A winding method of a flat wire double-winding stator and a double-winding stator

Abstract

The application relates to the field of electric machines, in particular to a winding method of a flat wire double-winding stator and a double-winding stator, which adopts flat wire double winding to greatly improve the working efficiency of the double-winding electric machine, the electric machine is smaller in size, and the power density is improved; the flat wire is uniformly subjected to specific cross-wire rules for the same-slot double winding, the two windings can operate simultaneously, the potential is completely consistent and symmetrical, and the phase is 0, the efficiency of the double-winding electric machine is greatly improved; moreover, the winding method makes the welding end of the stator core after winding very regular, is beneficial to automatic production, can realize the same-slot same-phase, avoids the situation that the instantaneous currents are opposite under the same-slot different-phase, does not need to increase the inter-phase insulation, optimizes the automatic process, and is more suitable for the high-voltage requirement of the electric machine in insulation.

Description

Technical Field

[0001] This invention relates to the field of electric motors, specifically to a winding method for a flat wire double-winding stator and a double-winding stator. Background Technology

[0002] In recent years, in pursuit of charging efficiency, new energy electric vehicles have further increased the DC-side voltage of their drive systems. This necessitates improving the voltage withstand capability of various components in the drive motor system, which inevitably increases costs for traditional systems. Currently, the solution of using an inverter cascade drive control system to connect multiple low-voltage inverters in series on the DC side is a better approach that balances high voltage withstand capability and low cost. To match such systems, the traditional main drive motor needs to be split into two low-voltage motors of equal capacity or a dual-winding low-voltage motor solution. Compared to the adjustment of the transmission input structure at the transmission end caused by splitting the motor, the dual-winding solution does not bring about a major change in the system's spatial layout and is a better option.

[0003] There are precedents for the application of dual-winding stator motor technology in new energy drive motors, but it is limited to scattered round wire windings. For this type of dual-winding motor, the motor efficiency is low and the size is large, which makes it difficult to meet the current needs for high efficiency and high power density of motors. Moreover, the scattered round wire dual windings are messy, making it difficult to ensure that the phase of the same slot is the same. In terms of magnetomotive force, it is impossible to achieve complete symmetry and zero phase, which is not conducive to automated production. Summary of the Invention

[0004] The technical problem this application aims to solve is to provide a method for winding a flat wire double-winding stator with regular and high efficiency, and a double-winding stator. By unifying the flat wires with a specific cross-wire rule to form double windings in the same slot, the two windings can operate simultaneously, achieving completely consistent and symmetrical potentials with zero phase, thus significantly improving the efficiency of the double-winding motor.

[0005] The specific technical solution of this application is as follows: a winding method for a flat wire double-winding stator, wherein the flat wire double-winding stator includes a stator core, and the winding method for the flat wire double-winding stator includes the following steps: S1. Select a stator core with M slots, P pole pairs, and N layers. The slot pitch of the stator core is M / 2P. S2. Establish the rules for bridging flat wires: The innermost layer of the stator core is the first layer, and all bridging in the first layer is based on a pitch of M / 2P-1; the outermost layer of the stator core is the Nth layer, and all bridging in the Nth layer is based on a pitch of M / 2P+1; the rest are intermediate layers, and all intermediate layers are based on a pitch of M / 2P. S3. Different phases of the two windings are selected for different slots for wire input, and bridging is performed according to the flat wire bridging rule described in S2, so as to finally obtain a flat wire double winding stator with a phase difference of 0 between the two windings.

[0006] Preferably, different phases of the same winding are selected to have slots with pitches separated by M / 2P-2.

[0007] Preferably, different phases of the same winding are selected to have slots with a pitch interval of M / 2P.

[0008] Preferably, the same phase of different windings is fed into adjacent slots.

[0009] Preferably, the same phase of different windings is selected to exit from slot M / P+1.

[0010] More preferably, N is 4, and the incoming line comes from the second layer of the corresponding slot.

[0011] More preferably, N is 4, and the wires emerge from the third layer of the corresponding slot.

[0012] Preferably, N is 4, and the crossover sequence of each layer in the same phase crossover slot of the same winding is the first layer, the second layer, the third layer, the fourth layer, the third layer, the second layer, and the first layer, and the subsequent crossover sequence is similar.

[0013] Preferably, a combination of Ipin and Upin wires is used for bridging, with Ipin wires used for incoming and outgoing wires, and Upin wires used for bridging at other locations.

[0014] This application also provides a dual-winding stator, comprising: The stator core has M slots arranged along its circumference and N layers arranged along its radial direction, where N is an even number greater than 2; the stator core includes a crown end and a welded end. Insulating paper, used for insulation between windings; The copper wires of Ipin and Upin types are used to bridge the corresponding slots to form a bridging wire type. The pitch of the short-pitch wire type in the bridging wire type is M / 2P-1, the pitch of the full-pitch wire type is M / 2P, and the pitch of the long-pitch wire type is M / 2P+1.

[0015] Compared with the prior art, the beneficial effects achieved by the present invention are as follows: This application utilizes flat wire for double winding, significantly improving the efficiency of the double-winding motor, reducing its size, and increasing power density. By using a specific crossover rule for the flat wire to form double windings in the same slot, the two windings can operate simultaneously, achieving completely consistent and symmetrical potentials with zero phase, greatly improving the efficiency of the double-winding motor. Furthermore, this winding method results in highly regular welded ends of the stator core after winding, facilitating automated production. It also ensures that the same phase in the same slot avoids the situation of opposite instantaneous currents under different phases in the same slot, eliminating the need for interphase insulation, optimizing automated processes, and better meeting the high-voltage requirements of motors. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the U-phase connection of the first set of windings in the embodiments of this application; Figure 2 This is a schematic diagram of the U-phase connection line of the second set of windings in an embodiment of this application; Figure 3 This is a schematic diagram of the complete wiring of the first set of windings in the embodiments of this application; Figure 4 This is a schematic diagram of the complete wiring of the second set of windings in an embodiment of this application; Figure 5 This is a schematic diagram of the three-phase bridging of two sets of windings in a partial cross section of a dual-winding stator in an embodiment of this application; In the diagram: U1, U-phase incoming line of the first winding; U2, U-phase incoming line of the second winding; W1, W-phase incoming line of the first winding; W2, W-phase incoming line of the second winding; V1, V-phase incoming line of the first winding; V2, V-phase incoming line of the second winding; X1, U-phase outgoing line of the first winding; X2, U-phase outgoing line of the second winding; Y1, W-phase outgoing line of the first winding; Y2, W-phase outgoing line of the second winding; Z1, V-phase outgoing line of the first winding; Z2, V-phase outgoing line of the second winding. Detailed Implementation To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0017] Therefore, the following detailed description of embodiments of the present invention is not intended to limit the scope of the claimed invention, but merely illustrates some embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0018] Example This embodiment provides a winding method for a flat wire double-winding stator, wherein the flat wire double-winding stator includes a stator core, and the winding method for the flat wire double-winding stator includes the following steps: S1. Select a stator core with M slots, P pole pairs, and N layers. The slot pitch of the stator core is M / 2P. S2. Establish the rules for bridging flat wires: The innermost layer of the stator core is the first layer, and all bridging in the first layer is based on a pitch of M / 2P-1; the outermost layer of the stator core is the Nth layer, and all bridging in the Nth layer is based on a pitch of M / 2P+1; the rest are intermediate layers, and all intermediate layers are based on a pitch of M / 2P. S3. Different phases of the two windings are selected for different slots for wire input, and bridging is performed according to the flat wire bridging rule described in S2, so as to finally obtain a flat wire double winding stator with a phase difference of 0 between the two windings.

[0019] This embodiment uses flat wire for double winding, which significantly improves the working efficiency of the double-winding motor, reduces the motor size, and increases power density. By using flat wire with a specific crossover rule for double winding in the same slot, the two windings can operate simultaneously, achieving completely consistent and symmetrical potentials with a phase of 0, greatly improving the efficiency of the double-winding motor. Moreover, this winding method results in very regular welded ends of the stator core after winding, which is conducive to automated production. It also ensures that the same slot and phase are maintained, avoiding the situation of opposite instantaneous currents under different phases in the same slot. Furthermore, it eliminates the need for interphase insulation, optimizes the automated process, and better meets the high-voltage requirements of the motor in terms of insulation.

[0020] Preferably, different phases of the same winding are selected to have slot inlets with a pitch interval of M / 2P-2, and different phases of the same winding are selected to have slot outlets with a pitch interval of M / 2P.

[0021] Preferably, the same phase of different windings selects adjacent slots for incoming lines, and the same phase of different windings selects slot M / P+1 for outgoing lines.

[0022] like Figures 1 to 4 As shown, this embodiment takes a three-phase permanent magnet flat wire double-winding stator with 48 slots, 4 pole pairs, 4 layers, and 1 branch as an example. The winding method of one phase U of the first winding is as follows: Figure 1The connection method starts with an I-pin wire entering from the second layer of slot 4 at the crown end of U1 path. Then, using an Upin wire, it connects to the first layer of slot 46 (M / 2P bridging), then bridging through slot 46 to the first layer of slot 41 (M / 2P-1 bridging), then using an Upin wire to connect to the second layer of slot 35, then bridging through slot 35 to the third layer of slot 29 (M / 2P bridging), then using an Upin wire to connect to the fourth layer of slot 23, then bridging through slot 23 to the fourth layer of slot 16 (M / 2P+1 bridging), and finally using an Upin wire to connect... Connect it to layer 3 of slot 10, then cross it in reverse through slot 10 to layer 2 of slot 16 (M / 2P bridging). Then, use Upin linear soldering to connect it to layer 1 of slot 10, then cross it through slot 10 to layer 1 of slot 5 (M / 2P-1 bridging). Next, use Upin linear soldering to connect it to layer 2 of slot 47, then cross it through slot 47 to layer 3 of slot 41 (M / 2P bridging). Then, use Upin linear soldering to connect it to layer 4 of slot 35, then cross it through slot 35 to layer 4 of slot 28 (M / 2P+1 bridging). Finally, use Upin linear soldering to connect it to... The 3rd layer of slot 22 is connected to the 2nd layer of slot 28 via a reverse jumper (M / 2P jumper), then connected to the 1st layer of slot 22 via an Upin linear soldering connection. It is then connected to the 1st layer of slot 17 via a jumper (M / 2P-1 jumper), then connected to the 2nd layer of slot 11 via an Upin linear soldering connection. It is then connected to the 3rd layer of slot 5 via a jumper (M / 2P jumper), then connected to the 4th layer of slot 47 via an Upin linear soldering connection. It is then connected to the 4th layer of slot 40 via a jumper (M / 2P+1 jumper), then connected to the 3rd layer of slot 34 via an Upin linear soldering connection. The 4th slot is reverse-connected to the 40th slot 2nd layer (M / 2P bridging), and then connected to the 34th slot 1st layer using Upin linear soldering. It is then connected to the 29th slot 1st layer via the 34th slot (M / 2P-1 bridging), and then connected to the 23rd slot 2nd layer using Upin linear soldering. It is then connected to the 17th slot 3rd layer via the 23rd slot (M / 2P bridging), and then connected to the 11th slot 4th layer using Upin linear soldering. It is then connected to the 4th slot 4th layer via the 11th slot (M / 2P+1 bridging), and finally connected to the 46th slot 3rd layer using Ipin linear soldering, and finally led out from the crown end of this layer.

[0023] The second winding of phase U and the remaining phases of the double winding also follow a similar winding principle.

[0024] Once the stator has been fully wound, from the welding end of the stator, the welding points of the pins are arranged in pairs of 1-2 layers and 3-4 layers, which is unusually neat. This is conducive to the automation of the welding end in the necessary processes such as cutting, welding, and coating on the same plane. From the crown end of the stator, the wire exit is simple, which is conducive to shortening the end height.

[0025] Preferably, a combination of Ipin and Upin wires is used for bridging, with Ipin wires used for incoming and outgoing wires, and Upin wires used for bridging at other locations.

[0026] This application also provides a dual-winding stator, comprising: The stator core has M slots arranged along its circumference and N layers arranged along its radial direction, where N is an even number greater than 2; the stator core includes a crown end and a welded end. Insulating paper, used for insulation between windings; The copper wires of Ipin and Upin types are used to bridge the corresponding slots to form a bridging wire type. The pitch of the short-pitch wire type in the bridging wire type is M / 2P-1, the pitch of the full-pitch wire type is M / 2P, and the pitch of the long-pitch wire type is M / 2P+1.

[0027] Those skilled in the art should understand that the discussion of any of the above embodiments is merely exemplary and is not intended to imply that the scope of protection of this application is limited to these examples; within the framework of this application, the technical features of the above embodiments or different embodiments can also be combined, the steps can be implemented in any order, and there are many other variations of different aspects of one or more embodiments of this application as described above, which are not provided in detail for the sake of brevity.

[0028] One or more embodiments in this application are intended to cover all such substitutions, modifications, and variations that fall within the broad scope of this application. Therefore, any omissions, modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of one or more embodiments in this application should be included within the protection scope of this application.

Claims

1. A method for winding a flat wire double-winding stator, wherein the flat wire double-winding stator comprises a stator core, characterized in that, The winding method for the flat wire double-winding stator includes the following steps: S1. Select a stator core with M slots, P pole pairs, and N layers. The slot pitch of the stator core is M / 2P. S2. Establish the rules for bridging flat wires: The innermost layer of the stator core is the first layer, and all bridging in the first layer is based on a pitch of M / 2P-1; the outermost layer of the stator core is the Nth layer, and all bridging in the Nth layer is based on a pitch of M / 2P+1. The rest are intermediate layers, and all intermediate layers are bridging based on a pitch of M / 2P; S3. Different phases of the two windings are selected for different slots for wire input, and bridging is performed according to the flat wire bridging rule described in S2, so as to finally obtain a flat wire double winding stator with a phase difference of 0 between the two windings.

2. The winding method for a flat wire double-winding stator according to claim 1, characterized in that, Different phases of the same winding are selected to enter the slot with a pitch interval of M / 2P-2.

3. The winding method for a flat wire double-winding stator according to claim 2, characterized in that, Different phases of the same winding select slots with a pitch interval of M / 2P for the outgoing lines.

4. The winding method for a flat wire double-winding stator according to claim 1, characterized in that, For the same phase of different windings, adjacent slots are selected for the incoming line.

5. The winding method for a flat wire double-winding stator according to claim 4, characterized in that, For the same phase of different windings, the M / P+1 slot is selected for output.

6. The winding method for a flat wire double-winding stator according to claim 2 or 4, characterized in that, N is 4, and the incoming line comes from the second layer of the corresponding slot.

7. The winding method for a flat wire double-winding stator according to claim 3 or 5, characterized in that, N is 4, and the cable exits from the third layer of the corresponding slot.

8. The winding method for a flat wire double-winding stator according to claim 1, characterized in that, When N is 4, the order of crossover in the same phase of the same winding is: first layer, second layer, third layer, fourth layer, fourth layer, third layer, second layer, first layer, and so on.

9. The winding method for a flat wire double-winding stator according to claim 1, characterized in that, Use a combination of Ipin and Upin wire types for bridging. Use the Ipin wire type for incoming and outgoing wires, and use the Upin wire type for bridging at other positions.

10. A dual-winding stator, characterized in that, include: The stator core has M slots arranged along its circumference and N layers arranged along its radial direction, where N is an even number greater than 2; the stator core includes a crown end and a welded end. Insulating paper, used for insulation between windings; Ipin and Upin wire types are used to bridge corresponding slots to form a bridging wire type. The pitch of the short pitch wire type in the bridging wire type is M / 2P-1, the pitch of the full pitch wire type is M / 2P, and the pitch of the long pitch wire type is M / 2P+1.

Images