Stator winding of flat wire motor and flat wire motor

Abstract

The invention discloses a flat wire motor stator winding, which comprises a wire inserting stator and a winding wound on the stator, and is characterized in that the wire inserting stator comprises a stator iron core provided with M stator slots at equal intervals, and a flat wire motor corresponding to the pole number P is provided, and the stator slots are divided into 2n slot layers along the radial direction of the stator iron core; the windings comprise three phases of phase windings, and each phase winding comprises a first winding unit and a second winding unit which are the same and formed by hairpin coils; the first winding unit comprises a plurality of different-layer hairpin coils with spans of q, q-1 and q + 2, the different-layer hairpin coils are arranged between two adjacent slot layers of the stator slot in a crossing manner, the span between two adjacent different-layer hairpin coils is q, and q is M / P; and each phase winding comprises a parallel branches. According to the invention, wire outgoing can be carried out on one side of the iron core, wire outgoing can also be carried out on two ends of the iron core, the method adapts to a winding scheme of integer hairpin coil number and non-integer hairpin coil number of a single branch, and combination of pole-to-slot ratio and parallel branch number can be flexibly carried out.

Description

A stator winding for a flat wire motor and the flat wire motor Technical Field

[0001] This invention relates to the field of flat wire motor technology, and more particularly to a flat wire motor stator winding and a flat wire motor. Background Technology

[0002] Flat wire motors, due to varying performance requirements, need to be expanded with different output winding schemes while maintaining the basic electromagnetic scheme on the same platform. This reduces investment in flat wire stator production lines, lowers production costs, and improves line utilization. Taking a 6-pole, 54-slot scheme as an example, with 6 copper wires arranged in each core slot, it can output 6 wires in 1 parallel, 6 wires in 2 parallel, 6 wires in 3 parallel, and 6 wires in 4 parallel, etc. Therefore, when arranging the stator winding scheme, the platform's expandability and compatibility must be considered simultaneously. This ensures that the winding design for different winding schemes is platform-wide and universal, requiring minimal adjustments to production line tooling.

[0003] The patent document "A Flat Wire Armature and Flat Wire Motor" disclosed in Chinese patent literature, publication number CN118353190A, publication date July 16, 2024, includes: a stator core and a stator winding. The inner wall of the stator core extends radially outward to form multiple mounting grooves. The stator winding includes multiple U-shaped flat wire hairpin conductors and multiple I-shaped flat wire hairpin conductors. The U-shaped flat wire hairpin conductors are connected circumferentially along the stator core to form U-phase windings, V-phase windings, and W-phase windings. The I-shaped flat wire hairpin conductors have three-phase leads and a neutral wire of the U-phase windings, V-phase windings, and W-phase windings at the insertion end. The U-shaped flat wire hairpin conductors and the I-shaped flat wire hairpin conductors have the same lead wire at the welding end. However, in this technology, the lead-out end of the winding is usually limited to one side of the iron core, which restricts the flexibility of the pole-slot ratio and the number of parallel branches. Under different winding schemes of parallel branches, there are many types of hairpin coils, and the poor compatibility of tooling equipment leads to complicated production line adjustments. Summary of the Invention

[0004] The present invention aims to overcome the problems in the prior art where the lead-out end of the winding is usually limited to one side of the iron core, which restricts the flexibility of the pole-slot ratio and the number of parallel branches. Furthermore, the invention addresses the issues of the wide variety of hairpin coils under different parallel branch winding schemes, poor compatibility of tooling equipment, and the resulting complexity of production line adjustments. The invention provides a flat wire motor stator winding and a flat wire motor.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: a flat wire motor stator winding, comprising a wire-inserted stator and a winding wound on the stator, wherein the wire-inserted stator comprises a stator core with M stator slots equally spaced along the circumference of the stator, corresponding to a flat wire motor with a pole number of P, the stator slots being divided into 2n slot layers along the radial direction of the stator core; the winding comprises a three-phase winding, each phase winding comprising a plurality of first winding units and a plurality of second winding units with identical hairpin coils; the first winding unit comprises a plurality of dissimilar hairpin coils with hairpin end spans of q, q-1 and q+2 respectively, the dissimilar hairpin coils being straddled between two adjacent slot layers of the stator slot, the welding end span between two adjacent dissimilar hairpin coils being q, where q is M / P; each phase winding comprises a parallel branches.

[0006] The winding design in this invention reduces the variety of hairpin wire types, thereby decreasing the investment in hairpin forming equipment and tooling in the production line. The wire type classification is simple, and the tooling equipment has greater versatility. Furthermore, for winding schemes with an integer number of hairpin coils in a single branch, the wire can exit from one side of the iron core, while for winding schemes with a non-integer number of hairpin coils in a single branch, the wire can exit from both ends of the iron core. This allows for flexible combinations of pole-slot ratios and the number of parallel branches. The connections between each phase winding and each branch can be achieved through busbars or direct lead-out connections using flat wires. At the same time, different parallel schemes can be switched simply by adjusting the twisting head tooling, improving production line utilization and compatibility.

[0007] Preferably, the first winding unit is introduced from the first layer in a cyclic sequence with hairpin end spans of q, q, q-1, q, q, q-1, q, q, q+2. After alternately winding b hairpin coils in the first and second layers, it moves to the third layer, then alternately winds b hairpin coils in the third and fourth layers, and moves to the fifth layer, and so on, until b hairpin coils are alternately wound in the 2n-1 and 2n layers, and then it is taken out from the 2n layer. The second winding unit is introduced from the first winding unit in the 2n layer at a distance of q stator slots from the first winding unit, in the reverse cyclic sequence. After alternately winding b hairpin coils in the 2n and 2n-1 layers, it moves to the 2n-2 layer, then alternately winds b hairpin coils in the 2n-2 and 2n-3 layers, and moves to the 2n-4 layer, and so on, until b hairpin coils are alternately wound in the 2nd and 1st layers, and then it is taken out from the first layer.

[0008] Preferably, the stator core has 54 slots, corresponding to a flat wire motor with 6 poles, and the stator slots are divided into 6 layers along the radial direction of the stator core.

[0009] Preferably, when each phase winding includes a parallel branch, b is 3P / 2: the second winding unit at the 2nth layer and the first winding unit at the 2nth layer are connected by welding a reverse-twisted copper wire with a span of q; the inlet of the parallel branch is the Xth stator slot in the 1st layer, and the outlet is the X+qth stator slot in the 1st layer. When the calculated number of stator slots is greater than M, an integer multiple of M is subtracted to make the number of stator slots in [1, M].

[0010] Preferably, when each phase winding contains two parallel branches, b is 3P / 2: the input end of the first parallel branch is the Xth stator slot of the 1st layer, and the output end is the X+qth stator slot of the 2nth layer; the input end of the second parallel branch is the X+2qth stator slot of the 2nth layer, and the output end is the X+qth stator slot of the 1st layer. When the calculated number of stator slots is greater than M, subtract an integer multiple of M to make the number of stator slots in [1, M].

[0011] Preferably, when each phase winding contains three parallel branches with the same winding method, b is P / 2: the inlet of the first parallel branch is the Xth stator slot of the first layer; after alternately winding P / 2 hairpin coils in the first and second layers, it crosses over to the third layer; after alternately winding P / 2 hairpin coils in the third and fourth layers, it crosses over to the fifth layer; after alternately winding P / 2 hairpin coils in the fifth and sixth layers and then rewinding P / 2 hairpin coils in reverse, it crosses over to the fourth layer; and after alternately winding P / 2 hairpin coils in the fourth and third layers... After the coil is moved to the second layer, P / 2 hairpin coils are wound alternately in the second and first layers, and the lead-out end is the X+qth stator slot in the first layer; the lead-in end of the second parallel branch is the X+1th stator slot in the first layer, and the lead-out end is the X+q+1th stator slot in the first layer; the lead-in end of the third parallel branch is the X+2th stator slot in the first layer, and the lead-out end is the X+q+2th stator slot in the first layer. When the calculated number of stator slots is greater than M, subtract an integer multiple of M to make the number of stator slots in [1, M].

[0012] Preferably, when each phase winding contains four parallel branches, b is 3P / 2, the decimal of the ratio of the number of hairpin coils to the number of branches is 0.5, and n is an odd number: the input end of the first parallel branch is the Xth stator slot of the 1st layer, and the output end is the X+4q+1st stator slot of the 3rd layer; the input end of the second parallel branch is the X+3q+1st stator slot of the 4th layer, and the output end is the X+qth stator slot of the 6th layer; the input end of the third parallel branch is the X+2qth stator slot of the 6th layer, and the output end is the X+4q+1st stator slot of the 4th layer; the input end of the fourth parallel branch is the X+5q+1st stator slot of the 3rd layer, and the output end is the X+qth stator slot of the 1st layer. When the calculated number of stator slots is greater than M, subtract an integer multiple of M to make the number of stator slots [1, M].

[0013] Preferably, the three-phase windings are a U-phase winding, a V-phase winding, and a W-phase winding; the U-phase winding is offset by several stator slots in a clockwise direction to obtain the V-phase winding; the V-phase winding is offset by several stator slots in a clockwise direction to obtain the W-phase winding; or the U-phase winding is offset by several stator slots in a counterclockwise direction to obtain the V-phase winding; the V-phase winding is offset by several stator slots in a counterclockwise direction to obtain the W-phase winding.

[0014] Preferably, when each phase winding contains four parallel branches: a type I hairpin coil is used as the lead wire of the first parallel branch in the (X+4q+1)th stator slot of the 3rd layer; a type I hairpin coil is used as the lead wire of the second parallel branch in the (X+3q+1)th stator slot of the 4th layer; a type I hairpin coil is used as the lead wire of the third parallel branch in the (X+4q+1)th stator slot of the 4th layer; and a type I hairpin coil is used as the lead wire of the fourth parallel branch in the (X+5q+1)th stator slot of the 3rd layer.

[0015] A flat wire motor includes the aforementioned flat wire motor stator winding.

[0016] The present invention has the following advantages: fewer hairpin coil types, which can reduce the investment in hairpin forming equipment and tooling in the production line; simpler coil type classification and more versatile tooling equipment; wires can be output from one side of the iron core or from both ends of the iron core; it can also adapt to winding schemes with integer and non-integer numbers of hairpin coils in a single branch; and it can flexibly combine pole-slot ratio and the number of parallel branches; the connection between each phase winding and each branch can be achieved by direct lead-out connection through busbars or flat wires; and different parallel schemes can be switched by simply adjusting the twisting head tooling, improving the utilization rate and compatibility of the production line. Attached Figure Description

[0017] Figure 1 is a schematic diagram of the stator winding of the flat wire motor in this invention.

[0018] Figure 2 is a schematic diagram of the cross-layer hairpin coil in this invention.

[0019] Figure 3 is a schematic diagram of the structure of the Type I hairpin coil in this invention.

[0020] In the diagram: 1. Stator core; 11. Stator slot; 2. Winding; 3. Different layer hairpin coil; 31. First connection part; 32. First slot part; 33. First bend part; 4. Outgoing wire part; 5. Type I hairpin coil; 51. Second slot part; 52. Second bend part; 53. Second outgoing wire part. Detailed Implementation

[0021] The present invention will now be further described with reference to the accompanying drawings and specific embodiments.

[0022] As shown in Figures 1-3, a flat wire motor stator winding includes a wire-embedded stator and windings wound on the stator. The wire-embedded stator includes a stator core with M stator slots evenly spaced along the circumference of the stator, corresponding to a flat wire motor with a pole number of P. The stator slots are divided into 2n slot layers along the radial direction of the stator core. The windings include three-phase windings. Each phase winding includes several first winding units and several second winding units with identical hairpin coils. The first winding unit includes multiple heterogeneous hairpin coils with hairpin end spans of q, q-1, and q+2, which are straddled between adjacent slot layers of the stator slot. The welding end span between two adjacent heterogeneous hairpin coils is q, where q is M / P. Each phase winding includes a parallel branches.

[0023] The winding design in this invention reduces the variety of hairpin wire types, thereby decreasing the investment in hairpin forming equipment and tooling in the production line. The wire type classification is simple, and the tooling equipment has greater versatility. Furthermore, for winding schemes with an integer number of hairpin coils in a single branch, the wire can exit from one side of the iron core, while for winding schemes with a non-integer number of hairpin coils in a single branch, the wire can exit from both ends of the iron core. This allows for flexible combinations of pole-slot ratios and the number of parallel branches. The connections between each phase winding and each branch can be achieved through busbars or direct lead-out connections using flat wires. At the same time, different parallel schemes can be switched simply by adjusting the twisting head tooling, improving production line utilization and compatibility.

[0024] Existing designs for flat-wire motor stator windings primarily focus on symmetrical winding structures to address loop current issues and reduce torque ripple. However, these designs often neglect platform versatility and cost considerations for tooling production. The winding leads are typically confined to one side of the core, limiting the flexibility of pole-to-slot ratios and parallel branch combinations. The variety of hairpin wire types and poor tooling compatibility lead to complex production line adjustments. Furthermore, achieving non-integer winding numbers in a single branch is difficult, affecting winding continuity and balance. The main technical problems addressed by this invention include: maintaining hairpin wire type versatility across different parallel branch numbers to reduce tooling investment; achieving continuous winding of non-integer winding numbers to ensure electrical balance; and adapting to multi-parallel branch requirements with specific pole-to-slot ratios (e.g., 6 poles, 54 slots) through core-end lead design. By optimizing hairpin wire span and branch layout, a universal design is achieved from 1-parallel to 4-parallel schemes and 6-parallel schemes, reducing tooling adjustments and improving production line utilization. The 6-parallel scheme is obtained by opening the outer anti-twisted copper wire to set up both outgoing and incoming wires, based on the 3-parallel scheme.

[0025] Specifically, Figure 1 is a schematic diagram of the stator winding of the flat wire motor in this invention. The inner wall of the stator core 1 is provided with multiple stator slots 11. The number of stator slots can be represented by M, which can be a natural number that is a multiple of 3, specifically 54. The M stator slots are located on the inner wall of the stator core and are evenly distributed along the circumference of the stator core. Each stator slot extends axially along the stator core and penetrates its inner wall along the axial direction. The winding 2 includes dissimilar hairpin coils 3 inserted into the stator slots, formed by connecting multiple dissimilar hairpin coils. In this invention, the output part 4 of any parallel branch of each phase winding can be located on the same side of the stator core or on both sides of the stator core.

[0026] As a specific embodiment, the first winding unit is introduced from the first layer of the stator slot in a cyclic sequence with hairpin end spans of q, q, q-1, q, q, q-1, q, q, q+2, starting with a hairpin coil of span q. It then winds b hairpin coils alternately in layers 1 and 2 along the circumference of the stator core, then moves to layer 3, then b hairpin coils alternately in layers 3 and 4, then moves to layer 5, and so on, until b hairpin coils are alternately wound in layers 2n-1 and 2n, then the second winding unit... The second winding unit is wound in the reverse cycle of the first winding unit, starting with a hairpin coil with a span of q+2. It is introduced from the first winding unit of the 2nth layer at a distance of q stator slots. After winding b hairpin coils alternately in the 2nth and 2n-1th layers, it moves to the 2n-2th layer. Then, after winding b hairpin coils alternately in the 2n-2th and 2n-3th layers, it moves to the 2n-4th layer, and so on, until it is wound b hairpin coils alternately in the 2nd and 1st layers and then taken out from the 1st layer.

[0027] Specifically, the first winding unit is composed of different-layer hairpin coils with spans of q, q-1, and q+2, wound alternately in the direction of decreasing stator slot numbering. The ratio of the number of different-layer hairpin coils with the three spans is 6:2:1, resulting in an average span of q for all different-layer hairpin coils. Similarly, the second winding unit is composed of different-layer hairpin coils with spans of q, q-1, and q+2, wound alternately in the direction of increasing stator slot numbering. The ratio of the number of different-layer hairpin coils with the three spans is 6:2:1, resulting in an average span of q for all different-layer hairpin coils. The direction of decreasing stator slot numbering can be clockwise, in which case the direction of increasing stator slot numbering is counterclockwise; or the direction of decreasing stator slot numbering can be counterclockwise, in which case the direction of increasing stator slot numbering is clockwise.

[0028] Figure 2 shows a schematic diagram of a multi-layer hairpin coil. Although different multi-layer hairpin coils differ in span, their overall structure is basically the same. A multi-layer hairpin coil includes two parallel first slot portions 32 and a first connecting portion 31 connecting one end of the two first slot portions 32. The two first slot portions 32 of a multi-layer hairpin coil with a span of q are respectively inserted into two adjacent layers of two stator slots 11 with a span of q; the two first slot portions 32 of a multi-layer hairpin coil with a span of q-1 are respectively inserted into two adjacent layers of two stator slots 11 with a span of q-1; and the two first slot portions 32 of a multi-layer hairpin coil with a span of q+2 are respectively inserted into two adjacent layers of two stator slots 11 with a span of q+2.

[0029] The other ends of the two first through-slot portions 32 are respectively connected to first bending portions 33. The two first bending portions 33 are bent along the circumference of the stator core 1, and the bending directions are opposite. By setting the first bending portions 33 at both ends of the non-layer hairpin coils 3, it is convenient to weld the first bending portions 33 of two adjacent non-layer hairpin coils in the same parallel branch to achieve series connection. The first bending portions 33 in the non-layer hairpin coils at the beginning and end of the parallel branch, which are not welded, serve as the output portion 4 of the parallel branch, and are connected to the busbar or directly output.

[0030] Figure 3 shows a schematic diagram of the structure of a type I hairpin coil. The type I hairpin coil 5 is mainly used as the lead-in and lead-out wire for all winding schemes. One end is used as the lead-out wire and the other end is used for welding. When switching winding schemes, only two types of type I hairpin coils need to be added (Figure 3 shows one type of type I hairpin coil, and the copper wire hairpin shape twisting method of the other type of type I hairpin coil is mirrored. The two types of hairpin coils are used for the lead-in and lead-out of different slot layers) as the lead-out wire of the intermediate break point, keeping the line shape of other different layer hairpin coils unchanged. This improves the versatility of tooling equipment while minimizing the types of hairpin coils.

[0031] The type I hairpin coil 5 includes a second through-slot portion 51, one end of which is connected to a second bending portion 52, and the other end is connected to a second lead-out portion 53. For a winding scheme with a single branch and a non-integer number of hairpin coils, the second through-slot portion 51 of the type I hairpin coil is used to replace the two first through-slot portions of the heterogeneous hairpin coil. Its second bending portion 52 bends towards the adjacent heterogeneous hairpin coil and is welded to the first bending portion of the corresponding heterogeneous hairpin coil to achieve series connection. Its second lead-out portion 53 serves as the lead-out portion 4 of the corresponding parallel branch, and is connected to a busbar or directly leads out.

[0032] Furthermore, the three-phase windings are U-phase winding, V-phase winding, and W-phase winding; the U-phase winding is offset by several stator slots in a clockwise direction to obtain the V-phase winding; the V-phase winding is offset by several stator slots in a clockwise direction to obtain the W-phase winding; or the U-phase winding is offset by several stator slots in a counterclockwise direction to obtain the V-phase winding; the V-phase winding is offset by several stator slots in a counterclockwise direction to obtain the W-phase winding.

[0033] A flat wire motor includes the aforementioned flat wire motor stator winding.

[0034] For ease of description, the following example uses a flat wire motor with 54 stator slots, corresponding to 6 poles, where the stator slots are divided into 6 layers radially along the stator core. In this case, the V-phase and W-phase windings are connected in exactly the same way as the U-phase winding. Each pair of phases can be evenly distributed within the stator core at a 40° interval, which corresponds to each phase being offset by 6 stator slots clockwise or counterclockwise.

[0035] In the case of a 6-pole, 54-slot configuration, the spans of the heterogeneous hairpin coils are 8, 9, and 11. Specifically, in the first winding unit, the heterogeneous hairpin coils cycle in the sequence 9, 9, 8, 9, 9, 8, 9, 9, 11, alternating between layers 1 and 2, then alternating between layers 3 and 4, and finally alternating between layers 5 and 6. In the second winding unit, the single-layer hairpin coil cycles in the sequence 11, 9, 9, 8, 9, 9, 8, 9, 9, alternating between layers 6 and 5, then alternating between layers 4 and 3, and finally alternating between layers 2 and 1.

[0036] This invention uses a welding end lead-out winding scheme as the basic winding implementation scheme. Different lead-out schemes maintain the same hairpin wire type, ensuring the versatility of the tooling equipment for the hairpin wire type. For special winding schemes, such as the 6-pole 54-slot 6-wire 4-parallel scheme, a hairpin wire type (I-type hairpin coil) is added while keeping the original platform hairpin wire type unchanged to ensure the feasibility of the winding.

[0037] In the connection method of the stator winding of the flat wire motor of the present invention, the stator winding includes a three-phase winding. Taking four parallel branches as an example, each phase winding contains four parallel branches, and each branch is evenly distributed in the circumferential and radial directions of the iron core. There are three types of winding spans: 8, 9, and 11. The two straight edges of each type of non-layer hairpin coil are distributed in two adjacent layers within the iron core slots. The non-layer hairpin coils are reciprocated at both ends and circumferentially connected to the stator iron core, evenly distributed within the stator slots, ensuring mutual balance between the three phases and branches of the winding.

[0038] Example 1: This example illustrates a winding scheme with a single-branch non-integer number of hairpin coils. In the stator winding, the winding methods for the three phase windings are the same; the only difference is that each phase is offset by a certain number of stator slots clockwise or counterclockwise. Therefore, this example uses the U-phase winding as an example.

[0039] When the U-phase winding contains four parallel branches, b is 3P / 2 (i.e., 9 hairpin coils), the decimal of the ratio of the number of hairpin coils to the number of branches is 0.5, and n is an odd number: the lead-in end of the first parallel branch is the Xth stator slot of the first layer, and the lead-out end is the X+4q+1th stator slot of the third layer; in the X+4q+1th stator slot of the third layer, an I-type hairpin coil is used as the lead-out line of the first parallel branch; in the Xth stator slot of the first layer, the first bend of the non-welded hairpin coil is used as the lead-in line of the first parallel branch.

[0040] The input end of the second parallel branch is the (X+3q+1)th stator slot of the 4th layer, and the output end is the (X+q)th stator slot of the 6th layer. In the (X+3q+1)th stator slot of the 4th layer, an I-type hairpin coil is used as the input wire of the second parallel branch. In the (X+q)th stator slot of the 6th layer, the first bend of the non-welded hairpin coil is used as the output wire of the second parallel branch.

[0041] The input end of the third parallel branch is the (X+2q)th stator slot of the 6th layer, and the output end is the (X+4q+1)th stator slot of the 4th layer. In the (X+4q+1)th stator slot of the 4th layer, an I-type hairpin coil is used as the output wire of the third parallel branch. In the (X+2q)th stator slot of the 6th layer, the first bend of the non-welded hairpin coil of the different layer is used as the input wire of the third parallel branch.

[0042] The inlet of the fourth parallel branch is the (X+5q+1)th stator slot of the 3rd layer, and the outlet is the (X+q)th stator slot of the 1st layer. In the (X+5q+1)th stator slot of the 3rd layer, an I-type hairpin coil is used as the inlet of the fourth parallel branch; in the (X+q)th stator slot of the 1st layer, the first bend of the non-welded hairpin coil is used as the outlet of the fourth parallel branch.

[0043] When the calculated number of stator slots is greater than M, subtract an integer multiple of M to make the number of stator slots fall within the range [1, M]. For example, if the input terminal is the 20th stator slot in the 1st layer, and the corresponding output terminal is the 57th stator slot in the 3rd layer, since 57 is greater than the number of stator slots 54, we need to subtract 54 from 57 to get 3. That is, the actual output terminal is the 3rd stator slot in the 3rd layer. Both "lead-in" and "output" are ways of describing the output section; "in" and "output" are simply descriptions of the current direction, and they can be interchanged.

[0044] Specifically, the outer diameter side of the motor stator core is the 6th layer of the winding, and the inner diameter side is the 1st layer of the winding. 7-1→52-2 means: the 7th stator slot of the 1st layer is connected to the 52nd stator slot of the 2nd layer.

[0045] First parallel branch: The 7th stator slot of the 1st layer is the lead-in line, 7-1→52-2→43-1→34-2→25-1→17-2→8-1→53-2→44-1→35-2→26-1→18-2→9-1→54-2→45-1→36-2→27-1→16-2→7-3→52-4→43-3→34-4→25-3→17-4→8-3→53-4→44-3, and the 44th stator slot of the 3rd layer is the lead-out line.

[0046] The second parallel branch: the 35th stator slot of the 4th layer is the lead-in line, 35-4→26-3→18-4→9-3→54-4→45-3→36-4→27-3→16-4→7-5→52-6→43-5→34-6→25-5→17-6→8-5→53-6→44-5→35-6→26-5→18-6→9-5→54-6→45-5→36-6→27-5→16-6, and the 16th stator slot of the 6th layer is the lead-out line.

[0047] The third parallel branch: the 25th stator slot of the 6th layer is the lead-in line, 25-6→36-5→45-6→54-5→9-6→18-5→27-6→35-5→44-6→53-5→8-6→17-5→26-6→34-5→43-6→52-5→7-6→16-5→25-4→36-3→45-4→54-3→9-4→18-3→27-4→35-3→44-4, and the 44th stator slot of the 4th layer is the lead-out line.

[0048] The fourth parallel branch: the 53rd stator slot of the 3rd layer is the lead-in line, 53-3→8-4→17-3→26-4→34-3→43-4→52-3→7-4→16-3→25-2→36-1→45-2→54-1→9-2→18-1→27-2→35-1→44-2→53-1→8-2→17-1→26-2→34-1→43-2→52-1→7-2→16-1, and the 16th stator slot of the 1st layer is the lead-out line.

[0049] Example 2: When each phase winding contains a parallel branch, b is 3P / 2 (i.e., 9 hairpin coils): The second winding unit's input end in the 2nth layer and the first winding unit's output end in the 2nth layer are connected by a reverse-twisted copper wire with a span of q; the input end of the parallel branch is the Xth stator slot in the 1st layer, and the output end is the X+qth stator slot in the 1st layer. When the calculated number of stator slots is greater than M, subtract an integer multiple of M to make the number of stator slots in [1, M]. For example, when the input end is the 20th stator slot in the 1st layer and the corresponding output end is the 57th stator slot in the 3rd layer, since 57 is greater than the number of stator slots 54, it is necessary to subtract 54 from 57 to get 3, that is, the actual output end is the 3rd stator slot in the 3rd layer.

[0050] Specifically, the outer diameter side of the motor stator core is the 6th layer of the winding, and the inner diameter side is the 1st layer of the winding. 7-1→52-2 means that the 7th stator slot of the 1st layer is connected to the 52nd stator slot of the 2nd layer. The 16th stator slot of the 6th layer and the 25th stator slot of the 6th layer are connected by a hairpin coil of the same layer with a span of 9.

[0051] One parallel branch: The 7th stator slot on the first floor is the lead-in line, 7-1→52-2→43-1→34-2→25-1→17-2→8-1→53-2→44-1→35-2→26-1→18-2→9-1→54-2→45-1→36-2→27-1→16-2→7-3→52-4→43-3→34-4→25-3→17-4→8-3 →53-4→44-3→35-4→26-3→18-4→9-3→54-4→45-3→36-4→27-3→16-4→7-5→52-6→43-5→34-6→25-5→17-6→8-5→53-6→44-5→35-6→26-5→18-6→9-5→54-6→45-5→36-6→27-5→16 -6→25-6→36-5→45-6→54-5→9-6→18-5→27-6→35-5→44-6→53-5→8-6→17-5→26-6→34-5→43-6→52-5→7-6→16-5→25-4→36-3→45-4→54-3→9-4→18-3→27-4→35-3→44-4→53-3→ 8-4→17-3→26-4→34-3→43-4→52-3→7-4→16-3→25-2→36-1→45-2→54-1→9-2→18-1→27-2→35-1→44-2→53-1→8-2→17-1→26-2→34-1→43-2→52-1→7-2→16-1, the 16th stator slot of the first layer is the lead wire.

[0052] Example 3: When each phase winding contains two parallel branches, b is 3P / 2 (i.e., 9 hairpin coils): The input end of the first parallel branch is the Xth stator slot in the 1st layer, and the output end is the X+qth stator slot in the 2nth layer; the input end of the second parallel branch is the X+2qth stator slot in the 2nth layer, and the output end is the X+qth stator slot in the 1st layer. When the calculated number of stator slots is greater than M, subtract an integer multiple of M to make the number of stator slots in [1, M]. For example, when the input end is the 20th stator slot in the 1st layer and the corresponding output end is the 57th stator slot in the 3rd layer, since 57 is greater than the number of stator slots 54, it is necessary to subtract 54 from 57 to get 3, that is, the actual output end is the 3rd stator slot in the 3rd layer.

[0053] Specifically, the outer diameter side of the motor stator core is the 6th layer of the winding, and the inner diameter side is the 1st layer of the winding. 7-1→52-2 means: the 7th stator slot of the 1st layer is connected to the 52nd stator slot of the 2nd layer.

[0054] First parallel branch: The 7th stator slot of the 1st layer is the lead-in line, 7-1→52-2→43-1→34-2→25-1→17-2→8-1→53-2→44-1→35-2→26-1→18-2→9-1→54-2→45-1→36-2→27-1→16-2→7-3→52-4→43-3→34-4→25-3→17-4→8-3→53-4→44 -3→35-4→26-3→18-4→9-3→54-4→45-3→36-4→27-3→16-4→7-5→52-6→43-5→34-6→25-5→17-6→8-5→53-6→44-5→35-6→26-5→18-6→9-5→54-6→45-5→36-6→27-5→16-6, the 16th stator slot of the 6th layer is the lead wire.

[0055] Second parallel branch: The 25th stator slot on the 6th floor is the lead-in line, 25-6→36-5→45-6→54-5→9-6→18-5→27-6→35-5→44-6→53-5→8-6→17-5→26-6→34-5→43-6→52-5→7-6→16-5→25-4→36-3→45-4→54-3→9-4→18-3→27-4→35-3→4 4-4→53-3→8-4→17-3→26-4→34-3→43-4→52-3→7-4→16-3→25-2→36-1→45-2→54-1→9-2→18-1→27-2→35-1→44-2→53-1→8-2→17-1→26-2→34-1→43-2→52-1→7-2→16-1, the 16th stator slot of the first layer is the lead wire.

[0056] Example 4: When each phase winding contains three parallel branches with the same winding method, b is P / 2 (i.e., 3 hairpin coils): The inlet of the first parallel branch is the Xth stator slot of the 1st layer. After alternately winding P / 2 hairpin coils in the 1st and 2nd layers, it crosses over to the 3rd layer. After alternately winding P / 2 hairpin coils in the 3rd and 4th layers, it crosses over to the 5th layer. After alternately winding P / 2 hairpin coils in the 5th and 6th layers and then rewinding P / 2 hairpin coils in reverse, it crosses over to the 4th layer. After alternately winding P / 2 hairpin coils in the 4th and 3rd layers... Two hairpin coils are then wound across the second layer. After alternately winding P / 2 hairpin coils in the second and first layers, the lead-out end is the (X+q)th stator slot in the first layer. The lead-in end of the second parallel branch is the (X+1)th stator slot in the first layer, and the lead-out end is the (X+q+1)th stator slot in the first layer. The lead-in end of the third parallel branch is the (X+2)th stator slot in the first layer, and the lead-out end is the (X+q+2)th stator slot in the first layer. When the calculated number of stator slots is greater than M, subtract an integer multiple of M to make the number of stator slots [1, M]. For example, if the lead-in end is the 20th stator slot in the first layer, and the corresponding lead-out end is the 57th stator slot in the third layer, since 57 is greater than the number of stator slots 54, 57 needs to be subtracted from 54 to get 3, meaning the actual lead-out end is the 3rd stator slot in the third layer.

[0057] Specifically, the outer diameter side of the motor stator core is the 6th layer of the winding, and the inner diameter side is the 1st layer of the winding. 7-1→52-2 indicates that the 7th stator slot of the 1st layer is connected to the 52nd stator slot of the 2nd layer. The 16th and 25th stator slots of the 6th layer are connected by a non-circular hairpin coil with a span of 9mm; the 17th and 26th stator slots of the 6th layer are connected by a non-circular hairpin coil with a span of 9mm; the 18th and 27th stator slots of the 6th layer are connected by a non-circular hairpin coil with a span of 9mm.

[0058] First parallel branch: The 7th stator slot of the 1st layer is the lead-in line, 7-1→52-2→43-1→34-2→25-1→17-2→8-3→53-4→44-3→35-4→26-3→18-4→9-5→54-6→45-5→36-6→27-5→16-6→25-6→36-5→45-6→54-5→9-6→18-5→27-4→35-3→44-4→53-3→8-4→17-3→26-2→34-1→43-2→52-1→7-2→16-1, and the 16th stator slot of the 1st layer is the lead-out line.

[0059] The second parallel branch: The 8th stator slot of the first layer is the lead-in line, 8-1→53-2→44-1→35-2→26-1→18-2→9-3→54-4→45-3→36-4→27-3→16-4→7-5→52-6→43-5→34-6→25-5→17-6→26-6→34-5→43-6→52-5→7-6→16-5→25-4→36-3→45-4→54-3→9-4→18-3→27-2→35-1→44-2→53-1→8-2→17-1. The 17th stator slot of the first layer is the lead-out line.

[0060] The third parallel branch: The 9th stator slot of the first layer is the lead-in line, 9-1→54-2→45-1→36-2→27-1→16-2→7-3→52-4→43-3→34-4→25-3→17-4→8-5→53-6→44-5→35-6→26-5→18-6→27-6→35-5→44-6→53-5→8-6→17-5→26-4→34-3→43-4→52-3→7-4→16-3→25-2→36-1→45-2→54-1→9-2→18-1, and the 18th stator slot of the first layer is the lead-out line.

[0061] The above embodiments are further elaborations and descriptions of the present invention to facilitate understanding, and are not intended to limit the present invention in any way. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A stator winding for a flat wire motor, characterized in that, The system includes a wire-insulated stator and windings wound on the stator. The wire-insulated stator comprises a stator core with M stator slots evenly spaced along the circumference of the stator, corresponding to a flat wire motor with a pole number of P. The stator slots are divided into 2n slot layers along the radial direction of the stator core. The windings comprise three-phase windings. Each phase winding comprises several first winding units and several second winding units with identical hairpin coils. Each first winding unit comprises multiple dissimilar hairpin coils with hairpin end spans of q, q-1, and q+2, which are straddled between adjacent slot layers of the stator slot. The welding end span between two adjacent dissimilar hairpin coils is q, where q is M / P. Each phase winding comprises a parallel branches.

2. The stator winding of a flat wire motor according to claim 1, characterized in that, The first winding unit is introduced from layer 1 in a cyclic sequence with hairpin end spans of q, q, q-1, q, q, q-1, q, q, q+2. After winding b hairpin coils alternately in layers 1 and 2, it moves to layer 3. Then, after winding b hairpin coils alternately in layers 3 and 4, it moves to layer 5, and so on, until it is taken out from layer 2n after winding b hairpin coils alternately in layers 2n-1 and 2n. The second winding unit is introduced from layer 2n at a distance of q stator slots from the first winding unit, following the reverse cyclic sequence of the first winding unit. After winding b hairpin coils alternately in layers 2n and 2n-1, it moves to layer 2n-2. Then, after winding b hairpin coils alternately in layers 2n-2 and 2n-3, it moves to layer 2n-4, and so on, until it is taken out from layer 1 after winding b hairpin coils alternately in layers 2 and 1.

3. A flat wire motor stator winding according to claim 1 or 2, characterized in that, The stator core has 54 slots, corresponding to a flat wire motor with 6 poles. The stator slots are divided into 6 layers along the radial direction of the stator core.

4. A flat wire motor stator winding according to claim 3, characterized in that, When each phase winding contains a parallel branch, b is 3P / 2: the second winding unit at the 2nth layer and the first winding unit at the 2nth layer are connected by welding a reverse-twisted copper wire with a span of q; the inlet of the parallel branch is the Xth stator slot in the 1st layer, and the outlet is the X+qth stator slot in the 1st layer. When the calculated number of stator slots is greater than M, subtract an integer multiple of M to make the number of stator slots in [1, M].

5. A flat wire motor stator winding according to claim 3, characterized in that, When each phase winding contains two parallel branches, b is 3P / 2: the input end of the first parallel branch is the Xth stator slot of the 1st layer, and the output end is the X+qth stator slot of the 2nth layer; the input end of the second parallel branch is the X+2qth stator slot of the 2nth layer, and the output end is the X+qth stator slot of the 1st layer. When the calculated number of stator slots is greater than M, subtract an integer multiple of M to make the number of stator slots in [1, M].

6. A flat wire motor stator winding according to claim 3, characterized in that, When each phase winding contains three parallel branches with the same winding method, b is P / 2: The inlet of the first parallel branch is the Xth stator slot of the first layer. After alternately winding P / 2 hairpin coils in the first and second layers, it crosses over to the third layer. After alternately winding P / 2 hairpin coils in the third and fourth layers, it crosses over to the fifth layer. After alternately winding P / 2 hairpin coils in the fifth and sixth layers and then rewinding P / 2 hairpin coils in reverse, it crosses over to the fourth layer. After alternately winding P / 2 hairpin coils in the fourth and third layers... Then, move to the second layer. After alternately winding P / 2 hairpin coils in the second and first layers, the lead-out end is the X+qth stator slot in the first layer; the lead-in end of the second parallel branch is the X+1th stator slot in the first layer, and the lead-out end is the X+q+1th stator slot in the first layer; the lead-in end of the third parallel branch is the X+2th stator slot in the first layer, and the lead-out end is the X+q+2th stator slot in the first layer. When the calculated number of stator slots is greater than M, subtract an integer multiple of M to make the number of stator slots [1, M].

7. A flat wire motor stator winding according to claim 3, characterized in that, When each phase winding contains four parallel branches, b is 3P / 2, the decimal of the ratio of the number of hairpin coils to the number of branches is 0.5, and n is an odd number: the input end of the first parallel branch is the Xth stator slot of the 1st layer, and the output end is the X+4q+1st stator slot of the 3rd layer; the input end of the second parallel branch is the X+3q+1st stator slot of the 4th layer, and the output end is the X+qth stator slot of the 6th layer; the input end of the third parallel branch is the X+2qth stator slot of the 6th layer, and the output end is the X+4q+1st stator slot of the 4th layer; the input end of the fourth parallel branch is the X+5q+1st stator slot of the 3rd layer, and the output end is the X+qth stator slot of the 1st layer. When the calculated number of stator slots is greater than M, subtract an integer multiple of M to make the number of stator slots in [1, M].

8. A flat wire motor stator winding according to claim 1, 2, 4, 5, 6, or 7, characterized in that, The three-phase windings are a U-phase winding, a V-phase winding, and a W-phase winding; the U-phase winding is offset by several stator slots in a clockwise direction to obtain the V-phase winding; the V-phase winding is offset by several stator slots in a clockwise direction to obtain the W-phase winding; or the U-phase winding is offset by several stator slots in a counterclockwise direction to obtain the V-phase winding; the V-phase winding is offset by several stator slots in a counterclockwise direction to obtain the W-phase winding.

9. A flat wire motor stator winding according to claim 7, characterized in that, When each phase winding contains four parallel branches: a type I hairpin coil is used as the lead wire of the first parallel branch in the (X+4q+1)th stator slot of the 3rd layer; a type I hairpin coil is used as the lead wire of the second parallel branch in the (X+3q+1)th stator slot of the 4th layer; a type I hairpin coil is used as the lead wire of the third parallel branch in the (X+4q+1)th stator slot of the 4th layer; and a type I hairpin coil is used as the lead wire of the fourth parallel branch in the (X+5q+1)th stator slot of the 3rd layer.

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

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