Even layer flat wire winding with 4 poles and 4 slots per phase and motor

Abstract

This invention discloses an even-numbered layer flat wire winding and a motor with 4 slots per pole per phase. Each stator pole has 12 stator slots, the motor has p pole pairs, and each stator slot contains 2n layers. Each phase winding includes p first unit branches and p second unit branches connected in parallel. Each unit branch is composed of four cross-layer hairpin groups welded together sequentially, with the cross-layer hairpin groups connected in a Z-shape according to the stator slot number. Each unit branch includes three same-layer welded sections: a first same-layer welded section located on the 2nth layer, a second same-layer welded section located on the first layer, and a third same-layer welded section located on the 2nth layer. In the first unit branch, the spans of the first, second, and third same-layer welded sections are 13, 11, and 9, respectively; in the second unit branch, the spans of the first, second, and third same-layer welded sections are 15, 13, and 11, respectively. This structure effectively reduces cogging torque and torque pulsation, improving the smoothness of motor operation.

Description

Technical Field

[0001] This invention relates to the field of motor technology, specifically to an even-numbered layer flat wire winding with 4 slots per pole per phase and a motor thereof. Background Technology

[0002] In an example of a 96-slot, 16-pole, 8-layer full-pitch flat wire winding stator, motor, and drive device disclosed in the prior art, four parallel branch windings are formed in the radial direction of the stator core, with a slot number q of 2 per pole per phase. This has certain limitations in reducing cogging torque and torque pulsation, and improving the smoothness of motor operation. Furthermore, the windings are full-pitch without misaligned slots, which is not conducive to the attenuation of motor harmonics.

[0003] In an example of a 72-slot, 6-pole, 3-branch hairpin-type flat wire armature winding and motor disclosed in the prior art, three-phase flat wires are used in conjunction with hairpins to wind through a ring-shaped stator with multiple layers of 72 stator slots on the inner side to obtain a parallel three-branch winding. The number of slots q per pole per phase is 4, but the windings are only staggered by one slot, which has limited effect on reducing motor harmonics. Furthermore, the variety of hairpin types and the crossover of hairpins in the same layer complicate the manufacturing process and increase manufacturing costs. Summary of the Invention

[0004] To address the aforementioned deficiencies in existing technologies, an even-numbered layer flat wire winding and motor with 4 slots per pole per phase are provided. This not only effectively reduces cogging torque and torque pulsation, improving the smoothness of motor operation, but also achieves the purpose of saving copper wire material and reducing induced electromotive force harmonics through the staggered slot design.

[0005] The technical solution adopted by the present invention to solve the above-mentioned technical problems is as follows: The first aspect is an even-numbered layer flat wire winding and motor with 4 slots per pole per phase, including a stator body, multiple stator slots circumferentially spaced on the stator body, and stator windings passing through the stator slots; the stator windings are divided into three phases, and the windings of the other two phases are obtained after rotating a certain number of stator slots of any phase winding. Each pole of the stator has 12 stator slots, and each pole has 4 stator slots per pair. The number of pole pairs of the motor is p, where p is an integer ≥ 1. Each stator slot contains 2n layers, where n is an integer ≥ 1. The stator winding contains n types of cross-layer hairpins. The two side conductors of each type of cross-layer hairpin are placed in layers 2m-1 and 2m, respectively, where m is a positive integer not greater than n. Each phase winding includes p first unit branches and p second unit branches arranged in parallel. The conductors of the first unit branches are always located in two adjacent stator slots with the conductors of the second unit branches. Both the first unit branches and the second unit branches are composed of 4 cross-layer hairpin groups that are sequentially welded together. The cross-layer hairpin groups are sequentially welded together from the first layer position to the 2nth layer of the stator slot through n types of cross-layer hairpins, or from the 2nth layer position to the first layer of the stator slot through n types of cross-layer hairpins. Both the first and second unit branches include three same-layer welding segments, namely, the first same-layer welding segment located on the 2nth layer, the second same-layer welding segment located on the first layer, and the third same-layer welding segment located on the 2nth layer; wherein, in the first unit branch, the span of the first same-layer welding segment is 13, the span of the second same-layer welding segment is 11, and the span of the third same-layer welding segment is 9; in the second unit branch, the span of the first same-layer welding segment is 15, the span of the second same-layer welding segment is 13, and the span of the third same-layer welding segment is 11.

[0006] According to the above technical solution, in the cross-layer card issuing group, the span of both the cross-layer card issuing section and the cross-layer welding section is a whole span of 12.

[0007] According to the above technical solution, in the cross-layer card issuing group, the card issuing segment or welding segment has a short distance of 10 in the nth and n+1th layers, and the card issuing segment or welding segment has a full distance of 12 in the remaining cross layers.

[0008] According to the above technical solution, when n is an odd number, the n layers of the flat wire winding near the inner circle of the stator are staggered by two slots from the n layers near the outer circle of the stator.

[0009] According to the above technical solution, when n is an even number, the n layers of the flat wire winding near the inner circle of the stator and the n layers near the outer circle of the stator are staggered by two slots.

[0010] According to the above technical solution, the layer closest to the inner circle of the stator is the first layer, and the layer closest to the outer circle of the stator is the 2nth layer; or, the layer closest to the inner circle of the stator is the 2nth layer, and the layer closest to the outer circle of the stator is the first layer.

[0011] According to the above technical solution, the cross-layer card issuing group is from the bottom layer to the top layer, and the direction of the cross-layer welding section is opposite to the direction of the cross-layer card issuing section; one is clockwise and the other is counterclockwise; or, one is counterclockwise and the other is clockwise.

[0012] According to the above technical solution, the starting position of the first unit branch and the second unit branch are taken as the power line end, and the ending position is taken as the center line end. Alternatively, the starting positions of the first and second unit branches can be used as the centerline ends, and the ending positions as the power line ends.

[0013] Secondly, the motor includes an even-numbered layer of flat wire windings with 4 slots per pole per phase as described above, and the motor itself.

[0014] According to the above technical solution, the motor is a 24p slot 2p pole 2n layer 2p branch motor, which includes n types of cross-layer hairpins, where p is an integer ≥1 and n is an integer ≥1.

[0015] The present invention has the following beneficial effects: 1. In this invention, when the number of pole pairs in a motor is p, each phase winding is divided into p groups of units, and each group of units corresponds to a magnetic pole unit. Each group of units includes a first unit branch and a second unit branch. Both the first unit branch and the second unit branch are composed of 4 cross-layer hairpin groups. The cross-layer hairpin groups are connected in a Z-shape according to the stator slot number. The 4 cross-layer hairpin groups are connected by 3 types of same-layer welding segments, thereby satisfying the requirement that the number of slots q per pole per phase of the motor is an integer of 4 slots.

[0016] In the above structure, the winding method of the first unit branch and the second unit branch enables the motor to meet the design of an integer number of slots q per pole per phase, which can effectively reduce cogging torque and torque pulsation and improve the smoothness of motor operation.

[0017] Secondly, the design of the cross-layer winding group, combined with the Z-shaped connection of the cross-layer winding group according to the stator slot number, has the following advantages: First, when the number of flat wire layers is 2n, there are n types of flat wire windings, resulting in fewer winding types, all of which are cross-layer windings with no intersection, simplifying the manufacturing process. Second, the power line end and the center line end exit on the same layer, simplifying the busbar structure, reducing the space occupied at the ends, and lowering manufacturing costs. Third, it ensures that each layer of windings on each unit branch is interleaved in different stator slots, ensuring the spatial balance of the windings. This interleaving arrangement balances the resistance and inductance of each branch, eliminating phase and voltage differences between different branches; it also balances the current between branches, eliminating circulating current, improving the spatial harmonics of the motor, enhancing motor performance, and suppressing motor noise.

[0018] 2. Set the hairpin or welded end span between the flat wire in the nth layer and the flat wire in the (n+1)th layer to 10. When n is odd, the flat wire winding in the nth layer near the inner circle of the stator is staggered by two slots ahead of the flat wire winding in the nth layer near the outer circle of the stator. When n is even, the flat wire winding in the nth layer near the inner circle of the stator is staggered by two slots behind the flat wire winding in the nth layer near the outer circle of the stator. Then the flat wire winding from the nth layer to the (n+1)th layer is a short pitch of 10. The short pitch winding with two slots staggered is beneficial for saving copper wire material and for weakening induced electromotive force harmonics.

[0019] The above description is merely an overview of the technical solution of the present invention. In order to better understand the technical means of the present invention and to implement it according to the contents of the specification, the preferred embodiments of the present invention are described in detail below with reference to the accompanying drawings. Specific embodiments of the present invention are given in detail below with reference to the accompanying drawings. Attached Figure Description

[0020] The accompanying drawings, which are included to provide a further understanding of the invention and form part of this application, illustrate exemplary embodiments of the invention and are used to explain the invention, but do not constitute an undue limitation of the invention.

[0021] Figure 1 This is a single-slot topology diagram provided by an embodiment of the present invention; Figure 2 This is a unit magnetic pole topology diagram provided in an embodiment of the present invention; Figure 3 This is a diagram showing the arrangement of the winding slots according to an embodiment of the present invention; Figure 4 This invention provides a diagram showing the arrangement of a pair of poles in the winding slots of phase A (taking 10 layers in a single slot as an example). Figure 5 This invention provides a schematic diagram of the connection between the two branches of the magnetic pole pair winding of the A-phase unit (taking a single slot with 10 layers as an example). Figure 5a yes Figure 5 A schematic diagram of the winding connection of the first unit branch; Figure 5b yes Figure 5 Schematic diagram of the winding connection of the second unit branch; Figure 6 yes Figure 5 Connection diagram of the first branch of the magnetic pole pair in phase A; Figure 7 yes Figure 5 Connection diagram of the second branch of the magnetic pole pair in phase A; Figure 8 yes Figure 5 Schematic diagram of the two branches of the magnetic pole release terminal of the A-phase unit; Figure 9 yes Figure 5 Schematic diagram of the welding ends of the two branches of the magnetic poles of phase A unit; Figure 10 yes Figure 5 Schematic diagram of two-branch magnetic pole type of the A-phase unit; Figure 11 This is a schematic diagram of the A-phase winding connection of the first embodiment (96 slots, 8 poles, 10 layers, 8 branches, staggered slots) provided by the present invention; Figure 12 This is a schematic diagram of the B-phase winding connection of the first embodiment (96 slots, 8 poles, 10 layers, 8 branches, staggered slots) provided by the present invention; Figure 13 This is a schematic diagram of the C-phase winding connection of the first embodiment (96 slots, 8 poles, 10 layers, 8 branches, staggered slots) provided by the present invention; Figure 14 This is a schematic diagram of the A-phase winding connection of the second embodiment (96 slots, 8 poles, 10 layers, 8 branches, full pitch) provided by the present invention; Figure 15 This is a schematic diagram of the A-phase winding connection of the third embodiment (72 slots, 6 poles, 10 layers, 6 branches, staggered slots) provided by the present invention; Figure 16 This is a schematic diagram of the A-phase winding connection of the fourth embodiment (48 slots, 4 poles, 10 layers, 4 branches, staggered slots) provided by the present invention; Figure 17 This is a schematic diagram of the A-phase winding connection of the fifth embodiment (96 slots, 8 poles, 8 layers, 8 branches, staggered slots) provided by the present invention; Figure 18 This is a schematic diagram of the A-phase winding connection of the sixth embodiment (96 slots, 8 poles, 6 layers, 8 branches, staggered slots) provided by the present invention; In the diagram, 1. Stator body; 2. Stator inner circle; 3. Stator outer circle; 4. Stator slot; 5. Slot insulation paper; 6. Stator winding; 6-1. First layer of flat wire; 6-2. Second layer of flat wire; 6-3. Third layer of flat wire; 6-4. Fourth layer of edge wire; 6-5. nth layer of flat wire; 6-6. (n+1)th layer of flat wire; 6-7. (n+2)th layer of flat wire; 6-8. (2n-2)th layer of flat wire; 6-9. 1. 2n-1 layer flat wire; 6-10. 2n layer flat wire; 7. Stator slot number; 8. Rotor lamination; 9. Magnet slot; 10. Magnet; 11. Shaft; 12. Current inflow direction at the card-issuing end; 13. Current outflow direction at the card-issuing end; 14. First type of cross-layer card issuance; 15. Second type of cross-layer card issuance; 16. Third type of cross-layer card issuance; 17. Fourth type of cross-layer card issuance; 18. Fifth type of cross-layer card issuance. Detailed Implementation

[0022] The following is in conjunction with the appendix Figure 1-18 The principles and features of the present invention are described below. The examples given are for illustrative purposes only and are not intended to limit the scope of the invention. The invention is described more specifically in the following paragraphs by way of example with reference to the accompanying drawings. The advantages and features of the invention will become clearer from the following description and claims. It should be noted that the drawings are in a very simplified form and use non-precise proportions, and are only used to facilitate and clarify the illustration of the embodiments of the invention.

[0023] It should be noted that when a component is described as "fixed to" another component, it can be directly on the other component or may have a component in between. When a component is considered "connected to" another component, it can be directly connected to the other component or may have a component in between. When a component is considered "set on" another component, it can be directly set on the other component or may have a component in between. The terms "vertical," "horizontal," "left," "right," and similar expressions used in this document are for illustrative purposes only.

[0024] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0025] Reference Figures 1-18 As shown, the present invention provides an even-numbered layer flat wire winding with 4 slots per pole per phase.

[0026] Example 1 The stator includes a stator body 1, multiple stator slots 4 spaced circumferentially on the stator body, and stator windings 6 passing through the stator slots; slot insulation paper 5 is provided between the stator windings and the stator slots. The stator windings are divided into three phases; after rotating any one phase winding through several stator slots, the windings of the remaining two phases are obtained. The stator body includes an inner stator circle 2 and an outer stator circle 3. The multiple stator slots of the stator body are numbered to obtain stator slot numbers 7. Rotor laminations 8 are provided on the inner ring of the stator body, and magnet slots 9 are provided on the rotor laminations, with magnets 10 installed in the magnet slots; a rotating shaft 11 is provided on the inner ring of the rotor laminations. Figure 4 As shown, the current flowing into the card-issuing terminal is in direction 12, and the current flowing out of the card-issuing terminal is in direction 13.

[0027] Each pole of the stator has 12 stator slots, with 4 stator slots per pole per pole pair. The number of pole pairs in the motor is p, where p is an integer greater than or equal to 1. Common pole pair numbers for motors are 2, 3, 4, 5, 6, 7, and 8. The number of stator slots is Q. Therefore, the number of stator slots can be 48, 72, 96, 120, 144, 168, 192, etc.

[0028] Each stator slot contains 2n layers, where n is an integer greater than or equal to 1; for example... Figure 1As shown, the first layer of flat line is 6-1; the second layer of flat line is 6-2; the third layer of flat line is 6-3; the fourth layer of flat line is 6-4; ...; the nth layer of flat line is 6-5; the (n+1)th layer of flat line is 6-6; the (n+2)th layer of flat line is 6-7; ...; the (2n-2)th layer of flat line is 6-8; the (2n-1)th layer of flat line is 6-9; and the 2nth layer of flat line is 6-10.

[0029] The stator winding contains n types of cross-layer hairpins. The two side conductors of each cross-layer hairpin are located on layers 2m-1 and 2m, respectively, where m is a positive integer not greater than n. For example, the two side conductors of the first type of cross-layer hairpin are located on layers 1 and 2; the two side conductors of the second type are located on layers 3 and 4; ...; the two side conductors of the nth type of cross-layer hairpin are located on layers 2n-1 and 2n. This scheme has a relatively small number of hairpin types, with a total of n cross-layer hairpins. The hairpin diagrams for the above example are shown below. Figure 10 As shown: There are 5 types of card types for the 24p slot 2p pole 10 layer 2p branch motor, namely the first type of cross-layer card 14, the second type of cross-layer card 15, the third type of cross-layer card 16, the fourth type of cross-layer card 17, and the fifth type of cross-layer card 18.

[0030] Each phase winding includes p first unit branches and p second unit branches arranged in parallel. The conductors of the first unit branches are always located in two adjacent stator slots with the conductors of the second unit branches. Both the first and second unit branches are composed of four cross-layer hairpin groups that are sequentially welded together. The cross-layer hairpin groups are sequentially welded together from the first layer position to the 2nth layer of the stator slot through n types of cross-layer hairpins, or from the 2nth layer position to the first layer of the stator slot through n types of cross-layer hairpins. In the cross-layer hairpin groups, the rotation directions of the welding section and the hairpin section are opposite. Both the first and second unit branches include three same-layer welding segments, namely, the first same-layer welding segment located on the 2nth layer, the second same-layer welding segment located on the first layer, and the third same-layer welding segment located on the 2nth layer; wherein, in the first unit branch, the span of the first same-layer welding segment is 13, the span of the second same-layer welding segment is 11, and the span of the third same-layer welding segment is 9; in the second unit branch, the span of the first same-layer welding segment is 15, the span of the second same-layer welding segment is 13, and the span of the third same-layer welding segment is 11.

[0031] The aforementioned cross-layer hairpin group consists of n types of cross-layer hairpins welded together, with the windings running from the 1st layer to the 2nth layer, or from the 2nth layer to the 1st layer; in the cross-layer hairpin group, the conductors are connected in a Z-shape according to the stator slot number.

[0032] like Figures 3-10As shown, the example is a 24p slot, 2p pole, 10-layer, 2p branch. The n layers of the flat wire winding near the inner circle of the stator are staggered by two slots from the n layers near the outer circle of the stator. In the figure, A1+ to A1- is the first unit branch, and A2+ to A2- is the second unit branch. The specific connection method of the flat wire winding in this scheme is as follows: Figure 5 As shown: hairpin end (solid line), soldering end (dashed line). The distance between the conductors in two stator slots is 12 slots, where 12 is the number of stator slots corresponding to each magnetic pole. A span of 12 is considered a full pitch; less than 12 is a short pitch, and greater than 12 is a long pitch. When the flat wire winding from the nth layer to the (n+1)th layer is a short pitch, the short-pitch winding helps save copper wire material and weakens induced electromotive force harmonics.

[0033] The specific connection scheme for this example is as follows: 17(1) represents the 17th slot, 1st layer flat wire. The number outside the parentheses is the number of stator slots, and the number inside the parentheses is the number of flat wire layers. Figure 5a As shown, in Example 24p slot 2p pole 10 layer 2p branch, the connection relationship of the first unit branch of phase A winding is as follows: A1+-17(1)-29(2)-17(3)-29(4)-17(5)-27(6)-15(7)-27(8)-15(9)-27 (10)-14(10)-2(9)-14(8)-2(7)-14(6)-4(5)-16(4)-4(3)-16(2)-4(1) -15(1)-27(2)-15(3)-27(4)-15(5)-25(6)-13(7)-25(8)-13(9)-25(10 )-16(10)-4(9)-16(8)-4(7)-16(6)-6(5)-18(4)-6(3)-18(2)-6(1)-A1- In the first unit branch from A1+ to A1-, the following are included sequentially: Cross-level card issuance group {17(1)-29(2)-17(3)-29(4)-17(5)-27(6)-15(7)-27(8)-15(9)-27(10)}、 The first layer of welded sections {27(10)-14(10)}, Cross-level card issuance group {14(10)-2(9)-14(8)-2(7)-14(6)-4(5)-16(4)-4(3)-16(2)-4(1)}、 The second layer of welding segment {4(1)-15(1)}, Cross-level card issuance group {15(1)-27(2)-15(3)-27(4)-15(5)-25(6)-13(7)-25(8)-13(9)-25(10)}、 The third layer of welding segment {25(10)-16(10)}, Cross-level card issuance group {16(10)-4(9)-16(8)-4(7)-16(6)-6(5)-18(4)-6(3)-18(2)-6(1)}.

[0034] like Figure 5b As shown, in Example 24p slot 2p pole 10 layer 2p branch, the connection relationship of the second unit branch of phase A winding is as follows: A2+-18(1)-30(2)-18(3)-30(4)-18(5)-28(6)-16(7)-28(8)-16(9)-28 (10)-13(10)-1(9)-13(8)-1(7)-13(6)-3(5)-15(4)-3(3)-15(2)-3(1) -16(1)-28(2)-16(3)-28(4)-16(5)-26(6)-14(7)-26(8)-14(9)-26(10 )-15(10)-3(9)-15(8)-3(7)-15(6)-5(5)-17(4)-5(3)-17(2)-5(1)-A2- In the second unit branch from A2+ to A2-, the following are included in sequence: Cross-level card issuance group {18(1)-30(2)-18(3)-30(4)-18(5)-28(6)-16(7)-28(8)-16(9)-28(10)}、 The first layer of welded sections {28(10)-13(10)}, Cross-level card issuance group {13(10)-1(9)-13(8)-1(7)-13(6)-3(5)-15(4)-3(3)-15(2)-3(1)}、 The second layer of welding segment {3(1)-16(1)}, Cross-level card issuance group {16(1)-28(2)-16(3)-28(4)-16(5)-26(6)-14(7)-26(8)-14(9)-26(10)}、 The third layer of welded sections {26(10)-15(10)}, Cross-level card issuance group {15(10)-3(9)-15(8)-3(7)-15(6)-5(5)-17(4)-5(3)-17(2)-5(1)}.

[0035] In the above connection relationships, A1+ and A2+ are the power line ends, and A1- and A2- are the center line ends. In the above scheme, there are relatively few types of hairpins, with a total of n types of cross-layer hairpins. (Example above) Figure 5 The hair clip illustration is as follows: Figure 10As shown: 24p slot 2p pole 10 layer 2p branch motor, n=5, its hairpin type is 5 different layer hairpins.

[0036] In the first or second unit branch, to avoid circulating current caused by voltage differences between branches, each layer of windings in each branch is interleaved in different stator slots, ensuring the spatial balance of the windings. This balances the current between branches, eliminates circulating current, improves the spatial harmonics of the motor, enhances motor performance, and suppresses motor noise.

[0037] Example 2 Based on Example 1, the span of the hairpin section and the welding section of the winding is further defined, and two preferred forms are given.

[0038] as follows Figures 3-10 As shown: the card-issuing end (solid line), the welding end (dashed line). In this application, each pole corresponds to 12 stator slots, so the span between adjacent side conductors of the winding is 12, which is a full pitch; a span less than 12 is a short pitch; and a span greater than 12 is a long pitch.

[0039] The first type, in the cross-layer card issuing group, has a span of 12 for both the cross-layer card issuing section and the cross-layer welding section.

[0040] The second type is a cross-layer card-pinning group in which the card-pinning segment or welding segment has a short distance of 10 in the nth and n+1th layers, and the card-pinning segment or welding segment has a full distance of 12 in the remaining cross-layers.

[0041] as follows Figures 11-13 As shown, the example is a 96-slot, 8-pole, 10-layer, 8-branch winding using the second winding method. The n layers of the flat wire winding near the inner circle of the stator are staggered by two slots from the n layers near the outer circle of the stator.

[0042] like Figures 11-13 As shown, the example is a 96-slot, 8-pole, 10-layer, 8-branch winding. A1+~A8+, B1+~B8+, and C1+~C8+ are the power line ends, and A1-~A8-, B1-~B8-, and C1-~C8- are the center line ends. The 5 layers of flat wire windings closest to the inner circle of the stator are staggered by two slots from the 5 layers closest to the outer circle of the stator. The overall connection scheme is shown in the figure below. By arranging four consecutive branch windings of the two pole pairs of the unit magnetic pair along the circumferential direction of the stator core, the entire single-phase winding is obtained.

[0043] The flat wire winding is divided into phase A, phase B and phase C. Each phase winding is equipped with a power line end and a center line end. The connection path, hairpin type and slot arrangement of the three phase windings are the same. Only the starting stator slot position differs by Q / (3p) slots in sequence to achieve a 120° electrical angle phase difference.

[0044] In the second winding configuration, when n is odd, the n layers of flat wire windings closest to the inner circle of the stator are staggered by two slots from the n layers closest to the outer circle of the stator. Therefore, the flat wire windings from the 5th to the 6th layers can be short-pitch 10. Short-pitch windings are beneficial for saving copper wire material and for reducing induced electromotive force harmonics.

[0045] In Examples 1-2, based on the above "in the cross-layer card group, the card segment or welding segment has a short distance of 10 in the nth and n+1th layers, and the card segment or welding segment has a full distance of 12 in the remaining cross layers".

[0046] When n is odd, the n layers of flat wire windings near the inner circle of the stator are staggered by two slots from the n layers near the outer circle of the stator.

[0047] like Figures 11-16 As shown, in an embodiment where n is 5 and the stator slots are 10 layers, the 5 layers of flat wire windings near the inner circle of the stator and the 5 layers near the outer circle of the stator are staggered by two slots.

[0048] like Figure 18 As shown, in an embodiment where n is 3 and the stator slots are 6 layers, the 3 layers of flat wire windings near the inner circle of the stator and the 3 layers near the outer circle of the stator are staggered by two slots.

[0049] When n is an even number, the n layers of flat wire windings near the inner circle of the stator are offset by two slots from the n layers near the outer circle of the stator.

[0050] like Figure 17 As shown, in an embodiment where n is 4 and the stator slots are 8 layers, the 4 layers of flat wire windings near the inner circle of the stator and the 4 layers near the outer circle of the stator are staggered by two slots.

[0051] In embodiments 1-2, preferably, the layer closest to the inner circle of the stator is the first layer, and the layer closest to the outer circle of the stator is the 2nth layer; or, the layer closest to the inner circle of the stator is the 2nth layer, and the layer closest to the outer circle of the stator is the first layer.

[0052] In embodiments 1-3, according to the position of the winding in the slot, the stator slot number is connected in a Z-shape. The cross-layer hairpin group is from the bottom layer to the top layer. The direction of the cross-layer welding section is opposite to the direction of the cross-layer hairpin section; one is clockwise and the other is counterclockwise; or one is counterclockwise and the other is clockwise.

[0053] In embodiments 1-3, the starting positions of the first unit branch and the second unit branch are taken as the power line ends, and the ending positions are taken as the center line ends; Alternatively, the starting positions of the first and second unit branches can be used as the centerline ends, and the ending positions as the power line ends.

[0054] This invention also provides other winding connection branch configurations, including but not limited to the following examples: like Figure 14As shown, it is a 96-slot, 8-pole, 10-layer, 8-branch full-pitch winding (5 types of cross-layer hairpins).

[0055] like Figure 15 As shown, it is a 72-slot, 6-pole, 10-layer, 6-branch staggered-slot winding (5 types of cross-layer hairpins).

[0056] like Figure 16 As shown, it is a 48-slot, 4-pole, 10-layer, 4-branch staggered-slot winding (5 types of cross-layer hairpins).

[0057] like Figure 17 As shown, it is a 96-slot, 8-pole, 8-layer, 8-branch staggered-slot winding (4 types of cross-layer hairpins).

[0058] like Figure 18 As shown, it is a 96-slot, 8-pole, 6-layer, 8-branch staggered-slot winding (3 types of cross-layer hairpins).

[0059] This invention is applicable to the stator of a flat wire motor with an integer number of slots q per pole per phase, a number of pole pairs p, an even number of flat wire layers 2n, n types of flat wire hairpins, and 2p parallel winding branches (p first unit branches and p second unit branches).

[0060] In this invention, when the number of pole pairs in a motor is p, each phase winding is divided into p groups of units, and each group of units corresponds to a magnetic pole unit. Each group of units contains a first unit branch and a second unit branch. Both the first unit branch and the second unit branch are composed of 4 cross-layer hairpin groups. The cross-layer hairpin groups are connected in a Z-shape according to the stator slot number. The 4 cross-layer hairpin groups are connected by 3 types of same-layer welding segments, thereby satisfying the requirement that the number of slots q per pole per phase of the motor is an integer of 4 slots.

[0061] In the above structure, the winding method of the first unit branch and the second unit branch enables the motor to meet the design of an integer number of slots q per pole per phase, which can effectively reduce cogging torque and torque pulsation and improve the smoothness of motor operation.

[0062] Secondly, the design of the cross-layer winding group, combined with the Z-shaped connection of the cross-layer winding group according to the stator slot number, has the following advantages: First, when the number of flat wire layers is 2n, there are n types of flat wire windings, resulting in fewer winding types, all of which are cross-layer windings with no intersection, simplifying the manufacturing process. Second, the power line end and the center line end exit on the same layer, simplifying the busbar structure, reducing the space occupied at the ends, and lowering manufacturing costs. Third, it ensures that each layer of windings on each unit branch is interleaved in different stator slots, ensuring the spatial balance of the windings. This interleaving arrangement balances the resistance and inductance of each branch, eliminating phase and voltage differences between different branches; it also balances the current between branches, eliminating circulating current, improving the spatial harmonics of the motor, enhancing motor performance, and suppressing motor noise.

[0063] The present invention also provides a motor, comprising an even-numbered layer of flat wire windings with 4 slots per pole per phase as described above, and a motor. The motor is a 24p-slot, 2p-p-pole, 2n-layer, 2p-branch motor, containing n types of cross-layer hairpins, where p is an integer ≥1 and n is an integer ≥1.

[0064] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Those skilled in the art can readily implement the present invention based on the accompanying drawings and the above description. However, any modifications, alterations, or variations made by those skilled in the art without departing from the scope of the present invention, utilizing the disclosed technical content, are equivalent embodiments of the present invention. Furthermore, any modifications, alterations, or variations made to the above embodiments based on the essential technology of the present invention are still within the protection scope of the present invention.

Claims

1. An even-numbered layer flat wire winding and motor with 4 slots per pole per phase, including a stator body, multiple stator slots circumferentially spaced on the stator body, and stator windings passing through the stator slots; the stator windings are divided into three phases, and the windings of the other two phases are obtained after rotating the winding of any phase several stator slots. Its features are: Each pole of the stator has 12 stator slots, and each pole has 4 stator slots per pair. The number of pole pairs of the motor is p, where p is an integer ≥ 1. Each stator slot contains 2n layers, where n is an integer ≥ 1. The stator winding contains n types of cross-layer hairpins. The two side conductors of each type of cross-layer hairpin are placed in layers 2m-1 and 2m, respectively, where m is a positive integer not greater than n. Each phase winding includes p first unit branches and p second unit branches arranged in parallel. The conductors of the first unit branches are always located in two adjacent stator slots with the conductors of the second unit branches. Both the first and second unit branches are composed of four cross-layer hairpin groups that are sequentially welded together. The cross-layer hairpin groups are sequentially welded together from the first layer position to the 2nth layer of the stator slot through n types of cross-layer hairpins, or from the 2nth layer position to the first layer of the stator slot through n types of cross-layer hairpins. In the cross-layer hairpin groups, the rotation directions of the welding section and the hairpin section are opposite. Both the first and second unit branches include three same-layer welding segments, namely, the first same-layer welding segment located on the 2nth layer, the second same-layer welding segment located on the first layer, and the third same-layer welding segment located on the 2nth layer; wherein, in the first unit branch, the span of the first same-layer welding segment is 13, the span of the second same-layer welding segment is 11, and the span of the third same-layer welding segment is 9; in the second unit branch, the span of the first same-layer welding segment is 15, the span of the second same-layer welding segment is 13, and the span of the third same-layer welding segment is 11.

2. The even-numbered layer flat wire winding with 4 slots per pole per phase and the motor according to claim 1, characterized in that: In the cross-layer card issuing group, the span of both the cross-layer card issuing section and the cross-layer welding section is a whole span of 12.

3. The even-numbered layer flat wire winding and motor with 4 slots per pole per phase according to claim 1, characterized in that: In the cross-layer card-issuing group, the card-issuing segment or welding segment has a short distance of 10 in the nth and n+1th layers, and the card-issuing segment or welding segment has a full distance of 12 in the remaining cross-layers.

4. The even-numbered layer flat wire winding with 4 slots per pole per phase and the motor according to claim 1, characterized in that: When n is an odd number, the n layers of flat wire windings near the inner circle of the stator are staggered by two slots from the n layers near the outer circle of the stator.

5. The even-numbered layer flat wire winding with 4 slots per pole per phase and the motor according to claim 1, characterized in that: When n is an even number, the n layers of flat wire windings near the inner circle of the stator are offset by two slots from the n layers near the outer circle of the stator.

6. The even-numbered layer flat wire winding with 4 slots per pole per phase and the motor according to claim 1, characterized in that: The layer closest to the inner circle of the stator is designated as layer 1, and the layer closest to the outer circle of the stator is designated as layer 2n; or, the layer closest to the inner circle of the stator is designated as layer 2n, and the layer closest to the outer circle of the stator is designated as layer 1.

7. The even-numbered layer flat wire winding and motor with 4 slots per pole per phase according to claim 1, characterized in that: The cross-layer card-issuing group runs from the bottom layer to the top layer, and the direction of the welding section of the cross-layer group is opposite to that of the card-issuing section of the cross-layer group; one is clockwise and the other is counterclockwise; or one is counterclockwise and the other is clockwise.

8. The even-numbered layer flat wire winding with 4 slots per pole per phase and the motor according to claim 1, characterized in that: The starting positions of the first and second unit branches are taken as the power line ends, and the ending positions are taken as the center line ends; Alternatively, the starting positions of the first and second unit branches can be used as the centerline ends, and the ending positions as the power line ends.

9. An electric motor, characterized in that: Includes an even-numbered layer flat wire winding and a motor with 4 slots per pole per phase as described in any one of claims 1-8.

10. The motor according to claim 1, characterized in that: The motor is a 24p-slot, 2p-p-pole, 2n-layer, 2p-branch motor, containing n types of cross-layer hairpins, where p is an integer ≥1 and n is an integer ≥1.

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