wire winding and the fourth copper wire winding and the ending last end of the middle one of the fifth copper wire winding and the seventh copper wire winding are connected together.

[0035] The starting first end of the middle one of the first copper wire winding, the starting first end of the middle one of the third copper wire winding, the ending last end of the middle one of the fourth copper wire winding and the ending last end of the middle one of the sixth copper wire winding are connected together to form the second phase of the three-phase line; the starting first end of the first copper wire winding of the second copper wire winding and the fourth copper wire winding and the ending last end of the first copper wire winding of the fifth copper wire winding and the seventh copper wire winding are connected together to form the third phase of the three-phase line; and the starting first end of the last copper wire winding of the second copper wire winding and the fourth copper wire winding and the ending last end of the last copper wire winding of the fifth copper wire winding and the seventh copper wire winding are connected together to form the first phase of the three-phase line.

[0036] The motor electromagnetic driving structure of the application has the advantages that:

[0037] The motor electromagnetic driving structure of the application has the advantages that:

[0038] The motor electromagnetic driving structure of the application has the advantages that: BRIEF DESCRIPTION OF DRAWINGS

[0039] Figure 1 is a schematic diagram of the appearance of No. 1 copper wire.

[0040] Figure 2 is a schematic diagram of the four specifications of winding copper wire used in the application.

[0041] Figure 3 is a schematic diagram of the electric path of the stator of the application.

[0042] Figure 4 is a schematic diagram of the copper wire inserted and stacked in sequence.

[0043] Figure 5It is the schematic diagram of the circuit line group assembly of the application.

[0044] Figure 6 It is the schematic diagram of the 1# line insertion position and installation state of the application.

[0045] Figure 7 It is the schematic diagram of the circuit axial direction of the stator of the application.

[0046] Figure 8 It is the schematic diagram of the 1-21# copper line of the application.

[0047] Figure 9 It is the position structure diagram of the 1-21# copper line of the application on the stator shell.

[0048] Figure 10 It is the schematic diagram of the connection of each joint point of the circuit line group of the application.

[0049] Figure 11 It is the partial enlarged view of Figure 10

[0050] Figure 12 It is the connection diagram of the partial circuit line group of the application.

[0051] Figure 13 It is the schematic diagram of the three-phase electric connection structure of the busbar of the application.

[0052] Figure 14 It is the schematic diagram of the electromagnetic driving structure of the application.

[0053] Figure 15 It is the continuous wave winding structure diagram of the comparative example 1: embedded copper line;

[0054] Figure 16 It is the schematic diagram of the concentrated winding structure of the comparative example 2;

[0055] Figure 17 It is the schematic diagram of the concentrated winding structure of the comparative example 3: outer stator and inner rotor structure.

[0056] In the figure: rotor shell (1), permanent magnet (6), continuous wave winding copper line group (9), stator shell (10), three-phase line (14), busbar (15). DETAILED DESCRIPTION

[0057] The technical scheme of the application patent will be further specifically explained in combination with the drawings, but it is not the limitation of the protection scope of the application patent.

[0058] As Figure 7 and Figure 14 ​As shown, the structure of the embodiment includes a stator housing 10 and a continuous wave winding copper wire group 9 wound outside the stator housing 10, and the outer periphery of the stator core of the stator housing 10 is provided with stator slots, and each stator slot is wound with the continuous wave winding copper wire group 9. The continuous wave winding copper wire group 9 is formed by continuously winding a plurality of copper wire groups with different lengths and different distribution positions, and cooperates with the connection between different copper wire groups through a specific wiring connection to output a three-phase interface. The three-phase interface is used for external control connection to energize the continuous wave winding copper wire group 9 to realize electromagnetic control.

[0059] The continuous wave winding copper wire group 9 is connected to the external inverter controller after passing through the three-phase wire 14 and the busbar 15.

[0060] The rotor housing 1 is further provided outside the stator housing 10, and the inner periphery surface of the rotor housing 1 is provided with a permanent magnet 6 for cooperation with the continuous wave winding copper wire group 9. The permanent magnet 6 and the continuous wave winding copper wire group 9 are close to each other with a gap therebetween. The rotor housing 1 and the stator housing 10 are connected to the main shaft of the motor through a third generation hub bearing unit.

[0061] The continuous wave winding copper wire group 9 is embedded from outside to inside in the outer periphery of the stator housing 10. The outer periphery surface of the stator housing 10 is provided with N stator slots at intervals in the circumferential direction, and the stator teeth are formed between adjacent stator slots. The continuous wave winding copper wire group 9 is embedded from outside to inside in the stator slots. In the embodiment, the number of N can be set to 168, which is an integer multiple of 4.

[0062] As shown, Figure 6 The continuous wave winding copper wire group 9 is divided into a plurality of copper wire groups with different lengths and different distribution positions, and each copper wire group is continuously wound in an S-shaped path on a plurality of stator slots at an interval of two stator slots. That is, in each stator slot wound by each copper wire group, the adjacent stator slots wound are spaced apart by two vacant stator slots, thereby forming a continuous wave winding winding with a period of three stator slots.

[0063] As shown, Figure 6 Each copper wire group is a copper wire with two ends, and the two ends of the copper wire are not connected in a closed loop. The subsequent design of the connection line connects the two ends of the copper wire of each copper wire group.

[0064] As shown, Figure 4 Generally, the adjacent copper wire groups are wound in a staggered manner with a fixed hourglass direction along the circumferential direction of the stator housing 10 at an interval of one stator slot. The fixed hourglass direction is one of clockwise or counterclockwise.

[0065] There are a plurality of copper wire groups in the same stator slot, and the copper wires of each copper wire group are embedded in layers from inside to outside in the stator slot. The staggered winding and the embedding in layers from inside to outside finally make the same number of copper wires of each copper wire group exist in each stator slot.

[0066] Finally, as shown in Figures 5-7 , the multi-level continuous wave around copper wire.

[0067] As shown in Figure 3 , the axial ends and the outside of the stator slot are through, each stator slot is basically along the motor spindle axial opening and inclined parallel to both ends through, so that the copper wire winding around the copper wire winding in the stator slot is also inclined to the motor spindle.

[0068] As shown in Figure 1 , each stator slot of the stator shell 10 is not completely along the axial direction of the main shaft 11, but is inclined to the tangential direction by an angle of 4.75°-5.3° on the basis of the original parallel to the axial direction, so that the copper wire of the continuous wave around copper wire group 9 in the stator slot is also inclined to the tangential direction.

[0069] As shown in Figure 2 , the continuous wave around copper wire group 9 includes four kinds of copper wire winding with different lengths, and the four kinds of copper wire winding with different lengths are used to wind around the continuous number of stator slots covering nearly 1 / 4, 2 / 4, 3 / 4, 4 / 4 of the total number of stator slots in the entire circumferential direction of the stator shell 10.

[0070] That is, the continuous wave around copper wire group 9 includes four kinds of copper wire winding with different starting points, and the starting points of the four kinds of copper wire winding with different starting points are respectively from the stator slots at the middle of the upper side, the middle of the left side, the middle of the lower side and the middle of the right side of the stator shell 10.

[0071] That is, the continuous wave around copper wire group 9 includes four kinds of copper wire winding with different ending points, and the ending points of the four kinds of copper wire winding with different ending points are respectively wound to the stator slots at the middle of the upper side, the middle of the left side, the middle of the lower side and the middle of the right side of the stator shell 10.

[0072] Each of the above-mentioned copper wire winding is also periodically S-shaped around the continuous wave winding with three stator slots as a period.

[0073] As shown in Figure 8 , the continuous wave around copper wire group 9 includes seven kinds of copper wire winding with different lengths and different distribution positions, each of which contains three copper wire windings, a total of 21 copper wire windings.

[0074] As shown in Figure 9 (a), the first kind of copper wire winding includes three copper wire windings covering 1 / 4 of the stator slots in the complete circumferential direction of the stator shell 10, which are 1-3 lines, as shown in Figure 4Wherein each two adjacent copper wire windings are arranged in a fixed anticlockwise direction with one stator slot interval, that is, the starting point and the ending point are arranged in a fixed clockwise direction with one stator slot interval. The starting end of the three copper wire windings is wound from the three stator slots near the upper middle of the stator shell 10, and after winding through the complete circumferential 1 / 4 number of stator slots of the stator shell 10 in a fixed anticlockwise direction, the ending end is wound to the three stator slots in the middle of the left side of the stator shell 10.

[0075] As shown in Figure 9 (b), the second copper wire winding includes three copper wire windings covering the complete circumferential 2 / 4 number of stator slots of the stator shell 10, which are No. 4-6 lines, respectively. Each two adjacent copper wire windings are arranged in a fixed anticlockwise direction with one stator slot interval, that is, the starting point and the ending point are arranged in a fixed clockwise direction with one stator slot interval. The first copper wire winding No. 4 line is also arranged in a fixed anticlockwise direction with one stator slot interval compared with the last copper wire winding No. 3 line in the previous copper wire winding. The starting end of the three copper wire windings is wound from the three stator slots in the middle of the upper side of the stator shell 10, and after winding through the complete circumferential 2 / 4 number of stator slots of the stator shell 10 in a fixed anticlockwise direction, the ending end is wound to the three stator slots near the lower middle of the stator shell 10.

[0076] As shown in Figure 9 (c), the third copper wire winding includes three copper wire windings covering the complete circumferential 3 / 4 number of stator slots of the stator shell 10, which are No. 7-9 lines, respectively. Each two adjacent copper wire windings are arranged in a fixed anticlockwise direction with one stator slot interval, that is, the starting point and the ending point are arranged in a fixed clockwise direction with one stator slot interval. The first copper wire winding No. 7 line is also arranged in a fixed anticlockwise direction with one stator slot interval compared with the last copper wire winding No. 6 line in the previous copper wire winding. The starting end of the three copper wire windings and the starting end of the three copper wire windings of the first copper wire winding correspond to the same three stator slots, which are wound from the three stator slots near the upper middle of the stator shell 10, and after winding through the complete circumferential 3 / 4 number of stator slots of the stator shell 10 in a fixed anticlockwise direction, the ending end is wound to the three stator slots in the middle of the right side of the stator shell 10.

[0077] As shown in Figure 9(d) as shown, the fourth copper wire winding contains three copper wire windings each covering 4 / 4 stator slots in the complete circumferential direction of the stator shell 10, which are No. 10-12 wires, wherein each two adjacent copper wire windings are arranged in a staggered manner with a fixed counterclockwise interval of one stator slot in the circumferential direction, that is, the starting point and the ending point are arranged with a fixed clockwise interval of one stator slot; and the first copper wire winding No. 10 wire is also arranged in a staggered manner with a fixed counterclockwise interval of one stator slot in the circumferential direction compared with the last copper wire winding No. 9 wire in the previous copper wire winding. The starting points of the three copper wire windings correspond to the same three stator slots as the starting points of the three copper wire windings of the second copper wire winding, which start from the three stator slots in the middle of the upper side of the stator shell 10, and after being wound in a fixed counterclockwise direction through 4 / 4 stator slots in the complete circumferential direction of the stator shell 10, the ending points are wound to the three stator slots close to the middle of the upper side of the stator shell 10.

[0078] As Figure 9 (e) as shown, the fifth copper wire winding contains three copper wire windings each covering 3 / 4 stator slots in the complete circumferential direction of the stator shell 10, which are No. 13-15 wires, wherein each two adjacent copper wire windings are arranged in a staggered manner with a fixed counterclockwise interval of one stator slot in the circumferential direction, that is, the starting point and the ending point are arranged with a fixed clockwise interval of one stator slot; and the first copper wire winding No. 13 wire is also arranged in a staggered manner with a fixed counterclockwise interval of one stator slot in the circumferential direction compared with the last copper wire winding No. 12 wire in the previous copper wire winding. The starting points of the three copper wire windings are respectively wound from the three stator slots close to the middle of the left side of the stator shell 10, and after being wound in a fixed counterclockwise direction through 3 / 4 stator slots in the complete circumferential direction of the stator shell 10, the ending points of the three copper wire windings and the starting points of the three copper wire windings of the second copper wire winding and the fourth copper wire winding correspond to the same three stator slots, which are respectively wound to the three stator slots in the middle of the upper side of the stator shell 10.

[0079] As Figure 9(f) As shown in Fig. 6, the sixth copper wire winding includes three copper wire windings, 16-18, each of which covers 2 / 4 of the complete circumferential direction of the stator shell 10, and each of which is arranged to be wound in a fixed counterclockwise direction with one stator slot offset between every two adjacent copper wire windings, i.e., the start point and the end point are arranged to be separated by one stator slot in a fixed clockwise direction. In addition, the first copper wire winding 16 is also arranged to be wound in a fixed counterclockwise direction with one stator slot offset in the circumferential direction compared to the last copper wire winding 15 of the previous copper wire winding. The start points of the three copper wire windings are arranged to be wound from the three stator slots in the middle of the lower side of the stator shell 10. After being wound in a fixed counterclockwise direction through 2 / 4 of the complete circumferential direction of the stator shell 10, the end points of the three copper wire windings are arranged to be wound into the three stator slots in the middle of the upper side of the stator shell 10, which are the same as the end points of the three copper wire windings of the fourth copper wire winding.

[0080] As shown in Fig. 4, Figure 9 (g) As shown in Fig. 7, the seventh copper wire winding includes three copper wire windings, 19-21, each of which covers 1 / 4 of the complete circumferential direction of the stator shell 10, and each of which is arranged to be wound in a fixed counterclockwise direction with one stator slot offset between every two adjacent copper wire windings, i.e., the start point and the end point are arranged to be separated by one stator slot in a fixed clockwise direction. In addition, the first copper wire winding 19 is also arranged to be wound in a fixed counterclockwise direction with one stator slot offset in the circumferential direction compared to the last copper wire winding 18 of the previous copper wire winding. The start points of the three copper wire windings are arranged to be wound from the three stator slots in the middle of the right side of the stator shell 10. After being wound in a fixed counterclockwise direction through 1 / 4 of the complete circumferential direction of the stator shell 10, the end points of the three copper wire windings are arranged to be wound into the three stator slots in the middle of the upper side of the stator shell 10, which are the same as the start points of the three copper wire windings of the second copper wire winding and the fourth copper wire winding, and the end points of the three copper wire windings of the fifth copper wire winding.

[0081] In the copper wire windings 1-21, each two adjacent copper wire windings are arranged to be wound in a fixed counterclockwise direction with one stator slot offset in the circumferential direction.

[0082] As shown in Fig. 4, Figure 10-11 In the 21 copper wire windings of the seven different lengths and distribution positions, as shown in Fig. 4,

[0083] As shown in Fig. 4, Figure 11 (b) and Figure 12As shown in Fig. 1 (a) and Fig. 1 (b), the end terminals of the three copper wire windings of the first kind of copper wire winding are respectively connected to the start terminals of the three copper wire windings of the fifth kind of copper wire winding, i.e. the end terminal 1E of the No. 1 copper wire winding and the start terminal 13S of the No. 13 copper wire winding can be tightly electrically connected through the metal clamp connecting assembly, the end terminal 2E of the No. 2 copper wire winding and the start terminal 14S of the No. 14 copper wire winding can be tightly electrically connected through the metal clamp connecting assembly, and the end terminal 3E of the No. 3 copper wire winding and the start terminal 15S of the No. 15 copper wire winding can be tightly electrically connected through the metal clamp connecting assembly.

[0084] As shown in Fig. 1 (a) and Fig. 1 (b), Figure 11 (c) and Figure 12 As shown in Fig. 1 (a) and Fig. 1 (b), the end terminals of the three copper wire windings of the second kind of copper wire winding are respectively connected to the start terminals of the three copper wire windings of the sixth kind of copper wire winding, i.e. the end terminal 4E of the No. 4 copper wire winding and the start terminal 16S of the No. 16 copper wire winding can be tightly electrically connected through the metal clamp connecting assembly, the end terminal 5E of the No. 5 copper wire winding and the start terminal 17S of the No. 17 copper wire winding can be tightly electrically connected through the metal clamp connecting assembly, and the end terminal 6E of the No. 6 copper wire winding and the start terminal 18S of the No. 18 copper wire winding can be tightly electrically connected through the metal clamp connecting assembly.

[0085] As shown in Fig. 1 (a) and Fig. 1 (b), Figure 11 (d) and Figure 12 As shown in Fig. 1 (a) and Fig. 1 (b), the end terminals of the three copper wire windings of the third kind of copper wire winding are respectively connected to the start terminals of the three copper wire windings of the seventh kind of copper wire winding, i.e. the end terminal 7E of the No. 7 copper wire winding and the start terminal 19S of the No. 19 copper wire winding can be tightly electrically connected through the metal clamp connecting assembly, the end terminal 8E of the No. 8 copper wire winding and the start terminal 20S of the No. 20 copper wire winding can be tightly electrically connected through the metal clamp connecting assembly, and the end terminal 9E of the No. 9 copper wire winding and the start terminal 21S of the No. 21 copper wire winding can be tightly electrically connected through the metal clamp connecting assembly.

[0086] The connecting assembly 7 is a conductive component that does not contact each other. The connecting assembly 7 helps the end of each copper wire winding to be efficiently electrically connected.

[0087] As shown in Fig. 1 (a) and Fig. 1 (b), Figure 11 (a) and Figure 12 As shown in Fig. 1 (a) and Fig. 1 (b), on the upper side of the stator shell 10:

[0088] The start terminals of the first and last copper wire windings of the first kind of copper wire winding are respectively connected to the start terminals of the first and last copper wire windings of the third kind of copper wire winding, i.e. the start terminal 1S of the No. 1 copper wire winding and the start terminal 7S of the No. 7 copper wire winding can be tightly electrically connected through the metal clamp connecting assembly, and the start terminal 3S of the No. 3 copper wire winding and the start terminal 9S of the No. 9 copper wire winding can be tightly electrically connected through the metal clamp connecting assembly.

[0089] The first and last copper wire winding of the fourth copper wire winding are connected to the first and last copper wire winding of the sixth copper wire winding, respectively, that is, the terminal end 10E of the No. 10 wire and the terminal end 16E of the No. 16 wire can be tightly electrically connected through the metal hoop connecting assembly, and the terminal end 12E of the No. 12 wire and the terminal end 18E of the No. 18 wire can be tightly electrically connected through the metal hoop connecting assembly.

[0090] The first and last copper wire winding of the fourth copper wire winding are connected to the first and last copper wire winding of the sixth copper wire winding, respectively, that is, the terminal end 10E of the No. 10 wire and the terminal end 16E of the No. 16 wire can be tightly electrically connected through the metal hoop connecting assembly, and the terminal end 12E of the No. 12 wire and the terminal end 18E of the No. 18 wire can be tightly electrically connected through the metal hoop connecting assembly.

[0091] The first and last copper wire winding of the fourth copper wire winding are connected to the first and last copper wire winding of the sixth copper wire winding, respectively, that is, the terminal end 10E of the No. 10 wire and the terminal end 16E of the No. 16 wire can be tightly electrically connected through the metal hoop connecting assembly, and the terminal end 12E of the No. 12 wire and the terminal end 18E of the No. 18 wire can be tightly electrically connected through the metal hoop connecting assembly.

[0092] The first and last copper wire winding of the fourth copper wire winding are connected to the first and last copper wire winding of the sixth copper wire winding, respectively, that is, the terminal end 10E of the No. 10 wire and the terminal end 16E of the No. 16 wire can be tightly electrically connected through the metal hoop connecting assembly, and the terminal end 12E of the No. 12 wire and the terminal end 18E of the No. 18 wire can be tightly electrically connected through the metal hoop connecting assembly.

[0093] The first and last copper wire winding of the fourth copper wire winding are connected to the first and last copper wire winding of the sixth copper wire winding, respectively, that is, the terminal end 10E of the No. 10 wire and the terminal end 16E of the No. 16 wire can be tightly electrically connected through the metal hoop connecting assembly, and the terminal end 12E of the No. 12 wire and the terminal end 18E of the No. 18 wire can be tightly electrically connected through the metal hoop connecting assembly.

[0094] As Figure 7 and Figure 13As shown, the busbar 15 is installed on the upper side of the stator housing 10, and the three phases of the three-phase wire 14 are respectively connected to the three phases of the busbar 15 through the electric wires on the stator housing 10, and finally led out by the busbar 15 and connected to the inverter through the three-phase cable.

[0095] In the embodiment, as shown in the drawings, Figure 2 the application uses four specifications of winding copper wires, and twenty-one copper wires are made according to the different lengths of the first and end wires, and each copper wire is arranged in sequence.

[0096] As shown in the drawings, Figure 6 , Figure 4 , Figure 5 The twenty-one copper wires are sequentially embedded in the stator core by professional equipment in a tight and fixed manner from the outside to the inside, and the copper wires and the stator core are isolated by using insulation paper.

[0097] As shown in the drawings, Figure 3 , Figure 7 The joints of the copper wires are respectively welded and overlapped by using connectors to form a specially designed three-phase circuit. The three-phase circuit is finally connected to the three-phase cable through the busbar, and is connected to the inverter through the cable. The system principle is that the controller receives and outputs signals to the inverter, and the inverter adjusts the current and voltage of the circuit to affect the output of the electromagnetic system and control the operation.

[0098] The application has the advantages of: 1) the cogging torque is small, and the vibration and noise are reduced; 2) the high-order harmonics are reduced, and the iron loss is reduced, and the motor efficiency is improved; 3) the coil length and area are increased, the heat dissipation space is larger, the heat dissipation effect is improved, and the efficiency is higher.

[0099] The embodiments of the application are as follows:

[0100] Embodiment 1:

[0101] In the embodiment, the electromagnetic design described in the application adopts a permanent magnet synchronous scheme. Due to the limited installation space of the 12-inch rim motor, the motor is designed as an inner stator and an outer rotor structure (see Figure 14 ).

[0102] The winding circuit of the stator housing 10 as an inner stator uses continuous wave winding copper wires, which are sequentially stacked and embedded in the stator core, and the joints of the copper wires are welded and overlapped to form a new structure of three-phase circuit. Then, the application uses two-component customized epoxy resin to encapsulate the stator assembly for the winding circuit structure part, so as to fill the gap between the winding and the partition plate, and to ensure the stability, safety and heat dissipation performance of the winding circuit.

[0103] The whole motor electromagnetic drive structure is connected to the inverter through three-phase cable for power supply and then runs.

[0104] The embodiment innovatively designs the circuit arrangement, and the continuous wave winding structure features a one-time formed non-discontinuous line. The plugging step of the single line is that the first end enters the stator first, and the subsequent part is continuously embedded into the stator slot until the tail end is fixed in the stator slot.

[0105] To increase the interaction range of the circuit and the magnetic field, the circuit of the embodiment is arranged on the outer ring part of the stator shell 10, which makes the embedding direction of the copper wire become from outside to inside, which is different from the traditional continuous wave winding circuit arranged from inside to outside.

[0106] The copper wire groups are evenly distributed on the outer ring of the stator, and the embodiment selects Φ1.8 mm round enameled copper wire with a single wire withstand voltage of 5000V. According to the number of single-sided bending arcs 6, 13, 20, and 27, it is divided into four types (see Figure 2 ), and 21 wires are designed (see Figure 8 ). The stator core wire slot is a total of 168 slots, and each wire is sequentially embedded in the respective point. Each slot is evenly distributed with 4 sections of copper wire, and the single slot slot fullness rate is 47%. After the 2D bending process, the bending arc is 3D bent, and the wave arc structure is formed skillfully. This design helps the wires to be tightly stacked, compresses the electric path volume, and controls the diameter of the outer ring of the stator.

[0107] After the copper wire is fixed, the wire joints are welded and connected. The wire sequence is 1-21, S is the first end, and E is the end. The wiring layout (see Figure 11 、 Figure 10 ), and the wire sequence connection path in this example is:

[0108]

[0109]

[0110] Other wire sequence connection paths:

[0111]

[0112] All the above copper winding joints are parallel welded connections, and are not allowed to contact other groups of copper windings not in the table.

[0113] The bus bar current phase connection path is:

[0114]

[0115] As a preferred, the magnet is selected to be a neodymium iron boron magnet. According to the matching simulation verification of the stator component circuit design, the size of the single magnet is 56mmx12mmx2.3mm, a total of 28 pairs of levels, 56 magnets, and all are surface-mounted on the inside of the rotor component. The core performance of the single magnet is:

[0116] ①Magnet grade: N42SH (maximum operating temperature 150℃)

[0117] ②Remanence (Br) @20℃: Nominal 1.32T, Minimum 1.30T

[0118] ③Coercivity (Hci) @20℃: Minimum 1590kA / m (20kOe)

[0119] ④Remanence (Br) @100℃: Minimum 1.20T

[0120] ⑤Coercivity (Hci) @100℃: Minimum 875kA / m

[0121] ⑥Magnetization through 2.30mm thickness (parallel magnetization)

[0122] ⑦Coating: Ni-Cu-Ni + epoxy resin

[0123] After the above circuit and magnetic field design, the stator and rotor outer dimensions are adjusted. The stator outer diameter including the circuit part is designed to be Φ274mm, the magnet air gap is designed to be 0.8mm-1mm, and the minimum diameter of the rotor outer shell is 299.2mm. On the basis of the minimum diameter of the outer wall contour, the tire mounting surface structure is designed according to the standard size of 12-inch rim, and the overall outer contour outer diameter is finally determined to be 330mm in diameter, which meets the industry standard.

[0124] Through experimental measurement: under 72V voltage, the efficiency of the present application can reach more than 90%, the maximum peak power can reach 25KW, and the maximum peak torque can reach 420N.m. Under the same voltage, its performance exceeds the performance of the industry benchmark centralized winding electromagnetic scheme.

[0125] Due to the ingenious combination of circuit wiring structure and continuous wave winding copper wire design, the present application not only improves the performance, but also reduces the amount of copper wire used and reduces the use cost. The amount of copper wire used is reduced to 1KG, which is only 40% of the amount of copper wire used in the benchmark centralized winding electromagnetic scheme.

[0126] Example 2 (the present application scheme):

[0127] The difference between example 1 and example 2 is only that the applied voltage is different, and the rated voltage applied is set to 72V. Example 1 is 100V. The motor structure and parameters of example 1 and example 2 are consistent, and the voltage is different because the voltage provided by the inverter is different in the past, and the performance exhibited is different.

[0128] Comparative example 1:

[0129] As shown in the following table, the existing continuous wave winding structure with embedded copper wire is compared. Figure 15 ​

[0130] Comparative Example 2:

[0131] As shown in the following table, the performance of the motor according to the present application is compared with that of a motor with a conventional concentrated winding structure. Figure 16

[0132] Concentrated winding structure schematic diagram

[0133] Comparative Example 3:

[0134] As shown in the following table, the performance of the motor according to the present application is compared with that of a motor with a conventional concentrated winding structure under an outer stator inner rotor structure. Figure 17 Comparison table of performance parameters with benchmark electromagnetic scheme

[0135]

[0136]

[0137]

[0138] As shown in the above table, under the same 72V voltage platform, the speed, peak torque, peak power and motor efficiency of the motor according to the present application are stronger than those of the industry benchmark motor. The speed is increased by about 0.8%, the peak torque is increased by about 10%, the peak power is increased by about 56%, and the motor efficiency is increased by 5%. The performance of the vehicle in terms of endurance, acceleration and climbing is greatly improved.

[0139] In addition, the current industry leader proposes new demands for high-performance vehicles, which require that under a 96V voltage platform, the speed is ≥1500rpm, the peak torque is ≥450N.m, the peak power is ≥33kw, and the motor efficiency is ≥92%. The voltage platform of the motor according to the present application can reach 100V, meeting the demand for voltage platform, and the motor performance indicators also meet the requirements.

[0140] The above specific embodiments are used to explain and illustrate the present application, rather than limit the present application. Any modification and change made to the present application within the spirit and protection scope of the claims of the present application shall fall within the protection scope of the present application.

[0141] The above description is only the preferred embodiments of the present application, and any equivalent changes or modifications made to the structure, features and principles described in the scope of the present application shall be included in the scope of the present application.​​

Claims

1. An electromagnetic drive structure for a motor using continuous wave-wound copper wire and multi-layer stacking, characterized in that: Including the stator housing (10); It includes a continuous wave-wound copper wire group (9), which is wound in a stator slot on the outer periphery of the stator housing (10); the continuous wave-wound copper wire group (9) is formed by continuous wave winding of multiple copper wire windings of different lengths and different distribution positions. The three-phase interface of the three-phase line (14) and the different copper wire windings of the continuous wave winding copper wire group (9) are connected by specific wiring.

2. The electromagnetic drive structure for a motor using continuous wave-wound copper wire and multi-layer stacking as described in claim 1, characterized in that: Outside the stator housing (10), there is also a rotor housing (1), and a permanent magnet (6) is provided on the inner circumferential surface of the rotor housing (1) for cooperating with the continuous wave wound copper wire group (9).

3. The electromagnetic drive structure for a motor using continuous wave-wound copper wire and multi-layer stacking as described in claim 1, characterized in that: The outer circumferential surface of the stator housing (10) is provided with N stator slots at circumferential intervals, and each copper wire winding of the continuous wave-wound copper wire group (9) is embedded into the stator slot from the outside to the inside.

4. The electromagnetic drive structure for a motor using continuous wave-wound copper wire and multi-layer stacking as described in claim 1, characterized in that: The continuous wave winding copper wire group (9) is divided into multiple copper wire windings, each of which is continuously wave wound in an S-shaped path with two stator slots as the period.

5. The electromagnetic drive structure for a motor using continuous wave-wound copper wire and multi-layer stacking as described in claim 1, characterized in that: The adjacent copper wire windings are staggered by a predetermined clockwise interval of k stator slots along the circumference of the stator housing (10).

6. The electromagnetic drive structure for a motor using continuous wave-wound copper wire and multi-layer stacking as described in claim 1, characterized in that: The copper wires of the copper wire windings wound in the stator slots are arranged at an angle to the motor shaft.

7. The electromagnetic drive structure for a motor using continuous wave-wound copper wire and multi-layer stacking as described in claim 6, characterized in that: The copper wires of the copper wire windings wound in the stator slots are arranged at an angle of 4.75°-5.3° in the tangential direction, based on the original parallel axial direction.

8. The electromagnetic drive structure for a motor using continuous wave-wound copper wire and multi-layer stacking as described in claim 1, characterized in that: The continuous wave winding copper wire group (9) includes four copper wire windings of different lengths. The four copper wire windings of different lengths are respectively used to wind in the continuous stator slots that cover and occupy the entire circumferential 1 / 4, 2 / 4, 3 / 4 and 4 / 4 of the stator housing (10); Or / and the continuous wave winding copper wire group (9) includes four copper wire windings with different starting points. The starting points of the four copper wire windings are respectively wound from the stator slots in the middle of the upper side, the middle of the left side, the middle of the lower side, and the middle of the right side of the stator housing (10). Alternatively / and the continuous wave winding copper wire group (9) includes four copper wire windings with different endpoints, the endpoints of which are respectively wound to the middle of the upper side, the middle of the left side, the middle of the lower side, and the middle of the right side of the stator housing (10).

9. The electromagnetic drive structure for a motor using continuous wave-wound copper wire and multi-layer stacking as described in claim 1, characterized in that: The continuous wave winding copper wire group (9) includes seven different copper wire windings of different lengths and different distribution positions. Each copper wire winding group contains three copper wire windings, for a total of 21 copper wire windings. The first type of copper wire winding includes three copper wire windings that cover a full circumferential 1 / 4 of the stator slots of the stator housing (10). The starting point of the three copper wire windings is wound from the three stator slots near the middle of the upper side of the stator housing (10), and the ending point is wound to the three stator slots in the middle of the left side of the stator housing (10). The second type of copper wire winding includes three copper wire windings that cover 2 / 4 of the stator slots of the stator housing (10) in a complete circumferential direction. The starting point of the three copper wire windings is wound from the three stator slots in the middle of the upper side of the stator housing (10), and the ending point is wound to the three stator slots in the middle of the lower side of the stator housing (10). The third type of copper wire winding includes three copper wire windings that cover the entire circumferential 3 / 4 of the stator slots of the stator housing (10). The starting point of the three copper wire windings is wound from the three stator slots near the middle of the upper side of the stator housing (10), and the ending point is wound to the three stator slots in the middle of the right side of the stator housing (10). The fourth type of copper wire winding includes three copper wire windings that cover the complete circumferential 4 / 4 stator slots of the stator housing (10). The starting point of the three copper wire windings is wound from the three stator slots in the middle of the upper side of the stator housing (10), and the ending point is wound to the three stator slots near the middle of the upper side of the stator housing (10). The fifth type of copper wire winding includes three copper wire windings that cover the entire circumferential 3 / 4 of the stator slots of the stator housing (10). The starting point of the three copper wire windings is respectively wound from the three stator slots near the middle left side of the stator housing (10), and the ending point is respectively wound to the three stator slots in the middle upper side of the stator housing (10). The sixth type of copper wire winding includes three copper wire windings that cover 2 / 4 of the stator slots of the stator housing (10) in a complete circumferential direction. The starting point of the three copper wire windings is wound from the three stator slots in the middle of the lower side of the stator housing (10), and the ending point is wound to the three stator slots in the upper middle of the stator housing (10). The seventh type of copper wire winding includes three copper wire windings that cover a full circumferential 1 / 4 of the stator slots of the stator housing (10). The starting ends of the three copper wire windings are respectively wound from the three stator slots near the middle right side of the stator housing (10), and the ending ends are respectively wound to the three stator slots in the middle upper side of the stator housing (10).

10. The electromagnetic drive structure for a motor using continuous wave-wound copper wire and multi-layer stacking as described in claim 1, characterized in that: Of the 21 copper wire windings with seven different lengths and distribution positions: On the left side of the stator housing (10): the end points of the three copper wire windings of the first type of copper wire winding are respectively connected to the beginning points of the three copper wire windings of the fifth type of copper wire winding; On the underside of the stator housing (10): the end points of the three copper wire windings of the second type of copper wire winding are respectively connected to the beginning points of the three copper wire windings of the sixth type of copper wire winding; On the right side of the stator housing (10): the end points of the three copper wire windings of the third type of copper wire winding are respectively connected to the beginning points of the three copper wire windings of the seventh type of copper wire winding. On the upper side of the stator housing (10): The starting points of the first and last copper wire windings of the first type of copper wire winding are respectively connected to the starting points of the first and last copper wire windings of the third type of copper wire winding. The starting points of the first and last copper wire windings of the fourth type of copper wire winding are respectively connected to the starting points of the first and last copper wire windings of the sixth type of copper wire winding. The starting point of the middle copper wire winding of the second and fourth types of copper wire windings and the ending point of the middle copper wire winding of the fifth and seventh types of copper wire windings are connected together. The starting point of the middle copper wire winding of the first type of copper wire winding, the starting point of the middle copper wire winding of the third type of copper wire winding, the ending point of the middle copper wire winding of the fourth type of copper wire winding, and the ending point of the middle copper wire winding of the sixth type of copper wire winding are connected together to form the second phase of the three-phase line (14); the starting point of the first copper wire winding of the second type of copper wire winding and the first copper wire winding of the fourth type of copper wire winding, and the ending point of the first copper wire winding of the fifth type of copper wire winding and the seventh type of copper wire winding are connected together to form the third phase of the three-phase line (14); the starting point of the last copper wire winding of the second type of copper wire winding and the fourth type of copper wire winding, and the ending point of the last copper wire winding of the fifth type of copper wire winding and the seventh type of copper wire winding are connected together to form the first phase of the three-phase line (14).

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