Short-distance flat wire stator winding, flat wire motor and vehicle

Abstract

The invention discloses a short-distance flat wire stator winding, a flat wire motor and a vehicle, the stator winding comprises a three-phase winding, each winding branch comprises two parallel branches, and each branch comprises a plurality of coils which are sequentially arranged on an iron core groove and are mutually connected in series; the two branches are reversely wound, each branch comprises a single coil with the span being y-2, y, y + 1 and y + 2, each branch takes the single coil as a winding starting line and a neutral point outgoing line, and during winding, the coils with the spans being y and y + 1 are arranged on the outermost layer and the secondary outer layer of a notch or the innermost layer and the secondary inner layer of a slot bottom; the coil with the span of y-2 is arranged on the secondary inner layer and the middle layer of the slot bottom or the secondary outer layer and the middle layer of the slot opening, and the coil with the spans of y + 1 and y + 2 is arranged on the middle layer. The invention has the advantages of compact structure, balanced potential of each branch, no circulating current and the like, and eliminates a series of problems caused by asymmetry of each branch.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of electric machines, and particularly relates to a short-distance flat wire stator winding, a flat wire motor and a vehicle. BACKGROUND

[0002] With the rapid development of new energy automobile technology, the performance requirements of the driving motor, as one of the key executive components of the electric vehicle, are getting higher and higher. At present, high speed, light weight and high efficiency have become the development trend of the driving motor, and higher requirements are put forward for the power density, high efficiency area and heat dissipation capacity of the motor.

[0003] The stator winding can be divided into round wire and flat wire. The difference between the flat wire motor and the round wire motor lies in the forming method of the copper wire. The flat wire is beneficial to the improvement of the slot fill rate of the motor. The stator winding can be divided into round wire and flat wire. Compared with the round wire winding, the flat wire winding can effectively improve the slot fill rate of the motor, reduce the copper loss of the motor and thus provide the motor efficiency. Meanwhile, the flat wire winding can also reduce the height of the motor winding end part and thus reduce the volume of the motor and provide the power / torque density. However, the flat wire winding has inherent skin effect phenomenon, especially for the high-speed motor, the skin effect is more obvious. In order to reduce the skin effect, the number of conductors in the stator slot is generally increased, such as 4 layers, 6 layers, 8 layers and the like. Due to the large number of layers, the wire type is also large, and the branch asymmetry phenomenon may also occur.

[0004] With the development of electric drive of passenger cars, the system has increasingly strict requirements on the vibration and noise of the motor. Since the pre-forming and twist head welding process are required in the manufacturing process of the flat wire motor, the winding coefficient cannot be changed arbitrarily in the winding process to reduce the electromagnetic force harmonic like the traditional round wire motor. Therefore, how to simply and conveniently change the flat wire motor into a short-distance winding has become a problem to be solved in the industry. SUMMARY

[0005] The technical problem to be solved by the application is to overcome the shortcomings of the prior art and provide a short-distance flat wire stator winding, a flat wire motor and a vehicle, which have compact structure, simple manufacturing, symmetrical branches and neat arrangement.

[0006] To solve the above technical problems, the application adopts the following technical solutions: A short-pitch flat wire stator winding includes three-phase windings, each phase winding comprising multiple sets of parallel winding branches. Each set of winding branches includes two parallel branches, each branch comprising multiple coils arranged sequentially and connected in series on the circumferential core slots of the stator core. The coils of the same branch in each set of winding branches are arranged in adjacent core slots. The winding directions of the two branches are opposite. Each branch includes coils with spans of y-2, y, y+1, and y+2, as well as a single coil. Each of the aforementioned branches uses a single coil as the starting wire and neutral point lead wire. The single coil is located in the outermost layer of the slot opening or the innermost layer of the slot bottom. During winding, coils with spans of y and y+1 are arranged in the outermost and second outermost layers of the slot opening, or the innermost and second innermost layers of the slot bottom. Coils with spans of y-2 are arranged in the second innermost and middle layers of the slot bottom, or the second outermost and middle layers of the slot opening. Coils with spans of y+1 and y+2 are arranged in the middle layer of the slot.

[0007] As a further improvement of the present invention, one of the branches in each winding branch is wound from the outermost layer of the slot opening to the innermost layer of the slot bottom. First, after the preset number of slots is filled between the outermost layer of the slot opening and the second outermost layer of the slot opening, the coil with a span of y-2 is used to switch from the second outermost layer of the slot opening to the middle layer. Then, after the preset number of slots is filled in the middle layer, the coil with a span of y-2 is used to switch from the middle layer to the second innermost layer of the slot bottom. Finally, the preset number of slots is filled in the innermost layer and the second innermost layer of the slot bottom, thus completing the branch winding.

[0008] As a further improvement of the present invention, another branch in each group of winding branches is wound from the innermost layer of the bottom of the iron core slot to the outermost layer of the slot opening. First, after the preset number of slots is filled between the innermost layer of the bottom of the slot and the second innermost layer of the bottom of the slot, the coil with a span of y-2 is used to switch from the second innermost layer of the bottom of the slot to the middle layer. Then, after the preset number of slots is filled in the middle layer, the coil with a span of y-2 is used to switch from the middle layer to the second outermost layer of the slot opening. Finally, the preset number of slots is filled in the outermost layer of the slot opening and the second outermost layer of the slot opening, thus completing the branch winding.

[0009] As a further improvement of the present invention, the phase winding includes a set of winding branches, the first branch of which includes a single coil A0, coils a1-A2, a3-A4, a5-A6, a7-A8, a9-A10, a11-A12, a13-A14, a15-A16, a17-A18, a19-A20, a21-A22, a23-A24, a25-A26, a27-A28, a29-A30, a31-A32, ..., a49-A50. a51-A52, single coil a53; the second branch includes single coil B0, coils b1-B2, b3-B4, b5-B6, b7-B8, b9-B10, b11-B12, b13-B14, b15-B16, b17-B18, b19-B20, b21-B22, b23-B24, b25-B26, b27-B28, b29-B30, b31-B32, ..., b49-B50, b51-B52, single coil b53; Single coil A0 is located in the 6th layer along the bottom of the slot in the iron core groove; single coil a53 is located in the 1st layer along the bottom of the slot in the iron core groove; single coil B0 is located in the 1st layer along the bottom of the slot in the iron core groove; single coil b53 is located in the 6th layer along the bottom of the slot in the iron core groove. The spans of a1-A2, a3-A4, a7-A8, a9-A10, a13-A14 and a15-A16 are all y, and the spans of a5-A6 and a11-A12 are both y+1. Their upper edge is located in the 5th layer of the iron core slot, and their lower edge is located in the 6th layer of the iron core slot. The span of A17-A18 is y-2, with its upper edge located in the 5th layer of the iron core slot and its lower edge located in the 4th layer of the iron core slot. The spans of a19-A20, a21-A22, a25-A26, a27-A28, a31-A32 and a33-A34 are all y+1, and the spans of a23-A24 and a29-A30 are all y+2. Their upper edges are located in the 3rd layer of the iron core slot, and their lower edges are located in the 4th layer of the iron core slot. The span between a35 and A36 is y-2, with the upper edge located in the 3rd layer of the core slot and the lower edge located in the 2nd layer of the core slot. The spans of a37-A38, a39-A40, a43-A44, a45-A46, a49-A50 and a51-A52 are all y, and the spans of a41-A42 and a47-A48 are both y+1. Their upper edges are located in the first layer of the iron core slot, and their lower edges are located in the second layer of the iron core slot. The spans of b1-B2, b3-B4, b7-B8, b9-B10, b13-B14 and b15-B16 are all y, and the spans of b5-B6 and b11-B12 are all y+1. Their upper edge is located in the second layer of the iron core slot, and their lower edge is located in the first layer of the iron core slot. The span of b17-B18 is y-2, with its upper edge located in the second layer of the iron core slot and its lower edge located in the third layer of the iron core slot. The spans of b19-B20, b21-B22, b25-B26, b27-B28, b31-B32 and b33-B34 are all y+1, and the spans of b23-B24 and b29-B30 are all y+2. Their upper edge is located in the 4th layer of the iron core slot, and their lower edge is located in the 3rd layer of the iron core slot. The span of b35-B36 is y-2, with its upper edge located in the 4th layer of the iron core slot and its lower edge located in the 5th layer of the iron core slot. The spans of b37-B38, b39-B40, b43-B44, b45-B46, b49-B50 and b51-B52 are all y, and the spans of b41-B42 and b47-B48 are all y+1. Their upper edge is located in the 6th layer of the iron core slot, and their lower edge is located in the 5th layer of the iron core slot. In the first branch, coil A0 is connected to coil a1-A2 by twist welding, coil a1-A2 is connected to coil a3-A4 by twist welding, coil a3-A4 is connected to coil a5-A6 by twist welding, coil a5-A6 is connected to coil a7-A8 by twist welding, and so on. The coil sequence is from layer 6 to layer 5, layer 5 to layer 4, layer 4 to layer 3, layer 3 to layer 2, completing the same layer in layer 1 and then returning to layer 2, layer 3 to layer 4, then layer 5, layer 6, and so on, to complete the winding of the first branch. The winding of the second branch is carried out in the same way.

[0010] As a further improvement of the present invention, the single coil includes a first coil, which serves as a starting lead and a neutral point lead. The first coil includes a first coil body and a first bending portion. The first coil body includes a first support rod, and the first support rod has a first head and a first bending portion at both ends, respectively. The first bending portion forms a welding end. The bending direction of the first head is opposite to the bending direction of the first bending portion.

[0011] As a further improvement of the present invention, the coil with a span of y-2, the coil with a span of y, the coil with a span of y+1, and the coil with a span of y+2 are all second coils. The second coil includes a second coil body and a second bending portion. The second coil body includes two second support rods arranged parallel to each other and a second head connecting one end of the two second support rods. The other end of the two second support rods is provided with a second bending portion to form a welding end. The second bending portion bends along the width direction of the second coil body and away from the direction of the second coil body.

[0012] As a further improvement of the present invention, the single coil includes a third coil, which serves as the starting lead and the neutral point lead. The third coil includes a third coil body and a third bend. The third coil body includes a third support rod, and the third support rod has a third head and a third bend at both ends, respectively. The third bend forms a welding end. The bending direction of the third head is opposite to the bending direction of the third bend.

[0013] As a further improvement of the present invention, the connection between each group of windings is either a star connection or a delta connection.

[0014] As a general technical concept, the present invention also provides a flat wire motor, including the above-described short-pitch flat wire stator winding.

[0015] As a general technical concept, the present invention also provides a vehicle including the aforementioned flat wire motor.

[0016] Compared with the prior art, the advantages of the present invention are as follows: 1. The short-pitch flat wire stator winding, flat wire motor, and vehicle of the present invention combine coils with different spans and types in each winding branch. By adjusting the span of the intermediate layer coils and the corresponding welding end connections, flexible switching between full-pitch and short-pitch schemes can be achieved as needed. There is no U-shaped coil in the same layer for commutation, reducing the number of wire types and eliminating irregular wire shapes, facilitating assembly and mass production. A single coil is used as a lead wire at the beginning and neutral point of each winding branch, and the neutral point is connected via a busbar. The two branches in each winding branch are wound in opposite directions to achieve branch symmetry. During winding, coils with spans of y and y+1 are arranged at the outermost slot of the iron core slot. Coils with a span of y-2 are arranged in the outer layer and the second outermost layer of the slot opening, or in the innermost layer and the second innermost layer of the slot bottom of the iron core slot. Alternatively, coils with spans of y+1 and y+2 are arranged in the middle layer of the iron core slot. This arrangement helps eliminate a series of problems caused by the asymmetry of each branch, simplifies the Busbar structure, and ensures that each branch is symmetrical in both the slot and the layer. That is, each parallel branch is distributed in a ring-shaped symmetrical structure within the iron core slot, thereby achieving a uniform and symmetrical distribution of each phase winding. This results in balanced potential in each branch, no circulating current, and harmonic cancellation, achieving maximum product compatibility and significantly improving motor performance. This invention not only solves a series of problems caused by the asymmetry of each branch but also effectively reduces the difficulty and high manufacturing cost of flat wire winding due to the increased number of phases in the motor, effectively reducing vehicle manufacturing costs.

[0017] 2. The short-pitch flat wire stator winding, flat wire motor, and vehicle of the present invention use U-shaped cross-layer coils with different spans for combination, which can easily and conveniently switch between full-pitch windings and short-pitch windings, significantly weakening high-order harmonic electromotive force, reducing motor vibration and noise, and improving the NVH performance of the whole vehicle. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the structural principle of the first coil in a specific embodiment of the present invention; Figure 2 This is a schematic diagram illustrating the structural principle of the second coil in a specific embodiment of the present invention; Figure 3 This is a schematic diagram illustrating the structural principle of the second coil in a specific embodiment of the present invention; Figure 4 This is a schematic diagram of the structural principle of the stator gate end in a specific embodiment of the present invention; Figure 5 This is a schematic diagram of the structural principle of the stator welding end in a specific embodiment of the present invention; Figure 6 This is a schematic diagram of the phase arrangement of any one phase winding in a specific embodiment of the present invention; Figure 7 This is a schematic diagram of the connection of the three-phase branch in a specific embodiment of the present invention; wherein, Figure (a) is a star connection and Figure (b) is a delta connection.

[0019] Legend: 1. First coil; 11. First coil body; 111. First support rod; 112. First head; 12. First bend; 2. Second coil; 21. Second coil body; 211. Second support rod; 212. Second head; 22. Second bend; 3. Third coil; 31. Third coil body; 311. Third support rod; 312. Third head; 32. Third bend; 4. Stator core; 41. Core slot. Detailed Implementation

[0020] The present invention will be further described below with reference to the accompanying drawings and specific preferred embodiments, but this does not limit the scope of protection of the present invention.

[0021] Example like Figures 1 to 7 As shown, the short-pitch flat wire stator winding of this embodiment includes three-phase windings. Each phase winding includes multiple sets of parallel winding branches, and each set of winding branches includes two parallel branches. Each branch includes multiple coils arranged sequentially and connected in series on the circumferential core slots 41 of the stator core 4, with the coils of the same branch in each set of winding branches arranged in adjacent core slots 41. The winding directions of the two branches are opposite. Both branches include coils with spans of y-2, y, y+1, and y+2, as well as a single coil. Both branches use a single coil as the winding start line and neutral point lead. The single coil is located either at the outermost layer of the slot opening (the first layer from the slot opening to the slot bottom) or at the innermost layer of the slot bottom (the last first layer from the slot opening to the slot bottom). During winding, coils with spans of y and y+1 are arranged in the outermost and second outermost layers of the slot opening of the iron core slot 41, or in the innermost and second innermost layers of the bottom of the iron core slot 41; coils with spans of y-2 are arranged in the second innermost and middle layers of the bottom of the iron core slot 41, or in the second outermost and middle layers of the slot opening of the iron core slot 41; coils with spans of y+1 and y+2 are arranged in the middle layer of the iron core slot 41.

[0022] In this embodiment, different spans and types of coils are combined in each winding branch. By adjusting the span of the intermediate layer coils and the corresponding welding end connections, flexible switching between full-pitch and short-pitch schemes can be achieved as needed. There are no U-shaped coils in the same layer for commutation, reducing the number of wire types and eliminating irregular wire shapes, facilitating assembly and mass production. A single coil is used as a lead at the beginning and neutral point of each winding branch. The neutral point is connected via a busbar. The two branches in each winding branch are wound in opposite directions to achieve branch symmetry. During winding, coils with spans of y and y+1 are arranged in the outermost and second outermost layers of the slot opening, or the innermost and second innermost layers of the slot bottom. Coils with spans of y-2 are arranged in the second innermost and middle layers of the slot bottom, or the second outermost and middle layers of the slot opening. Coils with spans of y+1 and y+2 are arranged in the middle layer of the slot. This helps to eliminate a series of problems caused by the asymmetry of each branch, simplifies the Busbar structure, and ensures that each branch is symmetrical in both the slot and the layer. That is, each parallel branch is distributed in a ring-shaped symmetrical structure in the slot, thereby achieving a uniform and symmetrical distribution of each phase winding. This results in balanced potential of each branch, no circulating current, and cancellation of harmonics, achieving maximum product compatibility and greatly improving the performance of the motor. This embodiment not only solves a series of problems caused by the asymmetry of each branch, but also effectively reduces the difficulty of flat wire winding process and high manufacturing cost caused by the increase in the number of phases of the motor, thus effectively reducing the production cost of the vehicle.

[0023] In this embodiment, one of the branches in each winding branch is wound from the outermost layer of the slot opening to the innermost layer of the slot bottom of the iron core slot 41. First, the preset number of slots is filled between the outermost layer of the slot opening and the second outermost layer of the slot opening. Then, a coil with a span of y-2 is used to switch from the second outermost layer of the slot opening to the middle layer. Next, the preset number of slots is filled in the middle layer. Then, a coil with a span of y-2 is used to switch from the middle layer to the second innermost layer of the slot bottom. Finally, the preset number of slots is filled in the innermost layer and the second innermost layer of the slot bottom, thus completing the branch winding.

[0024] Another branch in each winding branch is wound from the innermost layer of the bottom of the iron core slot 41 to the outermost layer of the slot opening. First, the preset number of slots is filled between the innermost layer of the bottom of the slot and the second innermost layer of the bottom of the slot. Then, a coil with a span of y-2 is used to transfer from the second innermost layer of the bottom of the slot to the middle layer. Next, the preset number of slots is filled in the middle layer. Then, a coil with a span of y-2 is used to transfer from the middle layer to the second outermost layer of the slot opening. Finally, the preset number of slots is filled in the outermost layer of the slot opening and the second outermost layer of the slot opening, thus completing the branch winding.

[0025] like Figure 1As shown, in this embodiment, the single coil includes a first coil 1, which serves as both the starting lead and the neutral point lead. The first coil 1 includes a first coil body 11 and a first bent portion 12. The first coil body 11 includes a first support rod 111, with a first head 112 and a first bent portion 12 at each end. The first bent portion 12 forms a welding end. The bending direction of the first head 112 is opposite to the bending direction of the first bent portion 12.

[0026] like Figure 2 As shown, in this embodiment, the coils with a span of y-2, y, y+1, and y+2 are all second coils 2. The second coil 2 includes a second coil body 21 and a second bending portion 22. The second coil body 21 includes two parallel second support rods 211 and a second head 212 connecting one end of the two second support rods 211. The other end of the two second support rods 211 is provided with a second bending portion 22 to form a welding end. The second bending portion 22 bends along the width direction of the second coil body 21 and away from the second coil body 21.

[0027] In this embodiment, the head of the second coil 2 is either V-shaped or arc-shaped. The coil with a V-shaped head is called a V-shaped coil, and the coil with an arc-shaped head is called a U-shaped coil. In this embodiment, coils of various spans can use either U-shaped or V-shaped coils. Since coils of various spans use the same shape, irregularly shaped coils and bridging coils are eliminated, thus facilitating assembly and mass production. Of course, in other embodiments, a combination of U-shaped and V-shaped coils can also be used.

[0028] like Figure 3 As shown, in this embodiment, the single coil includes a third coil 3, which serves as both the starting lead and the neutral point lead. The third coil 3 includes a third coil body 31 and a third bend portion 32. The third coil body 31 includes a third support rod 311, with a third head 312 and a third bend portion 32 at each end. The third bend portion 32 forms a welding end. The bending direction of the third head 312 is opposite to the bending direction of the third bend portion 32.

[0029] Furthermore, the bending directions of the first coil 1 and the third coil 3 are opposite. The first coil 1 is located in the first layer of the core slot 41, with one first coil 1 serving as the starting lead of the second branch and the other first coil 1 serving as the neutral point lead of the first branch. The third coil 3 is located in the sixth layer of the core slot 41, with one third coil 3 serving as the starting lead of the first branch and the other third coil 3 serving as the neutral point lead of the second branch.

[0030] In this embodiment, U-shaped coils with different spans are used in combination, and there are no U-shaped coils in the same layer for commutation. Each branch is completely symmetrical, eliminating branch current circulation. By using a combination of U-shaped coils with different spans across layers, short-pitch windings are achieved, which significantly weakens high-order harmonic electromotive force, reduces motor vibration and noise, and improves the overall NVH performance of the vehicle.

[0031] like Figure 7 As shown, in this embodiment, the connection between each group of windings is either a star connection or a delta connection.

[0032] In this embodiment, the neutral point of the coil (e.g.) Figure 7 The a53 and b53 windings are connected via a busbar, which is simple in structure and has a height that is similar to that of the welded end, reducing the height of the winding end and thus reducing the size of the motor.

[0033] Specifically, taking a short-pitch flat wire winding with 54 slots, 6 poles, 6 layers, and 2 branches as an example, the gate-type end and welded end of the motor stator are respectively as follows: Figure 5 and Figure 6 As shown, the motor neutral point is connected via a busbar, resulting in a simple structure. The number of coil layers increases sequentially from the slot opening to the slot bottom. The first branch of the U-phase is Aa, and the second branch is Bb. Since there are 3 slots per pole and 2 branches per phase, to achieve branch symmetry, the first and second layers, the second and third layers, the third and fourth layers, the fourth and fifth layers, and the fifth and sixth layers are all U-shaped coils with different spans. a1-A2, a3-A4, and a5-A6 constitute U-shaped coils, and so on.

[0034] Specifically, the first and sixth layers use type I single coils and connecting copper busbars to achieve the outgoing lines, the first and second layers and the fifth and sixth layers use U-shaped coils with spans of 10 and 9, the second and third layers and the fourth and fifth layers use U-shaped coils with a span of 7, and the third and fourth layers use U-shaped coils with spans of 10 and 11.

[0035] In this embodiment, the phase winding includes a set of winding branches. The first branch in the winding branches includes a single coil A0, coils a1-A2, a3-A4, a5-A6, a7-A8, a9-A10, a11-A12, a13-A14, a15-A16, a17-A18, a19-A20, a21-A22, a23-A24, a25-A26, a27-A28, a29-A30, a31-A32, ..., a49-A50, a51-A52, and a single coil a53. The second branch includes single coil B0, coils b1-B2, b3-B4, b5-B6, b7-B8, b9-B10, b11-B12, b13-B14, b15-B16, b17-B18, b19-B20, b21-B22, b23-B24, b25-B26, b27-B28, b29-B30, b31-B32, ..., b49-B50, b51-B52, and single coil b53.

[0036] Single coil A0 is located in the 6th layer along the bottom of the slot in slot 41 of the iron core, and its shape is as follows: Figure 3 The single coil shown. Single coil a53 is located in the first layer along the bottom of the slot in the iron core slot 41, and its shape is as follows... Figure 1 The single coil shown. Single coil B0 is located in the first layer along the bottom of the slot in core slot 41, and its shape is as follows... Figure 1 The single coil shown. Single coil b53 is located in the 6th layer along the bottom of the slot in core slot 41, and its shape is as follows... Figure 3 The single coil shown.

[0037] The spans of a1-A2, a3-A4, a7-A8, a9-A10, a13-A14, and a15-A16 are all 9, while the spans of a5-A6 and a11-A12 are both 10. Their upper edges are located in the 5th layer of the core slot 41, and their lower edges are located in the 6th layer of the core slot 41, with a shape like... Figure 2 The second coil 2 is shown.

[0038] The span between A17 and A18 is 7. Its upper edge is located in the 5th layer of core slot 41, and its lower edge is located in the 4th layer of core slot 41, with a shape like... Figure 2 The second coil 2 is shown.

[0039] The spans of a19-A20, a21-A22, a25-A26, a27-A28, a31-A32, and a33-A34 are all 10, while the spans of a23-A24 and a29-A30 are all 11. Their upper edges are located in the third layer of the core slot 41, and their lower edges are located in the fourth layer of the core slot 41, with a shape like... Figure 2 The second coil 2 is shown.

[0040] The span between a35 and A36 is 7, with its upper edge located in the 3rd layer of the core slot 41 and its lower edge located in the 2nd layer of the core slot 41, forming a shape like... Figure 2 The second coil 2 is shown.

[0041] The spans of a37-A38, a39-A40, a43-A44, a45-A46, a49-A50, and a51-A52 are all 9, while the spans of a41-A42 and a47-A48 are both 10. Their upper edges are located in the first layer of the core slot 41, and their lower edges are located in the second layer of the core slot 41, with a shape like... Figure 2 The second coil 2 is shown.

[0042] The spans of b1-B2, b3-B4, b7-B8, b9-B10, b13-B14, and b15-B16 are all 9, while the spans of b5-B6 and b11-B12 are both 10. Their upper edges are located in the second layer of the core slot 41, and their lower edges are located in the first layer of the core slot 41, with a shape as follows: Figure 2 The second coil 2 is shown.

[0043] The span between b17 and B18 is 7, with its upper edge located in the second layer of the core slot 41 and its lower edge located in the third layer of the core slot 41, forming a shape like... Figure 2 The second coil 2 is shown.

[0044] The spans of b19-B20, b21-B22, b25-B26, b27-B28, b31-B32, and b33-B34 are all 10, while the spans of b23-B24 and b29-B30 are both 11. Their upper edges are located in the 4th layer of the core slot 41, and their lower edges are located in the 3rd layer of the core slot 41, with a shape as follows: Figure 2 The second coil 2 is shown.

[0045] The span between b35 and B36 is 7, with its upper edge located in the 4th layer of the core slot 41 and its lower edge located in the 5th layer of the core slot 41, forming a shape like... Figure 2 The second coil 2 is shown. The spans of b37-B38, b39-B40, b43-B44, b45-B46, b49-B50, and b51-B52 are all 9, while the spans of b41-B42 and b47-B48 are both 10. Their upper edges are located in the 6th layer of the core slot 41, and their lower edges are located in the 5th layer of the core slot 41, with a shape like... Figure 1 to 3 The second coil 2 is shown. In the first branch, coil A0 is connected to coils a1-A2 via twist welding, coils a1-A2 are connected to coils a3-A4 via twist welding, coils a3-A4 are connected to coils a5-A6 via twist welding, coils a5-A6 are connected to coils a7-A8 via twist welding, and so on. The coil sequence is from layer 6 to layer 5, layer 5 to layer 4, layer 4 to layer 3, and layer 3 to layer 2. All coils are wound on layer 1. The winding of the second branch follows the same pattern.

[0046] The three-phase windings are connected in star or delta configurations using busbars or lead wires to eliminate phase differences between different branches and ensure complete symmetry in each branch. This embodiment prioritizes manufacturability; the coils consist of U-shaped coils and single wires, reducing the variety of U-shaped coils. Most sections utilize multi-layer wires, lowering manufacturing difficulty and facilitating mass production. In other embodiments, busbars can be used for all windings.

[0047] In this embodiment, the number of slots per pole and per phase of the flat wire winding is 3. The branch leads are adjacent to each other, making the three-phase leads of the motor relatively simple. The range of the three-phase leads under the two branches is small, which is beneficial to reduce the spatial dimensions of the winding circumference and end height.

[0048] In this embodiment, the stator winding consists of three types of coils, such as... Figure 5 As shown, the wiring is simple, with no complex inner-layer wires, making wiring easier. The flat wire stator and motor are designed with manufacturability in mind. The coil consists of a U-shaped coil and a single wire, reducing the variety of U-shaped coils, lowering manufacturing difficulty, and facilitating mass production. By adjusting the span of the 3rd and 4th layer U-shaped coils and the corresponding welding end connections, flexible switching between full-pitch and short-pitch schemes can be achieved as needed. This reduces the number of wire types, lowers the complexity of the manufacturing process, facilitates production, and eliminates a series of problems caused by asymmetry in each branch. The three-phase windings can be connected in star or delta configurations via busbars or lead wires, resulting in a compact structure.

[0049] like Figure 6 and ​As shown, this embodiment also provides a stator, which includes a stator core 4 and the aforementioned stator windings. The inner wall of the stator core 4 has 54 core slots 41 arranged circumferentially. A portion of the phase windings in the stator windings are wound within the core slots 41, while a portion of the phase windings are located outside the core slots 41. Each core slot 41 has 6 layers of phase windings of the same phase, and the number of layers of phase windings in each core slot 41 is the same. It can be understood that in practical applications, the number of winding layers in each stator slot is not limited to 6 layers, but can also be 2, 4, 8, or 10 layers, etc., and the winding method can refer to the aforementioned 6-layer winding method. In other embodiments, the pole-slot combination can also be set as an integer multiple of 48 slots and 8 poles, such as 96 slots and 16 poles.

[0050] This embodiment also provides a flat wire motor including the above-described stator winding, which can be applied to electric vehicles (EVs), pure electric vehicles (PEVs / BEVs), hybrid electric vehicles (HEVs), range-extended electric vehicles (REEVs), plug-in hybrid electric vehicles (PHEVs), and new energy vehicles. In the flat wire corrugated motor of this embodiment, the corrugated flat wire does not require welding, has no solder joints, and offers high design flexibility, reducing processing steps, simplifying the process, and lowering costs.

[0051] This embodiment also provides a vehicle including the above-mentioned flat wire motor, which can be an electric vehicle (EV), a pure electric vehicle (PEV / BEV), a hybrid electric vehicle (HEV), a range-extended electric vehicle (REEV), a plug-in hybrid electric vehicle (PHEV), a new energy vehicle, etc.

[0052] In this embodiment, the flat wire motor consists of four types of coils. By using different cross-layer wires in the fourth and fifth layers and different welding end connections, the flat wire conductors in the same slot can be of the same phase or different phases in the same slot. The NVH performance of the motor can be adjusted according to different connection schemes.

[0053] In this embodiment, manufacturability is fully considered. The coil consists of a U-shaped coil and two types of single wires, reducing the variety of U-shaped coils. Most of the coils use multi-layer wires, which reduces the manufacturing difficulty and facilitates mass production.

[0054] While the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the invention. Any person skilled in the art can make many possible variations and modifications to the technical solutions of the present invention, or modify them into equivalent embodiments, based on the methods and techniques disclosed above, without departing from the spirit and technical essence of the invention. Therefore, any simple modifications, equivalent substitutions, equivalent changes, and modifications made to the above embodiments based on the technical essence of the present invention, without departing from the content of the present invention, shall still fall within the scope of protection of the present invention.

Claims

1. A short-pitch flat wire stator winding, characterized in that, The system includes three-phase windings, each of which includes multiple sets of parallel winding branches. Each set of winding branches includes two parallel branches. Each branch includes multiple coils arranged sequentially and connected in series on the circumferential core slots (41) of the stator core (4). The coils of the same branch in each set of winding branches are arranged in adjacent core slots (41). The winding directions of the two branches are opposite. Each branch includes coils with spans of y-2, y, y+1, and y+2, as well as a single coil. Both branches are constructed with a single wire. The coil serves as the starting line for winding and the neutral point lead-out line. Each single coil is located in the outermost layer of the slot opening or the innermost layer of the slot bottom. During winding, coils with a span of y and a span of y+1 are arranged in the outermost and second outermost layers of the slot opening of the iron core slot (41), or the innermost and second innermost layers of the slot bottom of the iron core slot (41). Coils with a span of y-2 are arranged in the second innermost and middle layers of the slot bottom of the iron core slot (41), or the second outermost and middle layers of the slot opening of the iron core slot (41). Coils with a span of y+1 and a span of y+2 are arranged in the middle layer of the iron core slot (41).

2. The short-pitch flat wire stator winding according to claim 1, characterized in that, One of the branches in each winding branch is wound from the outermost layer of the slot opening to the innermost layer of the slot bottom in the iron core slot (41). First, the preset number of slots is wound between the outermost layer of the slot opening and the second outermost layer of the slot opening. Then, the coil with a span of y-2 is used to switch from the second outermost layer of the slot opening to the middle layer. Next, the preset number of slots is wound in the middle layer. Then, the coil with a span of y-2 is used to switch from the middle layer to the second innermost layer of the slot bottom. Finally, the preset number of slots is wound in the innermost layer and the second innermost layer of the slot bottom to complete the branch winding.

3. The short-pitch flat wire stator winding according to claim 2, characterized in that, Another branch in each winding branch is wound from the innermost layer of the bottom of the iron core slot (41) to the outermost layer of the slot opening. First, the preset number of slots is wound between the innermost layer of the bottom of the slot and the second innermost layer of the bottom of the slot. Then, the coil with a span of y-2 is used to switch from the second innermost layer of the bottom of the slot to the middle layer. Next, the preset number of slots is wound in the middle layer. Then, the coil with a span of y-2 is used to switch from the middle layer to the second outermost layer of the slot opening. Finally, the preset number of slots is wound in the outermost layer of the slot opening and the second outermost layer of the slot opening to complete the branch winding.

4. The short-pitch flat wire stator winding according to any one of claims 1 to 3, characterized in that, The phase winding includes a set of winding branches. The first branch in the winding branch includes a single coil A0, coils a1-A2, a3-A4, a5-A6, a7-A8, a9-A10, a11-A12, a13-A14, a15-A16, a17-A18, a19-A20, a21-A22, a23-A24, a25-A26, a27-A28, a29-A30, a31-A32, ..., a49-A50, a51-A5 2. Single coil a53; The second branch includes single coil B0, coils b1-B2, b3-B4, b5-B6, b7-B8, b9-B10, b11-B12, b13-B14, b15-B16, b17-B18, b19-B20, b21-B22, b23-B24, b25-B26, b27-B28, b29-B30, b31-B32, ..., b49-B50, b51-B52, and single coil b53; Single coil A0 is located in the 6th layer along the bottom of the slot in the iron core slot (41), and single coil a53 is located in the 1st layer along the bottom of the slot in the iron core slot (41); single coil B0 is located in the 1st layer along the bottom of the slot in the iron core slot (41), and single coil b53 is located in the 6th layer along the bottom of the slot in the iron core slot (41). The spans of a1-A2, a3-A4, a7-A8, a9-A10, a13-A14 and a15-A16 are all y, and the spans of a5-A6 and a11-A12 are all y+1. Their upper edge is located in the 5th layer of the iron core groove (41), and their lower edge is located in the 6th layer of the iron core groove (41). The span of A17-A18 is y-2, and its upper edge is located in the 5th layer of the iron core groove (41), and its lower edge is located in the 4th layer of the iron core groove (41). The spans of a19-A20, a21-A22, a25-A26, a27-A28, a31-A32 and a33-A34 are all y+1, and the spans of a23-A24 and a29-A30 are all y+2. Their upper edge is located in the 3rd layer of the iron core groove (41), and their lower edge is located in the 4th layer of the iron core groove (41). The span of a35-A36 is y-2, and its upper edge is located in the 3rd layer of the iron core groove (41), and its lower edge is located in the 2nd layer of the iron core groove (41). The spans of a37-A38, a39-A40, a43-A44, a45-A46, a49-A50 and a51-A52 are all y, and the spans of a41-A42 and a47-A48 are all y+1. Their upper edge is located in the first layer of the iron core groove (41), and their lower edge is located in the second layer of the iron core groove (41). The spans of b1-B2, b3-B4, b7-B8, b9-B10, b13-B14 and b15-B16 are all y, and the spans of b5-B6 and b11-B12 are all y+1. Their upper edge is located in the second layer of the iron core groove (41), and their lower edge is located in the first layer of the iron core groove (41). The span of b17-B18 is y-2, and its upper edge is located in the second layer of the iron core groove (41), and its lower edge is located in the third layer of the iron core groove (41). The spans of b19-B20, b21-B22, b25-B26, b27-B28, b31-B32 and b33-B34 are all y+1, and the spans of b23-B24 and b29-B30 are all y+2. Their upper edge is located in the 4th layer of the iron core groove (41), and their lower edge is located in the 3rd layer of the iron core groove (41). The span of b35-B36 is y-2, and its upper edge is located in the 4th layer of the iron core groove (41), and its lower edge is located in the 5th layer of the iron core groove (41). The spans of b37-B38, b39-B40, b43-B44, b45-B46, b49-B50 and b51-B52 are all y, and the spans of b41-B42 and b47-B48 are all y+1. Their upper edge is located in the 6th layer of the iron core groove (41), and their lower edge is located in the 5th layer of the iron core groove (41). In the first branch, coil A0 is connected to coil a1-A2 by twist welding, coil a1-A2 is connected to coil a3-A4 by twist welding, coil a3-A4 is connected to coil a5-A6 by twist welding, coil a5-A6 is connected to coil a7-A8 by twist welding, and so on. The coil sequence is from layer 6 to layer 5, layer 5 to layer 4, layer 4 to layer 3, layer 3 to layer 2, completing the same layer in layer 1 and then returning to layer 2, layer 3 to layer 4, then layer 5, layer 6, and so on, to complete the winding of the first branch. The winding of the second branch is carried out in the same way.

5. The short-pitch flat wire stator winding according to claim 4, characterized in that, The single coil includes a first coil (1), which serves as the starting lead and the neutral point lead. The first coil (1) includes a first coil body (11) and a first bend (12). The first coil body (11) includes a first support rod (111). The first support rod (111) has a first head (112) and a first bend (12) at both ends. The first bend (12) forms a welding end. The bending direction of the first head (112) is opposite to the bending direction of the first bend (12).

6. The short-pitch flat wire stator winding according to claim 4, characterized in that, The coil with a span of y-2, the coil with a span of y, the coil with a span of y+1, and the coil with a span of y+2 are all second coils (2). The second coil (2) includes a second coil body (21) and a second bending part (22). The second coil body (21) includes two parallel second support rods (211) and a second head (212) connecting one end of the two second support rods (211). The other end of the two second support rods (211) is provided with a second bending part (22) to form a welding end. The second bending part (22) bends along the width direction of the second coil body (21) and away from the second coil body (21).

7. The short-pitch flat wire stator winding according to claim 4, characterized in that, The single coil includes a third coil (3), which serves as the starting lead and the neutral point lead. The third coil (3) includes a third coil body (31) and a third bend (32). The third coil body (31) includes a third support rod (311). The third support rod (311) has a third head (312) and a third bend (32) at both ends. The third bend (32) forms a welding end. The bending direction of the third head (312) is opposite to that of the bending direction of the third bend (32).

8. The short-pitch flat wire stator winding according to any one of claims 5 to 7, characterized in that, The connection between each group of windings is either a star connection or a delta connection.

9. A flat wire motor, characterized in that, Includes the short-pitch flat wire stator winding as described in any one of claims 1 to 8.

10. A vehicle, characterized in that, Including the flat wire motor as described in claim 9.

Images