Printed circuit board (PCB) wiring structure for reducing winding end height for concentrated winding type motor

Abstract

The invention discloses a PCB wiring structure for reducing winding end height for a concentrated winding type motor, and relates to the field of stator cores, the PCB wiring structure comprises a stator core and a stator tooth part arranged at the inner side end of the stator core, stator grooves are formed in the stator core at equal intervals, the stator core is of a split structure, and the stator tooth part is arranged at the inner side end of the stator core. The stator tooth part is surrounded by a flat copper wire, and the upper end of the flat copper wire is provided with a PCB. According to the PCB wiring structure capable of reducing the winding end height for the concentrated winding type motor, the stator iron core adopts a split-half structure, so that integral manufacturing and splicing of a flat copper wire winding can be conveniently completed at a tooth part, the stator iron core is fixed through pins, the stator slots are designed to be parallel slots, the space utilization rate in the slots is remarkably improved, and the winding end height is reduced. According to the split-half structure, the assembly process of the winding is greatly simplified, dependence on complex process equipment is reduced, it is ensured that the motor still keeps structural reliability and precision during high-speed operation or load sudden change, and a mechanical foundation is laid for high-power-density design.

Description

Technical Field

[0001] This invention relates to the field of stator core technology, specifically to a PCB wiring structure for a concentrated winding motor that reduces the height of the winding ends. Background Technology

[0002] Concentrated winding motors, also known as stator winding concentrated motors, are designed to optimize size and heat dissipation by reducing the height of the winding ends. The core idea is to use a PCB-like connection structure to integrate and thin out the leads and wiring areas at the winding ends, thereby reducing the vertical height of the winding ends.

[0003] Existing technologies are costly, have insufficient overall slot fill rate, affect motor drive, and are cumbersome for mass production.

[0004] To overcome the above shortcomings, a prior art Chinese patent (publication number CN121440976A) discloses a wiring structure for a flat wire stator, including a stator core and stator slots. Windings are arranged inside the stator slots. The stator core and windings form the stator, which is a concentrated winding type. The longitudinal cross-section of the windings is octagonal, and the left and right sides of the windings can be bent to reduce the number of molds used and the winding difficulty. Each winding has two leads, one end on the outer diameter side of the stator and the other end on the inner diameter side. This wiring structure for the flat wire stator, with its octagonal winding cross-section and the ability to be bent on both sides, reduces the number of molds and the winding difficulty. Compared to traditional rectangular cross-section windings, it can increase slot fill factor by 4%–8%, has less end space, reduces the number of molds required, lowers winding difficulty, reduces cost, and achieves high slot fill factor, high power density, and high efficiency.

[0005] To overcome the above shortcomings, a Chinese patent (publication number CN109995153B) discloses a stator structure for a multi-combination adjustable PCB concentrated winding. This structure adopts a double-layer winding method and introduces the concept of "slots" into the coreless PCB stator winding. Each "slot" contains an upper element side of a coil and a lower element side of an adjacent coil. The upper and lower element sides of each "slot" are completely overlapped in the circumferential direction and isolated from each other by a PCB insulation layer in the axial direction, distributed in different PCB wiring layers. Each coil in this stator structure is uniformly distributed in the circumferential direction, and any two adjacent coils are located in different PCB wiring layers. Each coil has a pair of positive and negative output terminals, and each pair of positive and negative output terminals can be connected in series and parallel in various combinations according to different pole-slot combinations in the PCB disc permanent magnet motor design. The number of coils or "slots" in this stator structure can also be adjusted according to different pole-slot combinations.

[0006] While existing technologies can overcome the shortcomings mentioned above, other problems still exist during their operation, such as: the overall end height of the coil winding is relatively high, the motor is relatively heavy, which affects the overall efficiency; at the same time, the torque is insufficient, which can easily lead to insufficient power and affect the driving efficiency of the motor. Summary of the Invention

[0007] The purpose of this invention is to provide a PCB wiring structure for a concentrated winding motor that reduces the height of the winding ends, in order to solve the problems mentioned in the background art, such as the overall high height of the coil windings, the heavy weight of the motor, which affects the overall efficiency, and the insufficient torque, which easily leads to insufficient power and affects the driving efficiency of the motor.

[0008] To achieve the above objectives, the present invention provides the following technical solution: a PCB interconnection structure for reducing the height of the winding ends of a concentrated winding motor, comprising a stator core and stator teeth provided on the inner side of the stator core, wherein stator slots are equally spaced inside the stator core, the stator core has a split structure, flat copper wires are surrounded on the stator teeth, a PCB board is provided on the upper end of the flat copper wires, and connecting wires are embedded in the overall interconnection structure inside the PCB board, connecting the entire PCB board to the output end of the flat copper wire winding and welding it, thereby significantly reducing the overall end height.

[0009] Furthermore, after all the flat copper wires are wound around, they are spliced ​​together to form a winding. The stator core has a pin hole at its end. After the splicing is completed, a pin is inserted into the pin hole for overall fixation. The pin is embedded in the pin hole and does not exceed the end face of the stator core. The length of the pin is less than the stacking height of the stator core.

[0010] Furthermore, the stator core has an outer diameter of D1, an inner diameter of Di1, a stator slot width of h1, a maximum stator tooth width of h2, a minimum stator tooth width of h3, a stator slot length of b1, and a stator tooth angle of α, satisfying the following characteristics: .

[0011] Furthermore, the pin hole diameter is A, and the distance from the bottom of the slot to the outer diameter of the stator is b2, which satisfies the following characteristics: .

[0012] Furthermore, the diameter of the pin hole satisfies 0.25*b². <A<0.5*b2。

[0013] Furthermore, the stator slots are parallel slots, which significantly improves slot utilization compared to parallel teeth. The windings composed of flat copper wires are flat wires, and the windings are pre-made coils that match the tooth shape.

[0014] Furthermore, the stator core is assembled from stacked stator laminations, and each stator lamination has a semi-circular boss with pin holes on one side and a semi-circular notch on the other side.

[0015] Furthermore, the stator laminations of the stator core are stacked in a half-forward and half-reverse arrangement.

[0016] Furthermore, the PCB board has a soldering groove, the end face of which is flush with the winding end face of the flat copper wire.

[0017] Compared with the prior art, the beneficial effects of the present invention are: 1. The stator core adopts a split-half structure, which facilitates the overall fabrication and splicing of the flat copper wire windings at the tooth section and fixation with pins. The stator slots are designed as parallel slots, which significantly improves the space utilization within the slots. This split-half structure not only greatly simplifies the winding assembly process and reduces reliance on complex process equipment, but also facilitates subsequent inspection and maintenance. The parallel slot design makes the magnetic field distribution within the slots more uniform, reduces eddy current losses, and further optimizes electromagnetic performance. In addition, the pin fixing method enhances the overall mechanical stability of the stator, ensuring that the motor maintains structural reliability and accuracy even when running at high speed or experiencing sudden load changes, laying a mechanical foundation for high power density design.

[0018] 2. By embedding the overall wiring structure into the PCB board and then integrating it with the outgoing wires, this design significantly reduces the height of the winding ends. This key technology directly contributes to a more compact overall motor structure, achieving lightweighting and miniaturization. This integrated wiring method eliminates the messy end jumpers commonly found in traditional motors, resulting in a highly regular arrangement of the end windings. This not only reduces AC losses but also improves the heat dissipation path. The introduction of the PCB board achieves a high degree of circuit integration and insulation integration, improving the reliability and consistency of electrical connections. The compact overall structure makes the motor easier to install in space-constrained applications, such as new energy vehicle drive systems and high-end servo equipment. It also facilitates system-level heat dissipation design and lightweight layout.

[0019] 3. While reducing copper losses, the torque density and stator slot fill factor are improved, ultimately effectively enhancing the motor's efficiency and power density. This series of improvements creates a synergistic effect: lower copper losses directly reduce heat generation, allowing the motor to carry higher current under the same temperature rise conditions, thereby increasing output torque; the increased slot fill factor means that more conductive material can be accommodated in the same volume, further enhancing electromagnetic conversion capability. The dual improvement in efficiency and power density enables the motor to not only exhibit excellent energy-saving characteristics in steady-state operation, but also to have outstanding advantages in dynamic response and overload capacity, making it suitable for modern electric drive fields with stringent requirements for performance, size, and energy efficiency. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the overall three-dimensional structure of the present invention.

[0021] Figure 2 This is a top view schematic diagram of the stator lamination structure of the stator core of the present invention.

[0022] Figure 3 This is a schematic diagram of the internal wiring structure of the PCB board of the present invention.

[0023] Figure 4 This is a schematic diagram of the stator core structure of the present invention.

[0024] Figure 5 This is a partial schematic diagram of the stator core of the present invention.

[0025] Figure 6 This is a schematic diagram of the split stator core structure of the present invention.

[0026] Figure 7 This is a schematic diagram of a partial structure of the split stator core of the present invention.

[0027] Figure 8 This is a three-dimensional structural diagram of the pin hole of the present invention.

[0028] Figure 9 This is a schematic diagram showing the effect of terminal height on resistance in this invention.

[0029] Figure 10 This is a schematic diagram illustrating the effect of the height of the terminal on the efficiency of the present invention.

[0030] In the diagram: 1. Stator core; 2. Flat copper wire; 3. PCB board; 4. Stator teeth; 5. Stator slot; 6. Connecting wire; 7. Pin hole; 8. Stator lamination. Detailed Implementation

[0031] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0032] Example 1: As Figures 1-10The technical solution shown is a PCB wiring structure for a concentrated winding motor that reduces the height of the winding ends. To solve the problem of high winding end height, the solution discloses: a stator core 1 and stator teeth 4 provided on the inner end of the stator core 1, and stator slots 5 are evenly spaced inside the stator core 1. The stator core 1 has a split structure. Flat copper wires 2 are surrounded on the stator teeth 4. A PCB board 3 is provided on the upper end of the flat copper wires 2, and connecting wires 6 are embedded in the overall wiring structure inside the PCB board 3. The PCB board 3 is connected to the winding output end of the flat copper wires 2 and welded, so that the overall end height is greatly reduced.

[0033] After all the flat copper wires 2 are wound, they are spliced ​​together to form a winding. The stator core 1 has a pin hole 7 at its end. After the splicing is completed, a pin is inserted into the pin hole 7 for overall fixation. The pin is embedded in the pin hole 7 and is not higher than the end face of the stator core 1. The length of the pin is less than the stacking height of the stator core 1.

[0034] The stator core 1 has an outer diameter of D1 and an inner diameter of Di1. The stator slot 5 has a width of h1, the stator tooth 4 has a maximum width of h2 and a minimum width of h3, the stator slot 5 has a length of b1, and the stator tooth 4 has an angle of α. Its characteristics satisfy the following: .

[0035] The diameter of the pin hole 7 is A, and the distance from the bottom of the slot to the outer diameter of the stator is b2. Its characteristics satisfy: .

[0036] The diameter of pin hole 7 satisfies 0.25*b². <A<0.5*b2。

[0037] The stator slot 5 has a parallel slot shape, which can significantly improve the slot utilization rate compared to parallel teeth. The winding wire composed of flat copper wire 2 has a flat wire shape, and the winding is a coil prefabricated to match the tooth shape.

[0038] The stator core 1 is made up of stator laminations 8 stacked together, and one side of each stator lamination 8 has a semi-circular boss with pin holes 7, and the other side has a semi-circular notch.

[0039] The stator laminations 8 of the stator core 1 are stacked in a half forward-facing arrangement and a half reverse-facing arrangement.

[0040] A soldering groove is provided on the PCB board 3, and the end face of the soldering groove is flush with the winding end face of the flat copper wire 2.

[0041] The stator core 1 has a split structure. Flat copper wires 2 are wrapped around the stator teeth 4. After all the flat copper wires 2 are wrapped, they are spliced ​​together as a whole. After splicing, pins are inserted into the pin holes 7. The stator slots 5 adopt a parallel slot design, which can significantly improve the slot utilization rate. The connecting wires 6 adopt an integrated connection structure and are embedded in the PCB board 3. The PCB board 3 is then connected to the outgoing wires and welded together, which can significantly reduce the overall end height. The stator core 1 is made of stacked stator laminations 8, thereby achieving a low-end high-performance effect of the flat copper wire 2 winding. The motor is thus lighter, the overall structure is more compact, copper loss is reduced, and torque density is increased. At the same time, the slot fill factor of the stator core 1 is improved, which helps to improve the motor efficiency and power density.

[0042] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A PCB wiring structure for a concentrated winding motor with reduced winding end height, comprising a stator core (1) and stator teeth (4) provided on the inner side of the stator core (1), wherein stator slots (5) are provided at equal intervals inside the stator core (1), characterized in that: The stator core (1) has a split structure. Flat copper wire (2) is surrounded on the stator tooth (4). A PCB board (3) is provided at the upper end of the flat copper wire (2). The internal wiring structure of the PCB board (3) is embedded with connecting wires (6). The PCB board (3) is connected to the winding output end of the flat copper wire (2) and welded together, so that the overall end height is greatly reduced.

2. The PCB wiring structure for reducing the height of the winding ends in a concentrated winding motor according to claim 1, characterized in that: After all the flat copper wires (2) are wrapped, they are spliced ​​together to form a winding. The stator core (1) has a pin hole (7) at the end. After splicing, a pin is inserted into the pin hole (7) for overall fixation. The pin is embedded in the pin hole (7) and is not higher than the end face of the stator core (1). The length of the pin is less than the stacking height of the stator core (1).

3. The PCB wiring structure for reducing the height of the winding ends in a concentrated winding motor according to claim 2, characterized in that: The stator core (1) has an outer diameter of D1, an inner diameter of Di1, a stator slot (5) width of h1, a stator tooth (4) maximum width of h2, a stator tooth (4) minimum width of h3, a stator slot (5) length of b1, and a stator tooth (4) angle of α. Its characteristics satisfy: .

4. The PCB wiring structure for reducing the height of the winding ends in a concentrated winding motor according to claim 3, characterized in that: The pin hole (7) has a diameter of A and a distance of b2 from the bottom of the slot to the outer diameter of the stator. Its characteristics satisfy: b 1 / h 1 / h 3 / h 2 ∗ cos α ∗ A < b 2 < b 1 / h 1 / h 3 / h 2 ∗ cos α ∗ 3 A .

5. A PCB wiring structure for reducing the height of the winding ends in a concentrated winding motor according to claim 4, characterized in that: The diameter of the pin hole (7) satisfies 0.25*b2. <A<0.5*b2。 6. The PCB wiring structure for reducing the height of the winding ends in a concentrated winding motor according to claim 1, characterized in that: The stator slot (5) is a parallel slot, which can significantly improve the slot utilization rate compared to parallel teeth. The winding wire composed of flat copper wire (2) is a flat wire, and the winding is a coil prefabricated to match the tooth shape.

7. A PCB wiring structure for reducing the height of the winding ends in a concentrated winding motor according to claim 1, characterized in that: The stator core (1) is made up of stacked stator laminations (8), and one side of each stator lamination (8) is a semi-circular boss with pin holes (7), and the other side is a semi-circular notch.

8. A PCB wiring structure for reducing the height of the winding ends in a concentrated winding motor according to claim 1, characterized in that: The stator laminations (8) of the stator core (1) are stacked in a half-forward stacking arrangement and a half-reverse stacking arrangement.

9. A PCB wiring structure for a concentrated winding motor with reduced winding end height according to claim 1, characterized in that: The PCB board (3) has a welding groove, and the end face of the welding groove is flush with the winding end face of the flat copper wire (2).

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