Continuous winding assembly

Abstract

The present invention relates to a continuous winding assembly, and more particularly, to a continuous winding assembly for winding on a motor stator. The continuous winding assembly of the present invention combines three windings of different lengths to form a parallel winding, and applies equivalent series turns to allow application to odd layers, and enables electromagnetic balance between windings even in continuous hairpin windings of standard pitch, thereby suppressing circulating current and maximizing manufacturing efficiency.

Description

Technical Field

[0001] The present invention relates to a continuous winding assembly, and more specifically, to a continuous winding assembly for winding on a motor stator. Background Technology

[0002] Continuous hairpin windings consist of multiple conductors continuously traversing multiple slots, offering advantageous characteristics in terms of quality control and productivity by minimizing solder joints. Typically, a phase comprises two or more parallel windings, each formed by two conductors with opposite current directions. This structure is only suitable for motors with an even number of layers, imposing design constraints on the selection of a key parameter in motor design—the equivalent number of series turns. Figure 1 As shown, the equivalent number of series turns is a key factor determining torque and output. A larger equivalent number of series turns increases low-speed torque but reduces output torque at high speeds. Selecting an appropriate number of series turns within a limited range of current and voltage has always been a fundamental challenge in motor design.

[0003] The equivalent series turns of a hairpin winding are calculated by considering the number of slots, phases, layers, and parallel circuits. However, under actual mass production conditions, the selectable number of series turns is limited. This limitation reduces design flexibility. For example, under feasible mass production conditions, the maximum number of layers is 10, and the maximum number of parallel circuits is approximately 4. Under these conditions, the selectable equivalent series turns are limited to multiples of 8, namely 8, 16, 24, 32, 40, 48, and 64.

[0004] Furthermore, for two or more parallel windings forming a single phase, the back electromotive force (EMF) must maintain the same magnitude and phase; however, any imbalance will generate circulating currents that degrade motor performance. To address the back EMF imbalance between parallel windings, each parallel winding must change its position within the slot group, and non-standard pitch must be applied to odd-numbered layers. This necessitates different conductor patterns for each parallel winding, increasing the number of conductor types and introducing complexity into the manufacturing process. Therefore, existing technologies face significant limitations in design and manufacturing due to constraints on the equivalent number of series turns and the imbalance between parallel windings. New designs and technologies are needed to overcome these problems.

[0005] Related technical documents

[0006] (Patent Document 1) Korean Patent Publication 10-2021-0031762, "Winding Weaving Method of Electromechanical Components". Summary of the Invention

[0007] The present invention was conceived to solve the above-mentioned problems. The object of the present invention is to provide a continuous winding assembly in which three windings of different lengths are combined to form parallel windings and equivalent series turns are applied to allow application to an odd number of layers. Furthermore, even for continuous hairpin windings with standard pitch, electromagnetic balance between windings can be achieved, thereby suppressing circulating currents while maximizing manufacturing efficiency.

[0008] To achieve the above objective, according to one embodiment of the present invention, a continuous winding assembly for a stator is provided, the stator including predetermined slot groups disposed adjacent to the poles of a rotor at continuous positions, one slot group for each pole of the rotor, the continuous winding assembly including: a plurality of first winding portions electrically connected at one end to a current input terminal and configured with a standard pitch; a plurality of second winding portions electrically connected at one end to a neutral point and configured with a standard pitch; and a plurality of third winding portions electrically connected at one end to the plurality of first winding portions and the plurality of second winding portions respectively, and configured with a standard pitch, wherein the total number of layers wound by the plurality of first winding portions, the plurality of second winding portions, and the third winding portions is an odd number.

[0009] In addition, each of the plurality of first winding portions, the plurality of second winding portions, and the third winding portion is wound on a plurality of slot groups included in the stator and continuously traverses the plurality of slots, one slot per slot group.

[0010] Additionally, the plurality of first winding portions include a 1-1 terminal electrically connected to the current input terminal and a 1-2 terminal electrically connected to the plurality of third winding portions; the plurality of second winding portions include a 2-1 terminal electrically connected to the neutral point and a 2-2 terminal electrically connected to the plurality of third winding portions; and the plurality of third winding portions include a 3-1 terminal electrically connected to the 1-2 terminal and a 3-2 terminal electrically connected to the 2-2 terminal. The plurality of first winding portions, the plurality of second winding portions, and the third winding portions are arranged in equal numbers and connected in a one-to-one correspondence.

[0011] In addition, the current direction of the plurality of second winding portions is opposite to the current direction of the plurality of first winding portions and the plurality of third winding portions.

[0012] Additionally, the plurality of first winding portions are wound in an odd number of layers from the radial inside to the radial outside of the plurality of slots, and the plurality of second winding portions are wound in an even number of layers from the radial inside to the radial outside of the plurality of slots.

[0013] Additionally, the plurality of third winding portions are wound in the radially outermost odd-numbered layers of the plurality of slots, a portion of the outermost odd-numbered layers is wound with a portion of the plurality of first winding portions, and the remaining portion of the outermost odd-numbered layers that is not wound with the plurality of first winding portions is wound with a portion of the plurality of third winding portions.

[0014] Additionally, the third-1 terminal is wound in a groove adjacent to the first-2 terminal, the third-1 terminal and the first-2 terminal are welded together, and the third-2 terminal is wound in a groove adjacent to the second-2 terminal, the third-2 terminal and the second-2 terminal are welded together.

[0015] In addition, the plurality of first winding portions, the plurality of second winding portions, and the plurality of third winding portions are inserted into a plurality of slots, and include a plurality of slot insertion portions extending in the axial direction of the motor, and jump portions disposed between the slot insertion portions and extending at a standard pitch.

[0016] In addition, the plurality of first winding portions have a longer extension length than the plurality of second winding portions, and the plurality of second winding portions have a longer extension length than the plurality of third winding portions.

[0017] Furthermore, the number of slots in which the plurality of first winding portions, the plurality of second winding portions, and the plurality of third winding portions are wound satisfies the following equation:

[0018] Equation ,

[0019] Wherein, L1 is the number of slot insertions in the plurality of first winding portions, L2 is the number of slot insertions in the plurality of second winding portions, L3 is the number of slot insertions in the plurality of third winding portions, p is the number of poles, and n is the number of layers in each slot. Attached Figure Description

[0020] Figure 1 It is a graph showing the TN curve of the motor relative to torque and speed;

[0021] Figure 2 This is a schematic diagram showing a parallel winding of a continuous winding assembly according to the present invention;

[0022] Figure 3 This is a schematic diagram showing the first winding portion, the second winding portion, and the third winding portion of the continuous winding assembly according to the present invention;

[0023] Figure 4 This is a partial schematic diagram showing the first-1 terminal and the second-1 terminal of the continuous winding assembly according to the present invention;

[0024] Figure 5 This is a partial schematic diagram showing the first-2 terminals, the second-2 terminals, and the third winding portion of the continuous winding assembly according to the present invention;

[0025] Figure 6 This is a schematic diagram showing the entire winding of the continuous winding assembly according to the present invention;

[0026] Figure 7 This is a partial schematic diagram showing the first-1 terminal and the second-1 terminal of the entire winding of the continuous winding assembly according to the invention; and

[0027] Figure 8 This is a partial schematic diagram showing the first and second terminals, the second and second terminals, and the third winding portion of the entire winding of the continuous winding assembly according to the present invention.

[0028] Explanation of reference numerals in the attached figures

[0029] 1000: Continuous winding assembly

[0030] 100: First winding section

[0031] 110: Slot insertion part of the first winding section

[0032] 120: Jump section of the first winding

[0033] 130: Terminal 1-1

[0034] 140: Terminals 1-2

[0035] 200: Second winding section

[0036] 210: Slot insertion part of the second winding section

[0037] 220: Jump section of the second winding

[0038] 230: Terminal 2-1

[0039] 240: Terminal 2-2

[0040] 300: Third winding section

[0041] 310: Slot insertion part of the third winding section

[0042] 320: Jump section of the third winding

[0043] 330: Terminal 3-1

[0044] 340: Terminal 3-2

[0045] S: slot Detailed Implementation

[0046] The technical aspects of the invention will be described in more detail below with reference to the accompanying drawings. Prior to this, the terms and words used in the following description and claims should not be construed as limited to their ordinary or dictionary meanings, but should be interpreted based on the meaning and concept consistent with the technical spirit of the invention, as the inventors could appropriately define the terms to best describe the principles of their invention.

[0047] The following is for reference Figure 2 The basic configuration of the continuous winding assembly 1000 of the present invention will be described.

[0048] This invention applies to stators, wherein for each pole of the rotor, the stator includes a predetermined group of slots arranged adjacent to that pole and in continuous positions, such as... Figure 2 As shown, it may include a first winding portion 100, a second winding portion 200, and a third winding portion 300. Multiple first winding portions 100, second winding portions 200, and third winding portions 300 may be provided respectively. Figure 2 The diagram shows all the slots S of the stator unfolded in layers (where the number of slots S is shown as the product of the number of stator slots S and the number of layers). More specifically, one end of the first winding portion 100 can be electrically connected to the current input terminal. Additionally, one end of the second winding portion 200 can be electrically connected to the neutral point, and both ends of the third winding portion 300 can communicate with the first winding portion 100 and the second winding portion 200. By dividing the wire into these three sections, productivity can be improved.

[0049] Here, the first winding portion 100, the second winding portion 200, and the third winding portion 300 can be wound on multiple slot groups included in the stator, and can be formed to sequentially traverse multiple slots S, with one portion in each slot S of the slot group. Furthermore, the first winding portion 100, the second winding portion 200, and the third winding portion 300 can be arranged in numbers corresponding to the number of slots S included in the slot groups, thereby winding coils on all of the multiple slots S.

[0050] Here, the first winding portion 100 may include a first-1 terminal 130 electrically connected to the current input terminal and a first-2 terminal 140 electrically connected to the third winding portion 300; the second winding portion 200 may include a second-1 terminal 230 electrically connected to the neutral point and a second-2 terminal 240 electrically connected to the third winding portion 300; and the third winding portion 300 may include a third-1 terminal 330 electrically connected to the first-1 terminal 130 and a third-2 terminal 340 electrically connected to the second-2 terminal 240. The first winding portion 100, the second winding portion 200, and the third winding portion 300 may each be arranged in the same number and may be connected in a one-to-one correspondence. That is, the first winding portion 100, the second winding portion 200, and the third winding portion 300 may form a single parallel winding, which may be arranged in parallel for each slot S within the slot group.

[0051] The continuous winding assembly 1000 according to the invention can form a parallel winding in which current flows along a current supply terminal, a first winding portion 100, a third winding portion 300, a second winding portion 200, and a neutral point. In this case, the current direction in the second winding portion 200 can be opposite to the current direction in the first winding portion 100 and the third winding portion 300. Therefore, current can flow from the current supply terminal along the first winding portion 100 in a circumferential direction, move along the third winding portion 300 in the opposite circumferential direction, and be delivered to the neutral point.

[0052] Furthermore, the first winding portion 100, the second winding portion 200, and the third winding portion 300 can be wound in different layers of multiple slots S, and the total number of layers of the first winding portion 100, the second winding portion 200, and the third winding portion 300 can be an odd number. That is, by separating the layers through which current flows in one circumferential direction, the layers through which current flows in the opposite circumferential direction, and the layers through which the current flows in the opposite direction, it is possible to wind the coil in an odd number of layers while maintaining inductance balance, thereby increasing the design freedom of the stator and motor.

[0053] The following is for reference Figures 3 to 5 The detailed configuration of the first winding portion 100, the second winding portion 200 and the third winding portion 300 of the present invention will be described in more detail below.

[0054] The first winding portion 100, the second winding portion 200, and the third winding portion 300 can be inserted into a plurality of slots S, and each can include a plurality of slot insertion portions 110, 210, and 310 extending along the axial direction of the motor, and a portion disposed between the slot insertion portions 110, 210, and 310 at a standard pitch (in Figure 3The jump sections 120, 220, and 320 are shown as P. Here, the pitch of the jump sections 120, 220, and 320 corresponds to the number of slots between the slot insertion sections 110, 210, and 310 at both ends of the jump section plus 1, and all jump sections 120, 220, and 320 can have the same pitch.

[0055] More specifically, such as Figure 3 As shown, the first winding portion 100 may have a longer extension length than the second winding portion 200, and the second winding portion 200 may have a longer extension length than the third winding portion 300. More specifically, the lengths of the first winding portion 100, the second winding portion 200, and the third winding portion 300 are proportional to the number of slot insertion portions 110, 210, and 310 (where all jump portions 120, 220, and 320 have a standard pitch P), and the number of slot insertion portions 110, 210, and 310 of the first winding portion 100, the second winding portion 200, and the third winding portion 300 may follow the following equation.

[0056] Equation: ,

[0057] Where L1 is the number of slot insertion parts 110 in the first winding section, L2 is the number of slot insertion parts 210 in the second winding section, L3 is the number of slot insertion parts 310 in the third winding section, p is the number of poles, and n is the number of layers in each slot S.

[0058] The extension lengths of the first winding portion 100, the second winding portion 200, and the third winding portion 300 (i.e., the number of slots S they traverse) can be derived by multiplying L1, L2, and L3 by the number of slots S included in the standard pitch, respectively. That is, when the number of slot insertion portions 110, 210, and 310 is p, it means that the winding portion extends around the entire circumference of the stator.

[0059] The first winding portion 100 can be wound radially from the inside to the outside on an odd number of layers, and the second winding portion 200 can be wound radially from the inside to the outside on an even number of layers. That is, the layers with the first winding portion 100 and the second winding portion 200 wound on them can be arranged alternately in the radial direction. For example, when there are five layers, the first winding portion 100 can be wound radially from the inside on the first, third, and fifth layers, and the second winding portion 200 can be wound on the second and fourth layers. Figure 2 In the middle, the layer with the first winding portion 100 is shown in black. Figure 2 In the image, multiple slots S and layers with a second winding portion 200 and a third winding portion 300 are shown in gray.

[0060] like Figure 4As shown, the second-1 terminal 230 of the second winding portion 200 can be spaced from the first-1 terminal 130 of the first winding portion 100 by a pitch greater than one slot, and as... Figure 5 As shown, the second-2 terminal 240 of the second winding portion 200 can be spaced from the first-2 terminal 140 of the first winding portion 100 by a pitch greater than two or more slot groups. In this case, the third winding portion 300 can extend and be wound at a distance corresponding to the spacing between the first-2 terminal 140 and the second-2 terminal 240. More specifically, when there are five layers, the third winding portion 300 can be wound radially inward onto the fifth layer, i.e., the outermost layer of the plurality of slots S adjacent to the center hole of the stator. That is, a portion of the fifth layer may include the first winding portion 100 and the first-2 terminal 140, while the remaining portion of the fifth layer may include the third winding portion 300, such that portions of the first winding portion 100 and the third winding portion 300 together form a full circumferential winding. In this case, when the fifth layer is divided between the first winding portion 100 and the third winding portion 300, the lengths of the regions wound with the first winding portion 100 and the third winding portion 300 may be different. Therefore, the third-1 terminal 330 of the third winding portion 300 in the fifth layer can be wound in the slot S adjacent to the first-2 terminal 140 in the fifth layer, and the third-1 terminal 330 and the first-2 terminal 140 can be soldered or terminal-connected. Similarly, the third-2 terminal 340 can be wound in the slot S adjacent to the second-2 terminal 240 in the fourth layer, and the third-2 terminal 340 and the second-2 terminal 240 can be soldered or terminal-connected.

[0061] In the following text, reference will be made to Figures 6 to 8 The overall configuration of the continuous winding assembly 1000 according to the present invention will be described in more detail.

[0062] like Figure 6 As shown, at least one of the first winding portion 100, the second winding portion 200, or the third winding portion 300 can be inserted and wound into all the slots S. In this case, the corresponding strands of the first winding portion 100 and the second winding portion 200, as well as the corresponding strands of the first winding portion 100 and the third winding portion 300, can be wound at different positions within the slot group. Simultaneously, the strands of the second winding portion 200 and the third winding portion 300 can be wound at the same position within the slot group. For example, when the strand of the first winding portion 100 is wound in a first slot S on one side of the slot group, the multiple slots in which the strands for electrical connection of the second winding portion 200 and the third winding portion 300 are wound can be the second slot S on the same side of the slot group.

[0063] In addition, such as Figure 7As shown, the terminals of the first winding portion 100 and the second winding portion 200 can be arranged continuously (the six terminals on the left side of the figure are the first-1 terminals 130 of the first winding portion 100, and the six terminals on the right side of the figure are the second-1 terminals 230 of the second winding portion 200). Figure 8 As shown, the first winding portion 100 and the third winding portion 300, as well as the second winding portion 200 and the third winding portion 300, can be electrically connected to each other. In this case, the third-1 terminal 330 of the third winding portion 300 in the fifth layer can be wound in a slot S adjacent to the first-2 terminal 140 in the fifth layer, so that the third-1 terminal 330 and the first-2 terminal 140 can be soldered together. Furthermore, the third-2 terminal 340 of the third winding portion 300 in the fifth layer can be wound in a slot S adjacent to the second-2 terminal 240 in the fourth layer, so that the third-2 terminal 340 and the second-2 terminal 240 can be soldered together.

[0064] The continuous winding assembly according to the invention, having the above configuration, combines three windings of different lengths to form parallel windings, allows for use in odd-numbered layers by applying equivalent series turns, and enables electromagnetic balance between windings even for continuous hairpin windings with standard pitch, thus being advantageous in suppressing circulating currents and maximizing manufacturing efficiency.

[0065] The technical concept of this invention should not be explained solely based on the above-described embodiments. It should be understood that various modifications and alterations can be made within the scope of the claims without departing from the spirit of the invention as claimed. Therefore, such improvements and modifications, as long as they are obvious to those skilled in the art, fall within the protection scope of this invention.

Claims

1. A continuous winding assembly for a stator, the stator including predetermined slot groups disposed adjacent to poles of a rotor at continuous positions, one slot group per pole of the rotor, the continuous winding assembly comprising: Multiple first winding portions, each first winding portion being electrically connected at one end to a current input terminal and configured with a standard pitch; Multiple second winding portions, each of which is electrically connected at one end to a neutral point and is configured with a standard pitch; and Multiple third winding portions, each electrically connected at one and another end to a plurality of first winding portions and a plurality of second winding portions, are configured with a standard pitch. The total number of layers of the plurality of first winding portions, the plurality of second winding portions, and the third winding portion is an odd number.

2. The continuous winding assembly according to claim 1, wherein, Each of the plurality of first winding portions, the plurality of second winding portions, and the third winding portion is wound on a plurality of slot groups included in the stator and continuously traverses the plurality of slots, one slot per slot group.

3. The continuous winding assembly according to claim 1, in, The plurality of first winding portions include a terminal 1-1 electrically connected to the current input terminal and a terminal 1-2 electrically connected to the plurality of third winding portions. The plurality of second winding portions include a 2-1 terminal electrically connected to the neutral point and a 2-2 terminal electrically connected to the plurality of third winding portions, and The plurality of third winding portions include a 3-1 terminal electrically connected to the 1-2 terminal and a 3-2 terminal electrically connected to the 2-2 terminal. The plurality of first winding portions, the plurality of second winding portions and the third winding portions are arranged in equal numbers and connected in a one-to-one correspondence.

4. The continuous winding assembly according to claim 3, wherein, The current direction of the plurality of second winding portions is opposite to the current direction of the plurality of first winding portions and the plurality of third winding portions.

5. The continuous winding assembly according to claim 4, wherein, The plurality of first winding portions are wound in an odd number of layers from the radial inside to the radial outside of the plurality of slots, and the plurality of second winding portions are wound in an even number of layers from the radial inside to the radial outside of the plurality of slots.

6. The continuous winding assembly according to claim 5, wherein, The plurality of third winding portions are wound in the radially outermost odd-numbered layers of the plurality of slots, a portion of the outermost odd-numbered layers is wound with a portion of the plurality of first winding portions, and the remaining portion of the outermost odd-numbered layers that is not wound with the plurality of first winding portions is wound with a portion of the plurality of third winding portions.

7. The continuous winding assembly according to claim 6, wherein, The third-1 terminal is wound in the slot adjacent to the first-2 terminal in the plurality of slots, the third-1 terminal and the first-2 terminal are welded together, and the third-2 terminal is wound in the slot adjacent to the second-2 terminal in the plurality of slots, the third-2 terminal and the second-2 terminal are welded together.

8. The continuous winding assembly according to claim 3, wherein, The plurality of first winding portions, the plurality of second winding portions, and the plurality of third winding portions are inserted into a plurality of slots, and include a plurality of slot insertion portions extending in the axial direction of the motor, and jump portions disposed between the slot insertion portions and extending at a standard pitch.

9. The continuous winding assembly according to claim 3, wherein, The plurality of first winding portions have a longer extension length than the plurality of second winding portions, and the plurality of second winding portions have a longer extension length than the plurality of third winding portions.

10. The continuous winding assembly according to claim 8, wherein, The number of slots in which the plurality of first winding portions, the plurality of second winding portions, and the plurality of third winding portions are wound satisfies the following equation: Equation , Wherein, L1 is the number of slot insertions in the plurality of first winding portions, L2 is the number of slot insertions in the plurality of second winding portions, L3 is the number of slot insertions in the plurality of third winding portions, p is the number of poles, and n is the number of layers in each slot.

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