Manufacturing method of stator winding of split-conductor motor and stator of split-conductor motor

Abstract

This application proposes a method for manufacturing a stator winding of a split-wire motor and a split-wire motor stator. It relates to the field of motor and manufacturing technology. The method includes prefabricating multiple winding units, embedding the in-slot wires of the multiple winding units into corresponding stator slots, such that the in-slot wires in each stator slot are arranged in M ​​layers radially along the stator core and N columns circumferentially along the stator core, forming an M×N array of in-slot wires, where M≥2, N≥2; wherein, the arrangement of the N columns of in-slot wires in each layer includes embedding the i-th column of in-slot wires into the corresponding layer in the stator slot, moving it circumferentially along the stator core, where 1≤i<N; and embedding the N-th column of in-slot wires into the corresponding layer in the stator slot. This method embeds the in-slot wires of the prefabricated multiple winding units into the stator slots, significantly reducing solder joints, allowing for a wide range of turn adjustment, and providing flexibility in design and manufacturing.

Description

Technical Field

[0001] This invention relates to the field of motor and manufacturing technology, and in particular to a method for manufacturing a stator winding of a split-wire motor and a stator of a split-wire motor. Background Technology

[0002] With the rapid development of new energy vehicles, robots, drones, industrial automation and other fields, increasingly higher requirements are being placed on the power density, energy conversion efficiency, miniaturization and cost control of motors.

[0003] Flat wire motors, which use conductors with roughly rectangular cross-sections for winding, have advantages over traditional round wire motors, such as high slot fill factor, good heat dissipation, and short end dimensions. They can reduce motor size, copper consumption, and energy conversion efficiency while maintaining the same power output. Therefore, they are gradually replacing traditional round wire motors in the field of new energy vehicles and have broad market prospects.

[0004] Currently, the manufacturing processes for flat wire motors are mainly divided into two categories. One is the "insertion" process: first, one end of a single (or half) turn of flat wire is shaped, then arranged and inserted into the stator slot, followed by a series of subsequent processing steps such as secondary twisting, flattening, welding, and solder joint coating. Although this process uses semi-closed stator slots, which helps reduce cogging torque, it suffers from cumbersome and complex production processes, a large number of solder joints, and high requirements for connection reliability. Furthermore, during insertion and twisting, the inter-turn insulation of the flat wire conductor is easily damaged by friction and compression. During welding, the inter-turn insulation is easily damaged by high temperatures, leading to a decrease in motor insulation performance and subsequent motor insulation failure, severely affecting the motor's service life and operational stability. Another type is the "press-in" process: a pre-formed wave winding or lap winding is radially pressed into the stator slot as a whole. Although this process reduces the number of solder points and simplifies the end treatment, the process cost is high, and it usually requires the stator slot to be an open slot, which leads to an increase in the change of the air gap magnetic permeability of the motor, a significant increase in the cogging torque, and aggravation of vibration and noise. At the same time, it will also cause problems such as increased fluctuation of motor output torque and reduced efficiency, which greatly reduces the overall technical performance of the motor and makes it difficult to meet the requirements of high-end drive scenarios for motor smoothness and high-precision control.

[0005] It is evident that flat wire motors manufactured using "insertion" and "press-in" processes cannot simultaneously meet the two key requirements of "low cogging torque" and "few solder joints and high reliability connection." Furthermore, they suffer from problems such as high investment in production equipment, low degree of standardization, and high wire production costs.

[0006] Therefore, there is an urgent need to develop an efficient manufacturing method for stator windings of split-wire motors and a split-wire motor stator to achieve fewer solder joints in the windings, lower cogging torque, and improvements in motor performance, reliability, and production efficiency. Summary of the Invention

[0007] Regarding the issue mentioned above that flat wire motors manufactured using insertion and press-fit processes cannot simultaneously meet the two key requirements of low cogging torque and fewer solder joints and high-reliability connections, this paper addresses the problem that flat wire motors manufactured using insertion and press-fit processes cannot simultaneously meet the two key requirements of low cogging torque and fewer solder joints and high-reliability connections.

[0008] This application proposes a method for manufacturing a stator winding of a split-wire motor. The stator of the split-wire motor includes a stator core, which is annular and has multiple stator slots along its circumference. The manufacturing method includes: S1: Prefabricated multiple winding units; S2: The slot conductors of the multiple winding units are respectively embedded into the corresponding stator slots, such that the slot conductors in each stator slot are arranged in M ​​layers along the radial direction of the stator core and in N columns along the circumference of the stator core to form an M×N slot conductor array, where M≥2 and N≥2. The arrangement of the wires in the N columns of the slots in each layer is performed according to the following steps: S21: Embed the wire in the slot of column i into the corresponding layer in the stator slot, and translate it along the circumferential direction of the stator core, where 1≤i<N; S22: Embed the wire in the slot of column N into the corresponding layer in the stator slot.

[0009] Optionally, the stator slot includes a first sidewall and a second sidewall disposed opposite to each other, and a bottom wall connecting the first sidewall and the second sidewall. The first sidewall has a protrusion extending toward the second sidewall, and the protrusion and the second sidewall define the slot opening of the stator slot. Step S21, which involves embedding the wire in the i-th column of the slot into the corresponding layer of the stator slot and moving it along the circumference of the stator core, includes embedding the wire in the i-th column of the slot into the corresponding layer of the stator slot at the Nth position through the slot opening along the radial direction of the stator core, and moving it along the circumference of the stator core from the second sidewall to the first sidewall until it moves to the i-th position of the corresponding layer. Step S22, which involves embedding the Nth column of the slot wire into the corresponding layer of the stator slot, includes embedding the Nth column of the slot wire into the Nth position of the corresponding layer of the stator slot through the slot opening along the radial direction of the stator core.

[0010] Optionally, in each stator slot, N columns of slot conductors in the same layer are closely adjacent to each other in the circumferential direction of the stator core, and the two outermost columns of slot conductors are respectively adjacent to the first sidewall and the second sidewall.

[0011] Optionally, the prefabrication of multiple winding units in step S1 includes winding wires according to a predetermined winding shape and solidifying the wound wires into a winding unit through an integral molding and curing process.

[0012] Optionally, the winding unit includes N interconnected windings, which are arranged concentrically, with the winding with the largest pitch located in the outermost layer and the winding with the smallest pitch located in the innermost layer.

[0013] Optionally, the winding unit includes N interconnected windings, which are arranged in parallel according to the end torsion shifting method, so that the pitch of the N windings is the same. Optionally, prior to step S2, the process further includes attaching insulating paper to the inner wall of each of the stator slots. Optionally, the slotted conductors include multiple conductors arranged sequentially along the radial direction of the stator core.

[0014] Optionally, the winding unit is a wire lap winding or a wire wave winding.

[0015] Optionally, when the winding unit is a conductor wave winding, the method further includes arranging and combining the plurality of conductor wave windings according to a preset arrangement and combination method before step S2.

[0016] Optionally, the in-groove conductor includes at least one flat wire, or at least one round wire, or a combination of flat and round wires.

[0017] This application also proposes a stator for a split-conductor motor, comprising: The stator core is annular and has multiple stator slots along its circumference, and each stator slot has a semi-open slot opening. The stator winding includes multiple winding units, and the slot conductors of the multiple winding units are arranged in the corresponding stator slots, such that each stator slot has M layers of slot conductors along the radial direction of the stator core and N columns of slot conductors along the circumference of the stator core, forming an M×N slot conductor array, where M≥2 and N≥2.

[0018] Optionally, the stator slot includes a first sidewall and a second sidewall disposed opposite to each other, and a bottom wall connecting the first sidewall and the second sidewall. The first sidewall has a protrusion extending toward the second sidewall, and the protrusion and the second sidewall define the slot opening of the stator slot.

[0019] Optionally, in each stator slot, N columns of slot conductors in the same layer are closely adjacent to each other in the circumferential direction of the stator core, and the two outermost columns of slot conductors are respectively adjacent to the first sidewall and the second sidewall.

[0020] Optionally, each winding unit includes a first slot conductor group and a second slot conductor group, which are respectively disposed in two different stator slots and located in different layers within the two different stator slots. The first slot conductor group includes N columns of slot conductors arranged in parallel along the circumference of the stator core, and the second slot conductor group includes N columns of slot conductors arranged in parallel along the circumference of the stator core.

[0021] Optionally, in a stator slot having the first slot conductor group, the N columns of first slot conductors are arranged in parallel in a first order; in a stator slot having the second slot conductor group, the N columns of slot conductors are arranged in parallel in a second order.

[0022] Optionally, each stator slot has two adjacent layers with a second slot conductor group of one of the two adjacent winding units and a first slot conductor group of the other winding unit.

[0023] Optionally, each winding unit includes multiple slot conductor groups located in multiple different stator slots, and two adjacent slot conductor groups are located in different layers in two different stator slots, wherein each slot conductor group includes N columns of slot conductors arranged side by side along the circumference of the stator core.

[0024] Optionally, the stator of the split-wire motor also includes insulating paper that adheres to the inner wall of the stator slot and a sealing member that seals the slot opening.

[0025] Optionally, the winding unit includes N interconnected windings, which are arranged concentrically, with the winding with the largest pitch located in the outermost layer and the winding with the smallest pitch located in the innermost layer.

[0026] Optionally, the winding unit includes N interconnected windings, which are arranged in parallel according to the end torsion shifting method, so that the pitch of the N windings is the same.

[0027] The beneficial effects of this application include at least the following: This embodiment provides a method for manufacturing a stator winding of a split-wire motor, comprising prefabricating multiple winding units, each winding unit including two slot conductors; embedding the multiple slot conductors into corresponding stator slots, such that the slot conductors in each stator slot are arranged in M ​​layers radially along the stator core and N columns circumferentially along the stator core, forming an M×N slot conductor array, where M≥2, N≥2; wherein the arrangement of the N columns of slot conductors in each layer is performed according to the following steps: embedding the i-th column of slot conductors into the corresponding layer in the stator slot and moving it circumferentially along the stator core, where 1≤i<N; embedding the N-th column of slot conductors into the corresponding layer in the stator slot. This manufacturing method radially embeds the slot conductors in the prefabricated multiple winding units into the stator slots, which can retain a semi-open slot shape to optimize electromagnetic performance and suppress cogging torque, and has fewer solder joints, high connection reliability, and easily ensures product quality. In addition, the M×N in-slot wire array in the stator slots allows for a large range of turns adjustment in the stator windings of the split-wire motor, making the design flexible and easy to achieve the standardization and serialization of split-wire motor designs of the same specifications. It can also reduce the skin effect and proximity effect of the windings.

[0028] The features and technical advantages of this application have been broadly outlined above to facilitate a better understanding of the following detailed description. Additional features and advantages of this application, which form the subject matter of the claims, will be described below. Those skilled in the art will understand that the disclosed concepts and specific embodiments can be readily utilized as the basis for modifying or designing other structures or processes to achieve the same purpose as this application. Those skilled in the art will also recognize that such equivalent constructions do not depart from the spirit and scope of this application as set forth in the appended claims. Attached Figure Description

[0029] To gain a more comprehensive understanding of this application and its advantages, the following description is now taken in conjunction with the accompanying drawings, in which: Figure 1 This is a flowchart illustrating a method for manufacturing a stator winding of a motor with split conductors, according to an embodiment of this application. Figure 2 A flowchart illustrating the wiring configuration for each layer of N columns in the slots in this application embodiment; Figure 3 This is a schematic diagram illustrating the process of setting the slot wires in the stator slot winding unit according to an embodiment of this application; Figure 4 This is a schematic diagram of the structure of a winding unit according to an embodiment of this application; Figure 5 This is a schematic diagram of another winding unit according to an embodiment of this application; Figure 6 This is a diagram of phase A of the split conductor lap winding according to an embodiment of this application; Figure 7 for Figure 6 Schematic diagram of the middle stator slot; Figure 8 This is a diagram showing the A-phase unfolded of the split conductor wave winding according to an embodiment of this application; Figure 9 for Figure 8 A schematic diagram of the middle stator slot.

[0030] Unless otherwise indicated, corresponding numbers and symbols in different figures generally refer to corresponding parts. The accompanying drawings are provided to clearly illustrate relevant aspects of various embodiments and are not necessarily drawn to scale. Detailed Implementation

[0031] Various exemplary embodiments, features, and aspects of the present invention will now be described in detail with reference to the accompanying drawings. The same reference numerals in the drawings denote elements that have the same or similar functions. Although various aspects of the embodiments are shown in the drawings, they are not necessarily drawn to scale unless specifically indicated otherwise.

[0032] The term "exemplary" as used herein means "serving as an example, embodiment, or illustration." Any embodiment illustrated herein as "exemplary" is not necessarily to be construed as superior to or better than other embodiments. The terms "first," "second," "third," etc. (if present) in the specification, claims, and drawings of this invention are used to distinguish similar objects and are not necessarily used to describe a particular order or sequence.

[0033] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "coupled," "connected," and "linked" should be interpreted broadly. For example, they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal connection of two elements or the interaction between two elements. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0034] Furthermore, to better illustrate the present invention, numerous specific details are provided in the following detailed embodiments. Those skilled in the art should understand that the present invention can be practiced without certain specific details. In some instances, methods, means, elements, and circuits well known to those skilled in the art have not been described in detail in order to highlight the spirit of the invention.

[0035] A split-wire motor stator includes a stator core and stator windings. The stator core is annular and has multiple stator slots circumferentially distributed along its circumference. These slots are semi-open. In this embodiment, the slot openings face the axis of the stator core, making this type of split-wire motor stator suitable for external stator motors. In other embodiments, the slot openings are away from the axis of the stator core, making this type of split-wire motor stator suitable for internal stator motors.

[0036] The winding unit of this application adopts a novel split conductor winding structure, in which the shaped split conductor winding is embedded radially into the stator slot along the stator core to form a split conductor motor stator. This split conductor motor stator is applicable to single-phase motors, three-phase motors, or multi-phase motors.

[0037] The stator of the split-wire motor of this application includes a stator core, which is annular and has multiple stator slots along its circumference. Each stator slot has a semi-open opening. Based on this split-wire motor stator, embodiments of this application provide a method for manufacturing a split-wire motor stator winding, such as... Figure 1 , Figure 2 and Figure 3 As shown, the manufacturing method includes: S1: Prefabricated multiple winding units; S2: The slot conductors of the multiple winding units are respectively embedded into the corresponding stator slots, such that the slot conductors in each stator slot are arranged in M ​​layers along the radial direction of the stator core and in N columns along the circumference of the stator core to form an M×N slot conductor array, where M≥2 and N≥2. The arrangement of the wires in the N columns of the slots in each layer is performed according to the following steps: S21: Embed the wire in the slot of column i into the corresponding layer in the stator slot, and move it along the circumference of the stator core, where 1≤i<N; S22: Embed the wire in the slot of column N into the corresponding layer in the stator slot.

[0038] Specifically, in step S1, multiple winding units are prefabricated using a prefabrication process. Each winding unit includes N interconnected windings, which are arranged concentrically, with the winding with the largest pitch located on the outermost layer and the winding with the smallest pitch located on the innermost layer. For example... Figure 4As shown, each winding unit includes two windings 41 and 42, which are arranged concentrically, with winding 42 nested around winding 41 and adjacent to it. Winding 41 is a multi-turn coil wound from wire according to a preset shape, and winding 42 is also a multi-turn coil wound from wire according to a preset shape. Windings 41 and 42 have the same number of turns and are connected by wire 411. Winding 41 can be wound from a single wire, and winding 42 can also be wound from a single wire. Windings 41 and 42 are connected by wire 411. In some embodiments, windings 41 and 42 can be wound from the same conductor. For example, winding 41 can be wound first, and then winding 42 can be wound around the outer periphery of winding 41, or winding 42 can be wound first, and then winding 41 can be wound around the inner periphery of winding 42. The conductor connecting windings 41 and 42 is the same conductor used to wind windings 41 and 42. Both windings 51 and 52 include a first slot conductor and a second slot conductor. The first slot conductor includes multiple conductors arranged radially along the stator core, and the second slot conductor includes multiple conductors arranged radially along the stator core.

[0039] Furthermore, in step S1, multiple winding units are pre-wound using a prefabrication process. Each winding unit includes N interconnected windings, which are arranged in parallel according to an end-twist shifting method, ensuring that the pitch of the N windings is the same. For example... Figure 5 As shown, each winding unit includes two windings 51 and 52. Winding 51 can be a multi-turn coil wound from wire according to a preset shape, and winding 52 can also be a multi-turn coil wound from wire according to a preset shape. During the winding process, the ends of each turn of the coil need to be twisted and repositioned. Winding 51 and winding 52 are connected by wire 511. Winding 51 and winding 52 can be wound separately from wire and then connected by wire 511. In other embodiments, winding 51 and winding 52 can be wound from the same wire. Both winding 51 and winding 52 include a first slot wire and a second slot wire, and both the first slot wire and the second slot wire include multiple wires arranged sequentially along the radial direction of the stator core. In this embodiment, the first slot conductor of winding 51 and the first slot conductor of winding 52 are arranged in parallel and located outside the first slot conductor of winding 52. The second slot conductor of winding 51 and the second slot conductor of winding 52 are arranged in parallel and located inside the second slot conductor of winding 52. The pitch of winding 51 and winding 52 is the same.

[0040] In this embodiment, the first slot conductors of the N windings in each winding unit are arranged in parallel along the circumference of the stator core to form a first slot conductor group, and the second slot conductors of the N windings are arranged in parallel along the circumference of the stator core to form a second slot conductor group.

[0041] In step S2, the slot conductors of each winding unit are respectively arranged in the corresponding stator slots, and the span between two adjacent slot conductors in each winding unit is set according to actual needs. In each stator slot, the slot conductors are arranged in M ​​layers radially along the stator core and in N columns circumferentially along the stator core, forming an M×N slot conductor array, where M≥2 and N≥2. That is, in each stator slot, M layers of slot conductors are arranged radially from the bottom wall of the stator slot towards the slot opening, and N columns of slot conductors are arranged circumferentially along the stator core. In each stator slot, the N columns of slot conductors in the same layer are closely adjacent circumferentially along the stator core, and the two outermost columns of slot conductors are adjacent to the opposite side walls of the stator slot. In this embodiment, the N columns of slot conductors in each layer may include multiple conductors arranged sequentially radially along the stator core, i.e., the winding unit is composed of multiple layers and multiple columns of conductors. The number of conductors in the N columns of slots in each layer is selected according to the actual situation. Each stator slot forms an M×N array of conductors, which makes the number of turns of the stator winding of the split-wire motor adjustable, flexible in design, easy to realize the generalization and serialization of the design of split-wire motors of the same specification, and can also reduce the skin effect and proximity effect of the stator winding.

[0042] In each stator slot, the slot conductors are sequentially installed along the circumference of the stator core, and then sequentially installed along the radial direction of the stator core from the bottom wall of the slot towards the slot opening, layer by layer of slot conductors. That is, first, N columns of slot conductors are sequentially embedded into the first layer and moved to the corresponding positions as required, completing the installation of the first layer of N columns of slot conductors, which are installed on the bottom wall of the stator slot; then, N columns of slot conductors are sequentially embedded into the second layer and moved to the corresponding positions as required, completing the installation of the second layer of N columns of slot conductors, which are installed radially along the stator core onto the first layer of N columns of slot conductors. This process is repeated for each subsequent layer of N columns of slot conductors. Finally, N columns of slot conductors are sequentially embedded into the Mth layer and moved to the corresponding positions as required, completing the installation of the Mth layer of N columns of slot conductors, which are installed radially along the stator core onto the (M-1)th layer of N columns of slot conductors. The wires in the N columns of slots in each layer are arranged closely together, and the wires in the N columns of slots between layers are also arranged closely together.

[0043] Specifically, for the setting of the N columns of slot conductors in each layer, in step S21, the i-th column of slot conductors is embedded into the N-th position of the corresponding layer in the stator slot, and is moved along the circumference of the stator core from the side wall near the slot opening to the side wall away from the slot opening by external force until it moves to the i-th position of the layer.

[0044] In step S22, the Nth column of the slot wire is embedded in the Nth position of the corresponding layer in the stator slot, wherein the Nth column of the slot wire is adjacent to the (N-1)th column of the slot wire of the layer and the side wall near the slot opening.

[0045] Furthermore, such as Figure 3 As shown in (a), the stator slot opening is a semi-open slot, meaning the width of the stator slot opening 21 is less than the width of the stator slot itself. The stator slot includes a first sidewall 23 and a second sidewall 22 disposed opposite to each other, with one end of the first sidewall 23 and one end of the second sidewall 22 connected by a bottom wall 24. A protrusion 231 extending toward the second sidewall 22 is provided on the other end of the first sidewall 23, defining the stator slot opening 21 between the protrusion 231 and the second sidewall 22; this opening 21 is a semi-open slot. A groove 232 is provided on the second sidewall 22 near the opening 21.

[0046] The wiring arrangement within the N columns of slots in each layer is as follows: Figure 2 and Figure 3 As shown, in step S21, the wire in the i-th column slot is inserted into the N-th position of the corresponding layer in the stator slot through the slot opening along the radial direction of the stator core, and then moved along the circumference of the stator core from the second sidewall to the first sidewall until it moves to the i-th position of the layer.

[0047] In step S22, the wire in the Nth column of the slot is inserted into the Nth position of the corresponding layer in the stator slot through the slot opening along the radial direction of the stator core, wherein the wire in the Nth column of the slot is adjacent to the wire in the (N-1)th column of the slot and the second sidewall of the layer.

[0048] This embodiment effectively solves the problem of embedding multi-row slot conductors into stator slots through slot openings, which not only effectively suppresses cogging torque but also increases the range of turns adjustment.

[0049] In this embodiment, the arrangement order of the wires in the N columns of slots in each layer is as follows: along the circumference of the stator core from the first sidewall 23 to the second sidewall 22, the positions are: the first position, the second position, the i-th position, ..., the N-th position. The first position is where the wires in the first column of slots are arranged, the second position is where the wires in the second column of slots are arranged, the i-th position is where the wires in the i-th column of slots are arranged, and the N-th position is where the wires in the N-th column of slots are arranged.

[0050] In each stator slot, the N columns of slot conductors in the same layer are closely adjacent to each other in the circumferential direction of the stator core, and the two outermost columns of slot conductors are respectively adjacent to the first sidewall and the second sidewall of the stator slot.

[0051] Specifically, when N > 2 and M > 2, for the arrangement of the N columns of slots in the first layer, firstly, the first column of slots of wires is inserted into the Nth position of the first layer in the stator slot through the slot opening 21 along the radial direction of the stator core. The first column of slots of wires in the first layer is set on the bottom wall of the stator slot and is adjacent to the bottom wall of the stator slot. Then, by external force, the first column of slots of wires is moved along the circumference of the stator core from the second side wall 22 to the first side wall 23 until it moves to the first position of the first layer and is adjacent to the first side wall 23. Then, the second column of slots of wires is inserted into the Nth position of the first layer in the stator slot through the slot opening 21 along the radial direction of the stator core. Then, by external force, the second column of slots of wires is moved along the circumference of the stator core from the second side wall 22 to the first side wall 23. The conductor is moved circumferentially from the second sidewall 22 to the first sidewall 23 until it reaches the second position of the first layer and is adjacent to the conductor in the first column of slots. Then, the conductor in the i-th column of slots is inserted radially into the stator slot at the N-th position of the first layer through slot 21, where 2 < i < N. Then, the conductor in the i-th column of slots is moved circumferentially from the second sidewall 22 to the first sidewall 23 along the stator core until it reaches the i-th position of the first layer and is adjacent to the conductor in the (i-1)-th column of slots. Finally, the conductor in the N-th column of slots is inserted radially into the stator slot at the N-th position of the first layer through slot 21, and is adjacent to the conductor in the (N-1)-th column of slots and the second sidewall 22. In the first layer, the N columns of conductors are closely adjacent to each other circumferentially in the stator core, and the two outermost columns of conductors are adjacent to the first sidewall 23 and the second sidewall 22, respectively.

[0052] After completing the wiring setup in the N columns of slots in the first layer, complete the wiring setup in the N columns of slots in the second layer along the radial direction of the stator core in the first layer. The wiring in the N columns of slots in the first layer is adjacent to the wiring in the N columns of slots in the second layer. For the arrangement of the N columns of slots in the second layer, firstly, the first column of slot wires is inserted into the Nth position of the second layer in the stator slot through slot opening 21 along the radial direction of the stator core. Then, by external force, the first column of slot wires is moved from the second sidewall 22 to the first sidewall 23 along the circumference of the stator core until it reaches the first position of the second layer and is adjacent to the first column of slot wires and the first sidewall 23 in the first layer. Next, the second column of slot wires is inserted into the Nth position of the second layer in the stator slot through slot opening 21 along the radial direction of the stator core. Then, by external force, the second column of slot wires is moved from the second sidewall 22 to the first sidewall 23 along the circumference of the stator core until it reaches the second position of the second layer and is adjacent to the first sidewall 23. The wire in the second slot of layer 1 and the wire in the first slot of layer 2 are adjacent to each other; then the wire in the i-th slot is inserted into the N-th position of the second layer in the stator slot through the slot opening 21 along the radial direction of the stator core, where 2 < i < N. Then, the wire in the i-th slot is moved from the second side wall 22 to the first side wall 23 along the circumference of the stator core by external force until it moves to the i-th position of the second layer and is adjacent to the wire in the (i-1)-th slot of the second layer and the wire in the i-th slot of the first layer; finally, the wire in the N-th slot is inserted into the N-th position of the second layer in the stator slot through the slot opening 21 along the radial direction of the stator core and is adjacent to the wire in the (N-1)-th slot of the second layer, the wire in the N-th slot of the first layer and the second side wall 22. In the second layer, the wires in the N columns of slots are closely adjacent to each other in the circumferential direction of the stator core, and the wires in the two outermost columns of slots are adjacent to the first sidewall 23 and the second sidewall 22, respectively.

[0053] The N columns of slot wires in each layer are set sequentially until the N columns of slot wires in the Mth layer are set. For the N columns of slot wires in the Mth layer, first, the first column of slot wires is inserted into the Nth position of the Mth layer in the stator slot through the slot opening 21 along the radial direction of the stator core. Then, the first column of slot wires is moved by external force along the circumference of the stator core from the second sidewall 22 to the first sidewall 23 until it moves to the first position of the Mth layer and is adjacent to the first column of slot wires and the first sidewall 23 in the (M-1)th layer. Next, the second column of slot wires is inserted into the Nth position of the Mth layer in the stator slot through the slot opening 21 along the radial direction of the stator core. Then, the second column of slot wires is moved by external force along the circumference of the stator core from the second sidewall 22 to the first sidewall 23 until it moves to the second position of the Mth layer and is adjacent to the first sidewall 23 in the (M-1)th layer. The wire in the second column of slots in layer M is adjacent to the wire in the first column of slots in layer M; then the wire in the i-th column of slots is inserted into the N-th position of layer M in the stator slot through slot 21 along the radial direction of the stator core, where 2 < i < N. Then, the wire in the i-th column of slots is moved from the second sidewall 22 to the first sidewall 23 along the circumference of the stator core by external force until it moves to the i-th position of layer M and is adjacent to the wire in the (i-1)-th column of slots in layer M and the wire in the i-th column of slots in layer M-1; finally, the wire in the N-th column of slots is inserted into the N-th position of layer M in the stator slot through slot 21 along the radial direction of the stator core and is adjacent to the wire in the (N-1)-th column of slots in layer M, the wire in the N-th column of slots in layer M-1 and the second sidewall 22. In the Mth layer, the N columns of slot conductors are closely adjacent to each other in the circumferential direction of the stator core, and the two outermost columns of slot conductors are adjacent to the first sidewall 23 and the second sidewall 22, respectively.

[0054] The following explanation uses a double-layer lap winding motor with N=2, M=2 as an example. Each slot layer contains four conductors arranged radially along the stator core, resulting in eight layers of conductors arranged radially along the stator core. For the arrangement of the conductors in the first layer (two columns), refer to... Figure 3 In steps (b), (c), and (d), firstly, the first row of slot conductors 31 is inserted radially into the stator core through slot opening 21 at the second position of the first layer within the stator slot, where the first layer is adjacent to the bottom wall 24. Then, by external force, the first row of slot conductors 31 is moved circumferentially along the stator core from the second side wall 22 towards the first side wall 23 until it reaches the first position of the first layer and is adjacent to the first side wall 23. Next, the second row of slot conductors 32 is inserted radially into the stator core through slot opening 21 at the second position of the first layer within the stator slot, adjacent to the first row of slot conductors 31 and the second side wall 22.

[0055] After completing the setup of one layer of lap windings, i.e., after completing the setup of the conductors in the two rows of slots in the first layer, continue along the radial direction of the stator core above the first layer to complete the setup of another layer of lap windings, i.e., complete the setup of the conductors in the two rows of slots in the second layer. For the setup of the conductors in the N rows of slots in the second layer, refer to... Figure 3 In steps (e), (f), and (g), firstly, the first column slot wire 33 is inserted radially into the second position of the second layer in the stator slot through slot opening 21. Then, by external force, the first column slot wire 33 is moved circumferentially from the second sidewall 22 to the first sidewall 23 along the stator core until it reaches the first position of the second layer and is adjacent to the first sidewall 23 and the first column slot wire 31 in the first layer. Next, the second column slot wire 34 is inserted radially into the second position of the second layer in the stator slot through slot opening 21, and it is adjacent to the first column slot wire 33 in the second layer, the second column slot wire 32 in the first layer, and the second sidewall 22.

[0056] In this embodiment, refer to Figure 3 and Figure 4 In the first layer, the first column of slot conductors 31 and the second column of slot conductors 32 are respectively the first slot conductors of winding 41 and winding 42, or the second slot conductors of winding 42 and winding 41. In the second layer, the first column of slot conductors 33 and the second column of slot conductors 34 are respectively the first slot conductors of winding 41 and winding 42, or the second slot conductors of winding 42 and winding 41. (Refer to...) Figure 3 and Figure 5 In the first layer, the first column slot conductor 31 and the second column slot conductor 32 are respectively the first slot conductor of winding 52 and the first slot conductor of winding 51, or the second slot conductor of winding 52 and the second slot conductor of winding 51. In the second layer, the first column slot conductor 33 and the second column slot conductor 34 are respectively the first slot conductor of winding 52 and the first slot conductor of winding 51, or the second slot conductor of winding 52 and the second slot conductor of winding 51.

[0057] Furthermore, the prefabrication of multiple winding units in step S1 includes winding wires according to a predetermined winding shape, and then solidifying the wound wires into a winding unit through an integral molding and curing process, thereby prefabricating multiple winding units. In this embodiment, the winding unit can be constructed by first winding a multi-turn coil with wires, and then sequentially winding another multi-turn coil with wires around the already wound multi-turn coil, until N multi-turn coils are completed with wires. These multi-turn coils are interconnected, and the number of turns is selected according to actual needs. The multi-turn coils are solidified into a winding through an integral molding and curing process. Multi-turn coils can eliminate the risk of inter-turn insulation quality issues caused by secondary twisting and welding at the ends of each coil, and only require a few welding points between the parallel branches of the winding and the bridging wires, simplifying the manufacturing process.

[0058] Furthermore, the conductor in the slot includes at least one flat wire, or at least one round wire, or a combination of flat and round wires. Specifically, the winding can be made of flat wire, or round wire, or a combination of flat and round wires.

[0059] Furthermore, the winding unit may be a wire stack winding formed by winding wires according to a predetermined winding shape. In other embodiments, the winding unit may be a wire wave winding formed by winding wires according to a predetermined winding shape.

[0060] In this embodiment, when the winding unit is a wire lap winding, the wires in the slot of the wire lap winding are sequentially embedded into the corresponding stator slots through the slot openings, and the wires in the i-th column of the slot are embedded into the corresponding layer in the stator slot and moved along the circumference of the stator core, where 1≤i<N; then the wires in the N-th column of the slot are embedded into the corresponding layer in the stator slot.

[0061] When the winding unit is a conductor wave winding, before step S2, the plurality of conductor wave windings are arranged and combined according to a preset arrangement. Then, the conductors in the slots of the conductor wave windings are sequentially embedded into the corresponding stator slots through the slot openings, and the conductors in the i-th column of slots are embedded into the corresponding layer in the stator slot, and moved along the circumference of the stator core, where 1≤i<N; then, the conductors in the N-th column of slots are embedded into the corresponding layer in the stator slot.

[0062] In other embodiments, the slot conductors of multiple winding units can be synchronously wound and embedded into the corresponding stator slots by a machine along the radial or axial direction of the stator core.

[0063] Furthermore, prior to step S2, insulating paper is adhered to the inner wall of each stator slot. Specifically, insulating paper is adhered to the first side wall, second side wall, and bottom wall of each stator slot. This isolates the conductors within the slot from the stator slot, preventing grounding breakdown or leakage between the conductors and the stator core.

[0064] Furthermore, the sealing plate 4 is used to seal the slot opening 21 of the stator slot. Specifically, as shown... Figure 3 As shown in (h), the sealing plate 4 is sealed in the slot opening 21 and held in place by the groove 232 and the protrusion 231, thus sealing the conductors inside the slot within the stator slot. This resists the enormous electromagnetic force, vibration, and centrifugal force exerted during the operation of the split-wire motor, preventing the conductors from loosening or being thrown out. The sealing plate is made of insulating material, which increases the insulation strength of the conductors inside the slot to the stator core.

[0065] Furthermore, each row of slot conductors includes multiple conductors arranged radially along the stator core, such as... Figure 3 As shown in (g), the conductors 31 in the first row of slots in the first layer include conductors a1, b1, c1 and d1 arranged in sequence along the radial direction of the stator core; the conductors 32 in the second row of slots in the first layer include conductors a2, b2, c2 and d2 arranged in sequence along the radial direction of the stator core; the conductors 33 in the first row of slots in the second layer include conductors e1, f1, g1 and h1 arranged in sequence along the radial direction of the stator core; and the conductors 34 in the second row of slots in the second layer include conductors e2, f2, g2 and h2 arranged in sequence along the radial direction of the stator core. As can be seen, the conductors in each slot are divided into 4 layers along the radial direction of the stator core, resulting in 8 layers and 2 columns of conductors in the stator slot, forming an 8×2 conductor array. This allows for a large range of adjustment of the number of turns in the stator winding of the split-conductor motor, flexible design, and easy standardization and serialization of the design of split-conductor motors of the same specification. It can also reduce the skin effect and proximity effect of the winding.

[0066] The manufacturing method of this application can embed the wires in the pre-formed multiple winding units into the stator slots along the radial direction of the stator core, resulting in fewer solder joints and easier assurance of product quality. In addition, the M×N slot wire array in the stator slots allows for a large adjustment range of the number of turns of the wire motor, making the design flexible and easy to achieve the generalization and serialization of the design of wire motors of the same specification. It can also reduce the skin effect and proximity effect of the windings.

[0067] This application also provides a stator for a motor with split conductors, such as... Figure 6 , Figure 7 , Figure 8 and Figure 9 As shown, the stator of the split-conductor motor includes a stator core and a stator winding. The stator core is annular and has multiple stator slots along its circumference. The slot opening of each stator slot is semi-open.

[0068] The stator winding includes multiple winding units, and the slot conductors of the multiple winding units are arranged in the corresponding stator slots, such that each stator slot has M layers of slot conductors along the radial direction of the stator core and N columns of slot conductors along the circumference of the stator core, forming an M×N slot conductor array, where M≥2 and N≥2.

[0069] Furthermore, within each stator slot, N columns of slot conductors in the same layer are closely adjacent to each other in the circumferential direction of the stator core, and the two outermost columns of slot conductors are respectively adjacent to the first sidewall and the second sidewall.

[0070] Furthermore, each winding unit includes a first slot conductor group and a second slot conductor group, and the first slot conductor group and the second slot conductor group of each winding unit are respectively disposed in two different stator slots and located in different layers within the two different stator slots.

[0071] In this embodiment, each winding unit includes N windings, and each winding includes a first slot conductor and a second slot conductor. The first slot conductors of the N windings are arranged side-by-side along the circumference of the stator core to form a first slot conductor group, and the second slot conductors of the N windings are arranged side-by-side along the circumference of the stator core to form a second slot conductor group. That is, the first slot conductor group includes N columns of slot conductors arranged side-by-side along the circumference of the stator core, and the second slot conductor group includes N columns of slot conductors arranged side-by-side along the circumference of the stator core.

[0072] Furthermore, in the stator slots where the first slot conductor group is located, the N columns of first slot conductors are arranged side-by-side in a first order; in the stator slots where the second slot conductor group is located, the N columns of second slot conductors are arranged side-by-side in a second order. Specifically, when multiple windings are arranged concentrically, in the stator slots where the first slot conductors of the N winding units are located, the N columns of first slot conductors are arranged along the circumference of the stator core from the side wall near the slot opening to the side wall away from the slot opening in the following order: first slot conductor of the Nth winding, first slot conductor of the (N-1)th winding, ..., first slot conductor of the 1st winding. In the stator slots where the second slot conductors of the N windings are located, the N columns of second slot conductors are arranged along the circumference of the stator core from the side wall near the slot opening to the side wall away from the slot opening in the following order: second slot conductor of the 1st winding, second slot conductor of the 2nd winding, ..., second slot conductor of the Nth winding. In other embodiments, when multiple windings are arranged in parallel according to the end-torsion conversion method, in the stator slots where the N winding units have first slot conductors, the N columns of first slot conductors are arranged in the following order along the circumference of the stator core from the side wall near the slot opening to the side wall away from the slot opening: the first slot conductor of the Nth winding, the first slot conductor of the (N-1)th winding, ..., the first slot conductor of the 1st winding. In the stator slots where the N winding units have second slot conductors, the N columns of second slot conductors are arranged in the following order along the circumference of the stator core from the side wall near the slot opening to the side wall away from the slot opening: the second slot conductor of the Nth winding, the second slot conductor of the (N-1)th winding, ..., the second slot conductor of the 1st winding.

[0073] Taking phase A of a nine-phase motor with split conductors and double-layer lap windings as an example, such as Figure 6 and 7As shown, in a nine-phase motor, the stator core includes 54 stator slots, and multiple winding units are arranged within these slots, with a span of 9. Each phase stator winding includes 6 winding units. The first winding unit's first slot conductor group is arranged in the first layer within the first stator slot; the second winding unit's first slot conductor group is arranged in the first layer within the tenth stator slot, and the first winding unit's second slot conductor group is arranged in the second layer within the tenth stator slot; the third winding unit's first slot conductor group is arranged in the first layer within the nineteenth stator slot, and the second winding unit's second slot conductor group is arranged in the second layer within the nineteenth stator slot; the fourth winding unit's first slot conductor group is arranged in the twenty-eighth stator slot. The first layer of the conductor group in the first slot of the third winding unit is located in the second layer of the 28th stator slot. The first layer of the conductor group in the first slot of the fifth winding unit is located in the first layer of the 37th stator slot. The second layer of the conductor group in the second slot of the fourth winding unit is located in the second layer of the 37th stator slot. The first layer of the conductor group in the first slot of the sixth winding unit is located in the first layer of the 46th stator slot. The second layer of the conductor group in the second slot of the fifth winding unit is located in the second layer of the 46th stator slot. The second layer of the conductor group in the second slot of the sixth winding unit is located in the second layer of the first stator slot.

[0074] As can be seen, the first slot conductor group and the second slot conductor group of each winding unit are respectively arranged in two stator slots and are located in the upper and lower layers of the two different stator slots. Taking the first winding unit as an example, the first slot conductor group of the first winding unit is arranged in the first layer in the first stator slot, while the second slot conductor group of the first winding unit is arranged in the second layer in the tenth stator slot.

[0075] Each winding unit comprises two windings. The second winding is directly fitted outside the first winding, or the two windings are arranged side-by-side according to the end torsion configuration. The first slot conductors of the two windings are located in the same stator slot, and the second slot conductors of the two windings are located in another stator slot. In the stator slot with two rows of first slot conductors, the first slot conductors of the second winding and the first slot conductors of the first winding are arranged side-by-side along the circumference of the stator core, from the side wall near the slot opening to the side wall away from the slot opening. In the stator slot with two rows of second slot conductors, the second slot conductors of the first winding and the second slot conductors of the second winding are arranged side-by-side along the circumference of the stator core, from the side wall near the slot opening to the side wall away from the slot opening.

[0076] Each stator slot has a second slot conductor group for one of two adjacent winding units and a first slot conductor group for the other winding unit in its upper and lower layers. Taking the 10th stator slot as an example, the second layer of the 10th stator slot has the second slot conductor group for the first winding unit, while the first layer of the 10th stator slot has the first slot conductor group for the second winding unit.

[0077] Combination Figure 6 and Figure 7 The in-slot conductors are divided into upper and lower layers radially along the stator core and arranged in two columns circumferentially along the stator core, thus forming a 2×2 in-slot conductor array. Specifically, the first layer in the 10th stator slot has two columns of first in-slot conductors A1 and A2 arranged side-by-side, and the second layer in the 10th stator slot has two columns of second in-slot conductors E1 and E2 arranged side-by-side. The first in-slot conductors A1 and A2 are the first in-slot conductors of the two windings in the second winding unit, and the second in-slot conductors E1 and E2 are the second in-slot conductors of the two windings in the first winding unit.

[0078] Both windings are multi-turn coils, meaning that the conductors in each row of slots include multiple conductors arranged in parallel along the radial direction of the stator core. The conductor A1 in the first row of slot 1 includes conductors a1, b1, c1, and d1 arranged in parallel along the radial direction of the stator core; the conductor E1 in the second row of slot 1 includes conductors e1, f1, g1, and h1 arranged in parallel along the radial direction of the stator core; the conductor A2 in the first row of slot 2 includes conductors a2, b2, c2, and d2 arranged in parallel along the radial direction of the stator core; and the conductor E2 in the second row of slot 2 includes conductors e2, f2, g2, and h2 arranged in parallel along the radial direction of the stator core.

[0079] It can be seen that forming an 8×2 conductor array in the stator slot 10 makes the number of turns of the split-wire motor have a large adjustment range, flexible design, and makes it easy to achieve the generalization and serialization of the design of split-wire motors of the same specification. It can also reduce the skin effect and proximity effect of the winding.

[0080] Furthermore, each winding unit includes multiple slot conductor groups located in multiple different stator slots, and two adjacent slot conductor groups are located in different layers in two different stator slots. Each slot conductor group includes N columns of slot conductors arranged side by side along the circumference of the stator core.

[0081] Taking phase A of a three-phase motor with its split conductor wave windings as an example, such as Figure 8 and Figure 9As shown, in this three-phase motor, the stator core includes 48 stator slots, and the winding unit span is 6. Each phase stator winding includes 12 winding units. The first winding unit's first slot conductor group is arranged in the first layer of the first stator slot, the second winding unit's second slot conductor group is arranged in the second layer of the seventh stator slot, the third winding unit's third slot conductor group is arranged in the first layer of the thirteenth stator slot, the fourth winding unit's fourth slot conductor group is arranged in the second layer of the nineteenth stator slot, the fifth winding unit's fifth slot conductor group is arranged in the first layer of the 25th stator slot, the sixth winding unit's sixth slot conductor group is arranged in the second layer of the 31st stator slot, the seventh winding unit's seventh slot conductor group is arranged in the first layer of the 37th stator slot, and the eighth winding unit's eighth slot conductor group is arranged in the second layer of the 43rd stator slot.

[0082] The first slot conductor group of the second winding unit is located in the first layer of the 7th stator slot; the second slot conductor group of the second winding unit is located in the second layer of the 13th stator slot; the third slot conductor group of the second winding unit is located in the first layer of the 19th stator slot; the fourth slot conductor group of the second winding unit is located in the second layer of the 25th stator slot; the fifth slot conductor group of the second winding unit is located in the first layer of the 31st stator slot; the sixth slot conductor group of the second winding unit is located in the second layer of the 37th stator slot; the seventh slot conductor group of the second winding unit is located in the first layer of the 43rd stator slot; and the eighth slot conductor group of the second winding unit is located in the second layer of the first stator slot.

[0083] The first slot conductor group of the third winding unit is located in the third layer of the first stator slot; the second slot conductor group of the third winding unit is located in the fourth layer of the seventh stator slot; the third slot conductor group of the third winding unit is located in the third layer of the thirteenth stator slot; the fourth slot conductor group of the third winding unit is located in the fourth layer of the nineteenth stator slot; the fifth slot conductor group of the third winding unit is located in the third layer of the 25th stator slot; the sixth slot conductor group of the third winding unit is located in the fourth layer of the 31st stator slot; the seventh slot conductor group of the third winding unit is located in the third layer of the 37th stator slot; and the eighth slot conductor group of the third winding unit is located in the fourth layer of the 43rd stator slot.

[0084] The first slot conductor group of the fourth winding unit is located in the third layer of the seventh stator slot; the second slot conductor group of the fourth winding unit is located in the fourth layer of the thirteenth stator slot; the third slot conductor group of the fourth winding unit is located in the third layer of the 19th stator slot; the fourth slot conductor group of the fourth winding unit is located in the fourth layer of the 25th stator slot; the fifth slot conductor group of the fourth winding unit is located in the third layer of the 31st stator slot; the sixth slot conductor group of the fourth winding unit is located in the fourth layer of the 37th stator slot; the seventh slot conductor group of the fourth winding unit is located in the third layer of the 43rd stator slot; and the eighth slot conductor group of the fourth winding unit is located in the fourth layer of the first stator slot.

[0085] The first slot conductor group of the 5th winding unit is located in the 5th layer of the 1st stator slot; the second slot conductor group of the 3rd winding unit is located in the 6th layer of the 7th stator slot; the third slot conductor group of the 5th winding unit is located in the 5th layer of the 13th stator slot; the fourth slot conductor group of the 5th winding unit is located in the 6th layer of the 19th stator slot; the fifth slot conductor group of the 5th winding unit is located in the 5th layer of the 25th stator slot; the sixth slot conductor group of the 5th winding unit is located in the 6th layer of the 31st stator slot; the seventh slot conductor group of the 5th winding unit is located in the 5th layer of the 37th stator slot; and the eighth slot conductor group of the 5th winding unit is located in the 6th layer of the 43rd stator slot.

[0086] The first slot conductor group of the 6th winding unit is located in the 5th layer of the 7th stator slot; the second slot conductor group of the 6th winding unit is located in the 6th layer of the 13th stator slot; the third slot conductor group of the 6th winding unit is located in the 5th layer of the 19th stator slot; the fourth slot conductor group of the 6th winding unit is located in the 6th layer of the 25th stator slot; the fifth slot conductor group of the 6th winding unit is located in the 5th layer of the 31st stator slot; the sixth slot conductor group of the 6th winding unit is located in the 6th layer of the 37th stator slot; the seventh slot conductor group of the 6th winding unit is located in the 5th layer of the 43rd stator slot; and the eighth slot conductor group of the 6th winding unit is located in the 6th layer of the 1st stator slot.

[0087] The first slot conductor group of the 7th winding unit is set in the first layer in the second stator slot; the second slot conductor group of the 7th winding unit is set in the second layer in the eighth stator slot; the third slot conductor group of the 7th winding unit is set in the first layer in the fourteenth stator slot; the fourth slot conductor group of the 7th winding unit is set in the second layer in the 20th stator slot; the fifth slot conductor group of the 7th winding unit is set in the first layer in the 26th stator slot; the sixth slot conductor group of the 7th winding unit is set in the second layer in the 32nd stator slot; the seventh slot conductor group of the 7th winding unit is set in the first layer in the 38th stator slot; and the eighth slot conductor group of the 7th winding unit is set in the second layer in the 44th stator slot.

[0088] The first slot conductor group of the 8th winding unit is set in the first layer of the 8th stator slot; the second slot conductor group of the 2nd winding unit is set in the second layer of the 14th stator slot; the third slot conductor group of the 8th winding unit is set in the first layer of the 20th stator slot; the fourth slot conductor group of the 8th winding unit is set in the second layer of the 26th stator slot; the fifth slot conductor group of the 8th winding unit is set in the first layer of the 32nd stator slot; the sixth slot conductor group of the 8th winding unit is set in the second layer of the 38th stator slot; the seventh slot conductor group of the 8th winding unit is set in the first layer of the 44th stator slot; and the eighth slot conductor group of the 8th winding unit is set in the second layer of the 2nd stator slot.

[0089] The first slot conductor group of the 9th winding unit is located in the 3rd layer in the 2nd stator slot; the second slot conductor group of the 9th winding unit is located in the 4th layer in the 8th stator slot; the third slot conductor group of the 9th winding unit is located in the 3rd layer in the 14th stator slot; the fourth slot conductor group of the 9th winding unit is located in the 4th layer in the 20th stator slot; the fifth slot conductor group of the 9th winding unit is located in the 3rd layer in the 26th stator slot; the sixth slot conductor group of the 9th winding unit is located in the 4th layer in the 32nd stator slot; the seventh slot conductor group of the 9th winding unit is located in the 3rd layer in the 38th stator slot; and the eighth slot conductor group of the 9th winding unit is located in the 4th layer in the 44th stator slot.

[0090] The first slot conductor group of the 10th winding unit is located in the 3rd layer in the 8th stator slot; the second slot conductor group of the 10th winding unit is located in the 4th layer in the 14th stator slot; the third slot conductor group of the 10th winding unit is located in the 3rd layer in the 20th stator slot; the fourth slot conductor group of the 10th winding unit is located in the 4th layer in the 26th stator slot; the fifth slot conductor group of the 10th winding unit is located in the 3rd layer in the 32nd stator slot; the sixth slot conductor group of the 10th winding unit is located in the 4th layer in the 38th stator slot; the seventh slot conductor group of the 10th winding unit is located in the 3rd layer in the 44th stator slot; and the eighth slot conductor group of the 10th winding unit is located in the 4th layer in the 2nd stator slot.

[0091] The first slot conductor group of the 11th winding unit is located in the 5th layer of the 2nd stator slot; the second slot conductor group of the 11th winding unit is located in the 6th layer of the 8th stator slot; the third slot conductor group of the 11th winding unit is located in the 5th layer of the 14th stator slot; the fourth slot conductor group of the 11th winding unit is located in the 6th layer of the 20th stator slot; the fifth slot conductor group of the 11th winding unit is located in the 5th layer of the 26th stator slot; the sixth slot conductor group of the 11th winding unit is located in the 6th layer of the 32nd stator slot; the seventh slot conductor group of the 11th winding unit is located in the 5th layer of the 38th stator slot; and the eighth slot conductor group of the 11th winding unit is located in the 6th layer of the 44th stator slot.

[0092] The first slot conductor group of the 12th winding unit is located in the 5th layer of the 8th stator slot; the second slot conductor group of the 12th winding unit is located in the 6th layer of the 14th stator slot; the third slot conductor group of the 12th winding unit is located in the 5th layer of the 20th stator slot; the fourth slot conductor group of the 12th winding unit is located in the 6th layer of the 26th stator slot; the fifth slot conductor group of the 12th winding unit is located in the 5th layer of the 32nd stator slot; the sixth slot conductor group of the 12th winding unit is located in the 6th layer of the 38th stator slot; the seventh slot conductor group of the 12th winding unit is located in the 5th layer of the 44th stator slot; and the eighth slot conductor group of the 12th winding unit is located in the 6th layer of the 2nd stator slot.

[0093] As can be seen, the multiple slot conductor groups of each winding unit are located in multiple different stator slots, and adjacent slot conductor groups are located in different layers within two different stator slots. Each slot conductor group includes N columns of slot conductors arranged side-by-side along the circumference of the stator core. Taking the first winding unit as an example, the first slot conductor group of the first winding unit is located in the first layer in the first stator slot, the second slot conductor group of the first winding unit is located in the second layer in the seventh stator slot, the third slot conductor group of the first winding unit is located in the first layer in the thirteenth stator slot, and so on. Each stator slot has 6 layers of slot conductor groups arranged side-by-side along the radial direction of the stator core. In this embodiment, each slot conductor includes one conductor.

[0094] Each winding unit consists of two windings. The second winding is sleeved around the outside of the first winding unit along the circumference of the stator core, or the two windings are arranged in parallel according to the end torsion shifting method.

[0095] Taking stator slot 7 as an example, the first layer of stator slot 7 has the first slot conductor group of the second winding unit, the second layer has the second slot conductor group of the first winding unit, the third layer has the first slot conductor group of the fourth winding unit, the fourth layer has the second slot conductor group of the third winding unit, the fifth layer has the first slot conductor group of the sixth winding unit, and the sixth layer has the second slot conductor group of the fifth winding unit. The slot conductor group in the first layer includes slot conductors a1 and a2 arranged side by side along the circumference of the stator core, where slot conductor a1 is the first slot conductor of the first winding in the second winding unit, and slot conductor a2 is the first slot conductor of the second winding in the second winding unit.

[0096] The second layer of slot conductor group includes slot conductors b1 and b2 arranged in parallel along the circumference of the stator core, wherein slot conductor b1 is the second slot conductor of the second winding in the first winding unit, and slot conductor b2 is the second slot conductor of the first winding in the first winding unit.

[0097] The third layer of slot conductor group includes slot conductors c1 and c2 arranged in parallel along the circumference of the stator core, wherein slot conductor c1 is the first slot conductor of the first winding in the fourth winding unit, and slot conductor c2 is the first slot conductor of the second winding in the fourth winding unit.

[0098] The fourth layer of slot conductor group includes slot conductors d1 and d2 arranged in parallel along the circumference of the stator core. Slot conductor d1 is the second slot conductor of the second winding in the third winding unit, and slot conductor d2 is the second slot conductor of the first winding in the third winding unit.

[0099] The fifth layer of slot conductor group includes slot conductors e1 and e2 arranged in parallel along the circumference of the stator core, wherein slot conductor e1 is the first slot conductor of the first winding in the sixth winding unit, and slot conductor e2 is the first slot conductor of the second winding in the sixth winding unit.

[0100] The sixth layer of slot conductor group includes slot conductors f1 and f2 arranged in parallel along the circumference of the stator core. Slot conductor f1 is the second slot conductor of the second winding in the fifth winding unit, and slot conductor f2 is the second slot conductor of the first winding in the fifth winding unit.

[0101] As can be seen, the 6×2 slot conductor array in the stator slot 7 enables the number of turns adjustment range of the split-wire motor to be large, the design to be flexible, and it is easy to realize the generalization and serialization of the design of split-wire motors of the same specification. It can also reduce the skin effect and proximity effect of the winding.

[0102] The above-mentioned staggered arrangement of the split conductor wave windings is not unique. In order to simplify the production process, other embodiments may also adopt a staggered arrangement of more than two layers of split conductor wave windings.

[0103] Furthermore, the conductor in the slot includes at least one flat wire, or at least one round wire, or a combination of flat and round wires. Specifically, the winding can be made of flat wire, or round wire, or a combination of flat and round wires.

[0104] Furthermore, the winding unit includes N interconnected windings, which are arranged concentrically, with the winding with the largest pitch located in the outermost layer and the winding with the smallest pitch located in the innermost layer.

[0105] Furthermore, the winding unit includes N interconnected windings, which are arranged in parallel according to the end torsion shifting method, so that the pitch of the N windings is the same.

[0106] Furthermore, the stator of the split-lead motor also includes insulating paper that adheres to the inner wall of the stator slot. The stator of the split-lead motor also includes a sealing member that seals the opening of the stator slot.

[0107] The manufacturing method of the stator winding of the split-wire motor and the stator of the split-wire motor are described. By radially embedding the in-slot wires of multiple prefabricated winding units into the semi-open stator slots, fewer solder joints are required, making it easier to ensure product quality. In addition, the M×N in-slot wire array in the stator slots allows for a large range of turns adjustment in the split-wire motor, making the design flexible and easy to achieve the standardization and serialization of split-wire motors of the same specification. It can also reduce the skin effect and proximity effect of the windings. The semi-open slots of the stator slots can suppress cogging torque, thereby comprehensively improving the performance, reliability and production efficiency of the motor.

[0108] It should be noted that this embodiment mainly uses flat wire as the conductor, but in practical applications, flat wire and conductor can be used interchangeably. Similarly, conductors of other shapes or structures can also be used. For example, a conductor can be composed of multiple flat wires or other shaped conductors, such as one or more round wires. These flat or round conductors can be laid out loosely or pre-arranged.

[0109] Although embodiments of the present application and their advantages have been described in detail, it should be understood that various changes, substitutions and alterations may be made herein without departing from the spirit and scope of the present application as defined by the appended claims.

[0110] Furthermore, the scope of this application is not limited to the specific embodiments of the processes, machines, manufactures, compositions of matter, methods, and steps described herein. Those skilled in the art will readily understand from the disclosure of this application that, according to this application, currently existing or to be developed processes, machines, manufactures, compositions of matter, methods, or steps that perform substantially the same function or achieve substantially the same results as the corresponding embodiments described herein can be utilized. Therefore, it is intended that the appended claims encompass such processes, machines, manufactures, compositions of matter, methods, or steps within their scope.

Claims

1. A method for manufacturing a stator winding of a split-conductor motor, characterized in that, The stator of the split-conductor motor includes a stator core, the stator core being annular and having multiple stator slots along its circumference; the manufacturing method includes: S1: Prefabricated multiple winding units; S2: The slot conductors of the multiple winding units are respectively embedded into the corresponding stator slots, such that the slot conductors in each stator slot are arranged in M ​​layers along the radial direction of the stator core and in N columns along the circumference of the stator core to form an M×N slot conductor array, where M≥2 and N≥2. The arrangement of the wires in the N columns of the slots in each layer is performed according to the following steps: S21: Embed the wire in the slot of column i into the corresponding layer in the stator slot, and move it along the circumference of the stator core, where 1≤i<N; S22: Embed the wire in the slot of column N into the corresponding layer in the stator slot.

2. The method of manufacturing a stator winding for a fractional-slot conductor motor of claim 1, wherein, The stator slot includes a first sidewall and a second sidewall disposed opposite to each other, and a bottom wall connecting the first sidewall and the second sidewall. The first sidewall has a protrusion extending toward the second sidewall, and the protrusion and the second sidewall define the slot opening of the stator slot. Step S21, which involves embedding the wire in the i-th column of the slot into the corresponding layer of the stator slot and moving it along the circumference of the stator core, includes embedding the wire in the i-th column of the slot into the corresponding layer of the stator slot at the Nth position through the slot opening along the radial direction of the stator core, and moving it along the circumference of the stator core from the second sidewall to the first sidewall until it moves to the i-th position of the corresponding layer. Step S22, which involves embedding the Nth column of the slot wire into the corresponding layer of the stator slot, includes embedding the Nth column of the slot wire into the Nth position of the corresponding layer of the stator slot through the slot opening along the radial direction of the stator core.

3. The method for manufacturing a stator winding of a split-conductor motor according to claim 2, characterized in that, In each stator slot, N columns of slot conductors in the same layer are closely adjacent to each other in the circumferential direction of the stator core, and the two outermost columns of slot conductors are respectively adjacent to the first sidewall and the second sidewall.

4. The method for manufacturing a stator winding of a split-conductor motor according to claim 1, characterized in that, The prefabrication of multiple winding units in step S1 includes winding wires according to a predetermined winding shape and solidifying the wound wires into a winding unit through an integral molding and curing process.

5. The method for manufacturing a stator winding of a split-conductor motor according to claim 1, characterized in that, The winding unit includes N interconnected windings, which are arranged concentrically, with the winding with the largest pitch located in the outermost layer and the winding with the smallest pitch located in the innermost layer.

6. The method for manufacturing a stator winding of a split-conductor motor according to claim 1, characterized in that, The winding unit includes N interconnected windings, which are arranged in parallel according to the end torsion shifting method, so that the pitch of the N windings is the same.

7. The method for manufacturing a stator winding of a split-conductor motor according to claim 1, characterized in that, Before step S2, the process also includes attaching insulating paper to the inner wall of each of the stator slots.

8. The method for manufacturing a stator winding of a split-conductor motor according to claim 1, characterized in that, The slotted conductors include multiple conductors arranged radially along the stator core.

9. The method for manufacturing a stator winding of a split-conductor motor according to claim 1, characterized in that, The winding unit is a wire lap winding or a wire wave winding.

10. The method for manufacturing a stator winding of a split-conductor motor according to claim 9, characterized in that, When the winding unit is a conductor wave winding, before step S2, the plurality of conductor wave windings are arranged and combined according to a preset arrangement and combination method.

11. The method for manufacturing a stator winding of a split-conductor motor according to claim 1, characterized in that, The conductor in the slot includes at least one flat wire, or at least one round wire, or a combination of flat and round wires.

12. A stator for a split-conductor motor, characterized in that, include: The stator core is annular and has multiple stator slots along its circumference, and each stator slot has a semi-open slot opening. The stator winding includes multiple winding units, and the slot conductors of the multiple winding units are arranged in the corresponding stator slots, such that each stator slot has M layers of slot conductors along the radial direction of the stator core and N columns of slot conductors along the circumference of the stator core, forming an M×N slot conductor array, where M≥2 and N≥2.

13. The stator of the split-conductor motor according to claim 12, characterized in that, The stator slot includes a first sidewall and a second sidewall disposed opposite to each other, and a bottom wall connecting the first sidewall and the second sidewall. The first sidewall has a protrusion extending toward the second sidewall, and the protrusion and the second sidewall define the slot opening of the stator slot.

14. The stator of the split-conductor motor according to claim 13, characterized in that, In each stator slot, N columns of slot conductors in the same layer are closely adjacent to each other in the circumferential direction of the stator core, and the two outermost columns of slot conductors are respectively adjacent to the first sidewall and the second sidewall.

15. The stator of a split-conductor motor according to claim 12, characterized in that, Each winding unit includes a first slot conductor group and a second slot conductor group, which are respectively disposed in two different stator slots and located in different layers within the two different stator slots. The first slot conductor group includes N columns of slot conductors arranged in parallel along the circumference of the stator core, and the second slot conductor group includes N columns of slot conductors arranged in parallel along the circumference of the stator core.

16. The stator of the split-conductor motor according to claim 15, characterized in that, In a stator slot equipped with the first slot conductor group, the N columns of slot conductors are arranged in parallel in a first order; in a stator slot equipped with the second slot conductor group, the N columns of slot conductors are arranged in parallel in a second order.

17. The stator of a split-conductor motor according to claim 15, characterized in that, Each stator slot has two adjacent layers, each with a second slot conductor group of one of the two adjacent winding units and a first slot conductor group of the other winding unit.

18. The stator of a split-conductor motor according to claim 12, characterized in that, Each winding unit includes multiple slot conductor groups located in multiple different stator slots, and two adjacent slot conductor groups are located in different layers in two different stator slots. Each slot conductor group includes N columns of slot conductors arranged side by side along the circumference of the stator core.

19. The stator of the split-conductor motor according to claim 12, characterized in that, It also includes insulating paper that adheres to the inner wall of the stator slot and a sealing member that seals the slot opening.

20. The stator of a split-conductor motor according to claim 12, characterized in that, The winding unit includes N interconnected windings, which are arranged concentrically, with the winding with the largest pitch located in the outermost layer and the winding with the smallest pitch located in the innermost layer.

21. The stator of the split-conductor motor according to claim 12, characterized in that, The winding unit includes N interconnected windings, which are arranged in parallel according to the end torsion shifting method, so that the pitch of the N windings is the same.

Images