Interface dislocation complementary flexible stator and light weight high torque density permanent magnet motor

Abstract

The application discloses an interface dislocation complementary flexible stator and a lightweight high-torque-density permanent magnet motor, which is formed by splicing a planar full-pitch flexible winding into a circle; the planar full-pitch flexible winding comprises 2n conductive layers and 2n+1 flexible insulating layers which are stacked alternately; the 2n conductive layers comprise odd conductive layers and even conductive layers which are staggered left and right and stacked alternately from bottom to top; the planar full-pitch flexible winding comprises an overlapping region and two dislocation regions located on both sides of the overlapping region; when the planar full-pitch flexible winding is spliced into a circle, the two dislocation regions can be connected in a complementary manner; the coils of the odd conductive layers and the coils of the even conductive layers are arranged in a continuous series connection mode from outside to inside, the coils of the odd conductive layers and the coils of the even conductive layers are connected in a conductive manner through interlayer conductive connection holes at the ends, and the even conductive layers and the coils of the next odd conductive layers are still connected in a conductive manner through the interlayer conductive connection holes at the ends. The application can make the interface thickness of the spliced circle equal to the thickness of the non-spliced part, and the diameter of the spliced circle can reach millimeter level without welding points.

Description

Technical Field

[0001] This invention relates to a stator and a permanent magnet motor, particularly a flexible stator with inter-interface misalignment and a lightweight, high torque density permanent magnet motor. Background Technology

[0002] With the rapid commercialization of artificial intelligence and embody intelligent products, higher demands are being placed on the operating precision, efficiency, and miniaturization of radial dimensions of permanent magnet motors. Meanwhile, the precision micro-transmission sector, encompassing applications such as angiography imaging equipment, miniature aerial vehicles, industrial ultra-high precision testing platforms, bionic dexterous robotic arms, and microscale bionic transmission mechanisms, is further compressing the boundaries of motor dimensions, requiring drive units to iterate towards miniaturization and ultra-small size. In some specific applications, the overall radial dimension of the motor even needs to be controlled to the millimeter level.

[0003] A standard configuration of a conventional permanent magnet motor drive unit includes a housing, a slotted lamination stator (silicon steel magnetic core + armature winding), winding lead-out terminals, a permanent magnet rotor (permanent magnet, rotor end pressure plate, rotor magnetic core), a main shaft, support bearings, and front and rear end covers. Conventional iron-core permanent magnet motors have a slotted stator structure, and the permeability of the magnetic silicon steel material exhibits significant nonlinear magnetization characteristics with increasing input current and output load. This makes it difficult to further optimize torque pulsation and speed control accuracy across the entire operating range. Furthermore, the iron core itself generates two additional iron losses: hysteresis loss and eddy current loss. This increases overall energy consumption, motor weight, and installation space requirements, inherently contradicting the design development direction of miniature permanent magnet motors, which emphasizes high efficiency, lightweight design, and miniaturization.

[0004] To overcome the inherent defects of traditional iron-core motors, existing technologies disclose various slotless stator hollow armature motor solutions. A representative prior art document is patent CN2005100476786, which employs a coreless stator armature structure directly injection-molded from the windings. Specifically, the process involves: first, laying out and weaving independent single-piece coil units with insulated enameled wire; then, evenly arranging multiple sets of planar coils according to the three-phase winding sequence; using high-temperature resistant insulating film and epoxy adhesive for composite fixation; and finally, hot-pressing to form a single planar armature strip. This planar armature strip is then rolled into a cylindrical cup-shaped structure, followed by multiple post-processing steps such as bonding reinforcement, lead wire welding, and insulation encapsulation. The entire molding process is lengthy, has high technological barriers, and exhibits poor control over coil arrangement uniformity and positioning accuracy, making it difficult to adapt to automated, high-speed mass production lines and resulting in significant challenges in overall manufacturing cost control. Furthermore, the rolled-out interface requires welding or adjustments to the interface thickness.

[0005] In summary, developing a permanent magnet micro motor that features a simple molding process, streamlined processing steps, adaptability to high-speed mass production, and high precision, high energy efficiency, and lightweight design is an urgent industrial demand in niche sectors such as precision medical imaging, micro drones, industrial precision testing, humanoid dexterity hands, and micro-nano bionic transmission. This technology has significant engineering value and practical application significance for the technological iteration and industrialization of the aforementioned high-end precision equipment. Summary of the Invention

[0006] The technical problem to be solved by the present invention is to address the shortcomings of the prior art by providing an interface misalignment complementary flexible stator and a lightweight high torque density permanent magnet motor. This interface misalignment complementary flexible stator and lightweight high torque density permanent magnet motor can make the thickness of the rolled interface the same as that of the non-jointed parts, and there are no weld points. The radial thickness can reach millimeters.

[0007] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows:

[0008] A flexible stator with misaligned interface and a lightweight high torque density permanent magnet motor are disclosed, comprising a coaxially arranged flexible stator with misaligned interface, a rotor, and a housing; wherein an air gap exists between the flexible stator with misaligned interface and the rotor; the flexible stator with misaligned interface is formed by rolling and splicing together planar full-pitch flexible windings.

[0009] The planar full-pitch flexible winding includes 2n conductive layers and 2n+1 flexible insulating layers stacked alternately; wherein, the top and bottom surfaces of the conductive layers both have flexible insulating layers.

[0010] The 2n conductive layers include odd-numbered conductive layers that are staggered from bottom to top and left to right, and even-numbered conductive layers.

[0011] The planar full-pitch flexible winding includes an overlapping region and two misaligned regions located on both sides of the overlapping region; when the planar full-pitch flexible winding is rolled and spliced, the two misaligned regions can overlap and complement each other.

[0012] The coils of the odd-numbered conductive layers and the coils of the even-numbered conductive layers are arranged in a continuous series loop from the outside to the inside. The coils of the odd-numbered conductive layers are electrically connected to the coils of the even-numbered conductive layers through the interlayer conductive connection holes at the ends. The coils of the even-numbered conductive layers are also electrically connected to the next odd-numbered conductive layer through the interlayer conductive connection holes at the ends.

[0013] Furthermore, the formula for calculating the length L of each misaligned region is:

[0014] L=π×D×A c / 360.

[0015] in:

[0016] A c =a×1 / 2×Ap .

[0017] In the formula, D is the outer diameter, inner diameter, or median of the innermost radial conductive layer in the interface misalignment complementary flexible stator.

[0018] A c The circular angle of the misaligned region in the interface misaligned complementary flexible stator.

[0019] a is a constant, with a value ranging from 0.8 to 1.2.

[0020] A p It is the circumferential mechanical angle between the neutral lines of the two sides of a single winding coil, corresponding to the circumferential mechanical angle of a rotor pole.

[0021] Furthermore, the end span of the coil edge located in the misaligned area is greater than the end span of the coil edge located in the overlapping area of ​​the same group of coils, so that all interlayer conductive connection holes for conductive connection between odd-numbered conductive layer coils and even-numbered conductive layer coils are located in the overlapping area.

[0022] Furthermore, the circumferential mechanical angle between the neutral lines of the coil sides on both sides of a single winding coil in the conductive layer is 0.8 to 1.2 times the circumferential mechanical angle corresponding to a rotor pole.

[0023] Furthermore, each conductive layer is provided with k×m single-group winding coils, each of which is a multi-turn coil; where k is the number of unit motors and m is the number of motor phases; the single-group winding coils in the conductive layer are connected by star or delta connection.

[0024] Furthermore, the individual winding coils in the conductive layer are connected in a star configuration, specifically as follows:

[0025] A. When k=1 and 2n=2, each phase coil starts from the phase lead of the odd-numbered conductive layer and is wound from the outside to the inside, with each single winding coil as a unit. Each turn is first connected to the even-numbered conductive layer through the interlayer conductive connection hole at the non-lead end, and then connected to the odd-numbered conductive layer through the interlayer conductive connection hole at the lead end. This cycle continues until the phase coil is wound. When 2n>2, the even-numbered conductive layer is conductively connected to the next odd-numbered conductive layer through the interlayer conductive connection hole at the phase lead end, and so on, until all 2n conductive layers are wound.

[0026] B. When k > 1 and the in-phase coils of k unit motors are connected in series, the completed winding line of the 2nth layer of the odd-numbered unit motor is connected to the winding start line of the even-numbered unit motor through the interlayer conductive connection hole two. The completed winding line of the 2nth layer of the even-numbered unit motor is connected to the winding start line of the next odd-numbered unit motor through the interlayer conductive connection hole two, until the coil of the last unit motor of the current phase is completed. Finally, the completed winding lines of all phases are connected together to form the neutral line.

[0027] C. When k > 1 and the in-phase coils of k unit motors are connected in parallel, the winding start line of the odd-numbered unit motor is connected to the winding start line of the even-numbered unit motor, and the winding completion lines of all unit motors are connected together to form the neutral line.

[0028] Furthermore, the individual winding coils in the conductive layer are connected in a star configuration, specifically as follows:

[0029] A. When k=1 and 2n=2, the odd-numbered conductive layers start from the winding start line of the current phase coil and are wound from the outside to the inside, taking a single group of winding coils as the unit. Each turn needs to be connected to the even-numbered conductive layer through the interlayer conductive connection hole at the non-lead end, and then connected to the odd-numbered conductive layer through the interlayer conductive connection hole at the lead end. This cycle continues until the current phase coil is wound. When 2n>2, the even-numbered conductive layers are conductively connected to the next odd-numbered conductive layer through the interlayer conductive connection hole at the lead end. This cycle continues until all 2n layers are wound.

[0030] B. When k > 1 and the in-phase coils of k unit motors are connected in series, the winding completion line of the 2nth layer of the odd-numbered unit motor is connected to the winding start line of the current group coil of the even-numbered unit motor through the interlayer conductive connection hole three. The winding completion line of the 2nth layer of the even-numbered unit motor is connected to the winding start line of the next odd-numbered unit motor through the interlayer conductive connection hole three. After the current phase coil is connected, it is connected to the adjacent phase coil through the interlayer conductive connection hole in a delta connection.

[0031] C. When k > 1 and the in-phase coils of k unit motors are connected in parallel, the winding start line of the odd-numbered unit motor is connected to the winding start line of the even-numbered unit motor. After all the winding completion lines of the unit motors are connected together, they are connected to the winding start line of the adjacent phase coil through the interlayer conductive connection hole three.

[0032] Furthermore, the conductive layer can be freely matched and designed to optimize the number of coil turns, the safety distance between each coil turn, and the height of the coil ends to improve the fill rate of the conductor, thereby further improving the output torque and torque density.

[0033] Furthermore, the filling rate of conductors in odd-numbered and even-numbered conductive layers is controlled to be between 50% and 85% within their respective conductive layers.

[0034] Furthermore, the total thickness of the two misaligned regions after they are combined and complement each other is equal to the thickness of the overlapping region.

[0035] A lightweight, high torque density permanent magnet motor includes a coaxially arranged interface misaligned complementary flexible stator, rotor, housing, and shaft; wherein an air gap exists between the interface misaligned complementary flexible stator and the rotor.

[0036] The present invention has the following beneficial effects:

[0037] 1. The motor of this invention cleverly eliminates the motor tooth slots, effectively suppresses the nonlinear characteristics of the motor, and improves the accuracy under all operating conditions; moreover, it solves the problem of effective space in the motor, reduces weight and additional core losses, and facilitates the realization of high-efficiency, lightweight and miniaturized design of permanent magnet motors.

[0038] 2. The integrally molded flexible armature winding is first formed into a planar structure, then rolled into a cylindrical (cup-shaped) shape, and finally assembled with the housing. The dimensions of the conductive layer and coil are flexible, the arrangement is accurate, and the precision is easy to control. The overall process is easy to manufacture, the process is simple, the production cycle is fast, and the precision is high, making it suitable for mass production.

[0039] 3. This invention employs a multi-layer full-pitch winding (2n layers), interleaved and complementary interfaces, and star or delta connection schemes. Each winding in each layer has multiple turns. When star-connected, the conductive connection between adjacent layers is achieved through the interlayer conductive connection holes one and two at the winding ends. The 2n conductive layers eliminate the need for cross-wire connections between layers, between the neutral point and the neutral line, or for welding. (The coils of odd-numbered and even-numbered conductive layers are continuously connected in series from the outside in. Odd-numbered and even-numbered conductive layer coils are conductively connected through the interlayer conductive connection holes at the winding ends, and even-numbered conductive layers are also conductively connected to the next odd-numbered conductive layer coil through the same holes. Therefore, the wire ends of even-numbered conductive layers are necessarily on the outside. This facilitates connection to the starting winding wire of the next unit motor and direct connection to the neutral line.) This eliminates the need for interlayer crossovers and neutral point / neutral line connections. Furthermore, the use of multi-layer conductors, each layer forming multiple turns of coil, combined with the full-pitch winding of this invention, effectively increases the electrical load capacity and the degree of freedom in winding coefficient optimization, further enhancing the motor's output torque and torque density. The delta connection is similar to the star connection, but differs in that: in a delta connection, adjacent phase lines are also connected via interlayer conductive connection hole three. Interlayer conductive connection holes one, two, and three are integrally formed with the conductive layers, eliminating the need for welding between phase lines. Since the wire ends of even-numbered conductive layers are necessarily on the outside, these wire ends can be easily connected to the winding start line of the next unit motor via interlayer conductive connection hole three, and can also be directly connected to adjacent phase lines via interlayer conductive connection hole three. Therefore, it eliminates the need for interlayer crossovers and crossover connections between adjacent phase lines.

[0040] 4. All the above-mentioned connecting wires, various wound wires, neutral point, and neutral wire are integrally formed and connected inside the integrally formed flexible armature winding, without the need for cross-wire connections or welding. Using symmetrical windings, the phase leads and neutral wire are all on the same side of the motor, without occupying more motor space. This simplifies the manufacturing process and facilitates the miniaturization / micro-miniaturization of the motor.

[0041] 5. This invention pioneers a complementary interface misalignment scheme. The rolled-up interfaces of the odd-numbered conductive layers and the even-numbered conductive layers are separate and misaligned. The interlayer conductive connection holes connecting the odd-numbered and even-numbered conductive layers are all located within the overlapping area of ​​the odd-numbered and even-numbered conductive layers (i.e., the vias are not located in the area where the rolled-up interfaces are separated and misaligned). This cleverly avoids the shortcomings of connecting the coils and neutral wires on both sides of the rolled-up joint through additional connection methods (such as welding, wire bonding, plug-in connection, etc.), greatly simplifying the process. Moreover, there are no exposed conductors or points requiring welding at the rolled-up joint, significantly enhancing the reliability of the motor.

[0042] 6. Adhesive can be used on the assembly surface to strengthen the adhesion between the armature winding and the housing, thereby increasing the fit tolerance between the integrally molded flexible armature winding and the housing, and ensuring the uniformity, roundness, cylindricity and other design dimensional accuracy of the inner circumferential surface (and air gap) of the integrally molded flexible armature winding.

[0043] 7. The size and shape design of the integrated molded flexible armature winding of the present invention are flexible. The space utilization rate, electrical load capacity and motor volume of the integrated molded flexible armature winding can be optimized by flexibly designing the number of coil turns of the conductor in the conductive layer, the shape of the end (which can be a straight line, a straight line at different angles, an arc line, a semi-circular line, etc.), and the ratio of the axial dimension of the two ends to the axial dimension of the middle straight segment. Attached Figure Description

[0044] Figure 1 This is an exploded view of an interface misalignment complementary flexible stator and a lightweight high torque density permanent magnet motor according to the present invention.

[0045] Figure 2 Showing Figure 1 Left end view.

[0046] Figure 3 Showing Figure 2 BB cross-sectional view.

[0047] Figure 4 Showing Figure 3 A magnified view of the area within the middle circle.

[0048] Figure 5 The diagram shows a star connection of odd-numbered conductive layers and even-numbered conductive layers when k=1 and m=3; (a) shows the overall star connection diagram of odd-numbered conductive layers and even-numbered conductive layers; (b) shows the star connection diagram of odd-numbered conductive layers; and (c) shows the star connection diagram of even-numbered conductive layers.

[0049] Figure 6 The diagram shows the corner connection of odd-numbered conductive layers and even-numbered conductive layers when k=1 and m=3.

[0050] Figure 7 The diagram shows a partial corner connection diagram of odd-numbered conductive layers and even-numbered conductive layers when k=1 and m=3; where (a) shows the corner connection diagram of odd-numbered conductive layers; and (b) shows the corner connection diagram of even-numbered conductive layers.

[0051] Figure 8 The diagram shows the star connection principle of the coils of the odd-numbered conductive layer and the even-numbered conductive layer when k=1 and m=3; where (a) is the overall diagram of the star connection of the odd-numbered conductive layer and the even-numbered conductive layer; (b) is the star connection diagram of the odd-numbered conductive layer; and (c) is the star connection diagram of the even-numbered conductive layer.

[0052] Figure 9 The diagram shows the coil corner connection principle of odd-numbered conductive layers and even-numbered conductive layers when k=1 and m=3; where (a) is the overall diagram of the corner connection of odd-numbered conductive layers and even-numbered conductive layers; (b) is the corner connection diagram of odd-numbered conductive layers; and (c) is the corner connection diagram of even-numbered conductive layers.

[0053] Figure 10 The diagram shows the star connection diagrams of the odd-numbered and even-numbered conductive layers as asymmetrical windings when k=1 and m=3; where (a) is the overall star connection diagram of the odd-numbered and even-numbered conductive layers as asymmetrical windings; (b) is the star connection diagram of the odd-numbered conductive layers as asymmetrical windings; and (c) is the star connection diagram of the even-numbered conductive layers as asymmetrical windings.

[0054] Figure 11 The schematic diagram of the conductive layers with odd and even numbers of conductive layers is shown.

[0055] Figure 12 The diagram shows a star connection diagram of odd-numbered conductive layers and even-numbered conductive layers when k=2 and m=3; where (a) is the overall diagram of the star connection of odd-numbered conductive layers and even-numbered conductive layers; (b) is the star connection diagram of odd-numbered conductive layers; and (c) is the star connection diagram of even-numbered conductive layers.

[0056] Figure 13 The diagram shows the star connection principle of the coils of the odd-numbered conductive layer and the even-numbered conductive layer when k=2, m=3 and the unit motors are connected in series; (a) is the overall diagram of the series star connection of the odd-numbered conductive layer and the even-numbered conductive layer; (b) shows the series star connection diagram of the odd-numbered conductive layer; (c) shows the series star connection diagram of the even-numbered conductive layer.

[0057] Figure 14 The diagram shows the star connection principle of the coils of the odd-numbered conductive layer and the even-numbered conductive layer when k=2, m=3 and the unit motors are connected in parallel; (a) is the overall diagram of the parallel star connection of the odd-numbered conductive layer and the even-numbered conductive layer; (b) shows the parallel star connection diagram of the odd-numbered conductive layer; (c) shows the parallel star connection diagram of the even-numbered conductive layer.

[0058] Figure 15 This diagram shows a conventional rectangular shape for each turn of a single coil.

[0059] Figure 16 The diagram shows a rectangular shape for each turn of a single coil, including a separation hole.

[0060] Among them is: 10. Shell;

[0061] 20. Interface misalignment complementary flexible stator; 21. Separation hole; 22. Corner connector; 23. Neutral wire; 24. Interlayer conductive connection hole three; 25. Interlayer conductive connection hole one; 26. Interlayer conductive connection hole two;

[0062] 30. Planar full-pitch flexible winding;

[0063] 31. Conductive layer; 311. Odd-numbered conductive layers; 312. Even-numbered conductive layers; 313. Phase lead-out line;

[0064] 32. Flexible insulating layer; 321. Substrate layer; 322. Coating layer;

[0065] 33. Overlapping area; 34. Misaligned area; 341. Left misaligned area; 342. Right misaligned area;

[0066] 40.Permanent magnet;

[0067] 50. Shaft; 51. End plate one; 52. End plate two; 53. Bearing one; 53. Cable outlet hole; 54. Bearing two;

[0068] 60. Air gap. Detailed Implementation

[0069] The present invention will now be described in further detail with reference to the accompanying drawings and specific preferred embodiments.

[0070] In the description of this invention, it should be understood that the terms "left side," "right side," "upper part," "lower part," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. "First," "second," etc., do not indicate the importance of the components, and therefore should not be construed as a limitation of this invention. The specific dimensions used in this embodiment are only for illustrating the technical solution and do not limit the scope of protection of this invention.

[0071] Example 1

[0072] This invention uses an internal rotor motor as an example for detailed explanation. Alternatively, an external rotor motor can also be used.

[0073] like Figures 1 to 3 As shown, this embodiment of a flexible stator with inter-interface misalignment and a lightweight high torque density permanent magnet motor includes a housing 10, an inter-interface misalignment and a flexible stator 20, a planar full-pitch flexible winding, a permanent magnet 40, and a rotating shaft 50 arranged coaxially from the outside to the inside.

[0074] In this embodiment, the housing 10 can be made of either a magnetic material or a non-magnetic material.

[0075] In this embodiment, the permanent magnet 40 is cylindrical and serves as the rotor. It can be a straight-pole structure or a segmented oblique-pole structure. The permanent magnet 40 is coaxially sleeved on the outer circumference of the rotating shaft 50. It can be an integral magnetic ring structure or a tile, rectangular, or bread-shaped magnet. In this embodiment, the rotor does not have a magnetic core. Alternatively, it can contain a magnetic core.

[0076] In this embodiment, the rotating shaft 50 can be a solid rotating shaft or a hollow rotating shaft; a hollow rotating shaft allows conductive, communication, signal transmission wires or cables to pass through. The rotating shaft 50 and the permanent magnet 40 can be an integral structure, that is, the rotating shaft 50 and the permanent magnet 40 are made of the same material (either magnetic or non-magnetic material) and are integrally formed, which is used to generate a magnetic field and to connect with an external load to output torque.

[0077] End plate 1 51 and end plate 2 52 are coaxially arranged on the rotating shafts 50 on both sides of the permanent magnet 40. Bearing 1 53 and bearing 2 54 are respectively mounted on the rotating shafts 50 outside the end plate 1 51 and end plate 2 52.

[0078] In this embodiment, the bearing 53 and bearing 54 are one of a sliding bearing, a rolling bearing, a magnetic bearing, or an air bearing. Preferably, a wire outlet hole 531 is provided in the fixed, non-rotating ring of bearing 53 for the subsequent phase lead 313 to pass through. The wire outlet hole 531 can be any type of hole or slot.

[0079] In this embodiment, end plate 1 51 and end plate 2 52 can be separate structures or integrated structures with the rotating shaft. The motor may or may not have end covers.

[0080] For an m-phase, 2p-pole (p-pair) motor, if the number of poles of a unit motor is defined as 2p0 (p0-pair), then the entire motor is composed of k = p / p0 unit motors evenly distributed along the circumference. In this embodiment, m=3, p=1, k=1 is used as an example for detailed explanation. Alternatively, the number of phases m can also be two-phase, three-phase, four-phase, double three-phase, five-phase, or six-phase, etc.

[0081] In this embodiment, a flexible stator 20 with inter-interface misalignment and complementary structure is formed by rolling and splicing planar full-pitch flexible windings 20, and an air gap 60 is formed between the stator and the permanent magnet 40.

[0082] like Figure 4 The planar full-pitch flexible winding 20 includes 2n conductive layers 3 and 2n+1 flexible insulating layers 32 stacked alternately; where n is a natural number greater than or equal to 1; in this embodiment, n is preferably equal to 1; the conductive layers and the flexible insulating layers are preferably bonded together, either wholly or partially, with adhesive; the material of the conductive layers can be any conductive material, such as copper, aluminum, gold, silver or other alloys, preferably copper foil.

[0083] The planar full-pitch flexible winding 30 includes an overlapping region 33 and two misaligned regions 34 located on both sides of the overlapping region 33. When the planar full-pitch flexible winding 30 is rolled and spliced, the two misaligned regions 34 can overlap and complement each other. The total thickness of the two misaligned regions 34 after overlapping and complementing each other is preferably equal to the thickness of the overlapping region 33.

[0084] In this embodiment, the formula for calculating the length L of each misaligned region is:

[0085] L=π×D×A c / 360;

[0086] in:

[0087] A c =a×1 / 2×A p ;

[0088] In the formula, D is the outer diameter, inner diameter, or median of the innermost radial conductive layer in the interface misalignment complementary flexible stator.

[0089] A c The circular angle of the misaligned region in the interface misaligned complementary flexible stator.

[0090] a is a constant, preferably 0.8 to 1.2.

[0091] A p It is the circumferential mechanical angle between the neutral lines of the two sides of a single-wound coil.

[0092] like Figure 5 As shown, two conductive layers 31 are arranged between two adjacent flexible insulating layers 32 that are arranged sequentially among three flexible insulating layers 32. The two conductive layers 31 include an odd-numbered conductive layer 311 and an even-numbered conductive layer 312 that are staggered from bottom to top and left to right. The coils of the odd-numbered conductive layer 311 and the even-numbered conductive layer 312 are arranged in a continuous series loop from the outside to the inside. The coils of the odd-numbered conductive layer 311 and the even-numbered conductive layer 312 are electrically connected through interlayer conductive connection holes at the ends. The even-numbered conductive layer 312 is also electrically connected to the next odd-numbered conductive layer 311 through interlayer conductive connection holes at the ends.

[0093] The end span (i.e., span 1) of the coil side located in the misalignment region 34 is greater than the end span (i.e., span 2) of the coil side located in the overlapping region 33, so that all interlayer conductive connection holes for conductive connection between the odd-numbered conductive layer 311 coil and the even-numbered conductive layer 312 coil are located in the overlapping region 33.

[0094] The circumferential mechanical angle between the neutral lines of the coil sides on both sides of a single winding coil in the conductive layer 31 is 0.8 to 1.2 times the circumferential mechanical angle corresponding to a rotor pole, and preferably 1 time in this embodiment.

[0095] Each conductive layer contains k×m single-group winding coils, each of which is a multi-turn coil; where k is the number of unit motors and m is the number of motor phases; the single-group winding coils in the conductive layer are connected by star or delta connection. In this embodiment, each single-group coil is preferably a three-turn coil, k equals 1, m equals 3, and the single-group winding coils in the conductive layer are connected by star connection.

[0096] In this embodiment, the shape of each turn of the single coil is as follows: Figure 15 The image shown is a standard rectangle; as shown... Figure 16 As shown, it can also be a rectangle with a separation hole 21, or it can be hexagonal, octagonal, elliptical, circular, or rhomboid, etc.; when using Figure 16 When a rectangle with separation holes is shown, it can be used to optimize the harmonics of the motor magnetomotive force and reduce the AC copper loss under high-frequency operation, thereby improving the efficiency of the motor.

[0097] The multi-turn coils in each single coil group are as follows: Figure 8 and Figure 9 The symmetrical winding shown or as Figure 10 The asymmetric winding shown.

[0098] The specific connection method for star connection between single winding coils in the conductive layer is as follows:

[0099] A. When k=1 and 2n=2, each phase coil starts from the phase lead of the odd-numbered conductive layer and is wound from the outside to the inside, with each single winding coil as a unit. Each turn is first connected to the even-numbered conductive layer through the interlayer conductive connection hole at the non-lead end, and then connected to the odd-numbered conductive layer through the interlayer conductive connection hole at the lead end. This cycle continues until the phase coil is wound. When 2n>2, the even-numbered conductive layer is conductively connected to the next odd-numbered conductive layer through the interlayer conductive connection hole at the phase lead end, and so on, until all 2n conductive layers are wound.

[0100] B. When k > 1 and the in-phase coils of k unit motors are connected in series, the completed winding line of the 2nth layer of the odd-numbered unit motor is connected to the winding start line of the even-numbered unit motor through the interlayer conductive connection hole two. The completed winding line of the 2nth layer of the even-numbered unit motor is connected to the winding start line of the next odd-numbered unit motor through the interlayer conductive connection hole two, until the coil of the last unit motor of the current phase is completed. Finally, the completed winding lines of all phases are connected together to form the neutral line.

[0101] C. When k > 1 and the in-phase coils of k unit motors are connected in parallel, the winding start line of the odd-numbered unit motor is connected to the winding start line of the even-numbered unit motor, and the winding completion lines of all unit motors are connected together to form the neutral line.

[0102] In the embodiments, a preferred embodiment is one where n = 1, k = 1, and m = 3, which is used to describe the specific connection method of star connection between single winding coils in the conductive layer. Figure 5 and Figure 8 As shown, the winding end lines of the three phase winding coils are connected together in straight lines to form the neutral line, as follows. Figure 5 (a) to (c) Figure 8 As shown in (a) to (c), the coils of the odd-numbered conductive layers and the coils of the even-numbered conductive layers are arranged in a continuous series loop from the outside to the inside and are symmetrically set. The coils of the odd-numbered conductive layers and the even-numbered conductive layers are electrically connected through the second interlayer conductive connection hole at the end of the winding. The even-numbered conductive layer and the next odd-numbered conductive layer coil are also electrically connected through the first interlayer conductive connection hole at the end of the winding. Therefore, the wire end of the even-numbered conductive layer must be on the outside. This wire end is convenient for connecting to the winding start line of the next unit motor and also convenient for directly connecting to the neutral line 23. Thus, it is possible to achieve the goal of not needing to cross wires between layers, and the neutral point and the neutral line do not need to cross wires. Combined with the full-pitch winding preferred in this embodiment, the electrical load capacity and the degree of freedom in winding coefficient optimization are effectively increased, further improving the motor output torque and torque density.

[0103] Specifically, taking phase A as an example, the odd-numbered conductive layer 311 (e.g., conductive layer 1) starts from the phase lead 313 (defined as the winding start line) and is wound from the outside in as a set of coils (the designed number of turns can be an integer or a fraction). Each turn needs to be connected to the even-numbered conductive layer 312 (e.g., conductive layer 2) through the interlayer conductive connection hole 2 at the non-lead end, and then connected to the odd-numbered conductive layer 311 (e.g., conductive layer 1) through the interlayer conductive connection hole 1 at the lead end. This cycle continues until the set of coils is wound. If 2n > 2, then conductive layer 1 is conductively connected to the next odd-numbered conductive layer (i.e., conductive layer 3) through the interlayer conductive connection hole 1 at the lead end. Conductive layer 3 continues to be wound according to the above rules until all 2n layers are wound.

[0104] All the aforementioned connecting wires, various wound wires, neutral point, and neutral wire are integrally formed and connected within the integrally molded flexible armature winding, eliminating the need for cross-wire connections. The phase leads and neutral wire are located on the same side of the motor, without occupying more motor space. This simplifies the manufacturing process and facilitates miniaturization / micro-miniaturization of the motor. The leads are equipped with solder pads for soldering connecting wires and connecting them to the drive controller.

[0105] Example 2

[0106] The difference between this embodiment and Embodiment 1 is that, as Figure 10 As shown in (a) to (c), in the connection relationship between the 2n single coils located in the 2n conductive layers of a unit motor in each phase winding coil, the coils of the odd-numbered conductive layers and the coils of the even-numbered conductive layers are arranged in a continuous series loop from the outside to the inside and are asymmetrically set. The coils of the odd-numbered conductive layers and the coils of the even-numbered conductive layers are electrically connected through the interlayer conductive connection hole two at the winding end, and the coils of the even-numbered conductive layers and the next odd-numbered conductive layers are still electrically connected through the interlayer conductive connection hole one at the winding end. At this time, the phase lead 313 and the neutral line 23 are not on the same side end of the motor.

[0107] Example 3

[0108] The difference between this embodiment and Embodiment 1 is that: in this embodiment, the single-group winding coils in the conductive layer are connected by a corner joint, and an inter-layer conductive connection hole 3 is opened at the phase wire lead-out end of the 2n conductive layers. The specific details of the corner joint between the single-group winding coils in the conductive layer in this embodiment are as follows:

[0109] A. When k=1 and 2n=2, the odd-numbered conductive layers start from the winding start line of the current phase coil and are wound from the outside to the inside, taking a single group of winding coils as the unit. Each turn needs to be connected to the even-numbered conductive layer through the interlayer conductive connection hole at the non-lead end, and then connected to the odd-numbered conductive layer through the interlayer conductive connection hole at the lead end. This cycle continues until the current phase coil is wound. When 2n>2, the even-numbered conductive layers are conductively connected to the next odd-numbered conductive layer through the interlayer conductive connection hole at the lead end. This cycle continues until all 2n layers are wound.

[0110] B. When k > 1 and the in-phase coils of k unit motors are connected in series, the winding completion line of the 2nth layer of the odd-numbered unit motor is connected to the winding start line of the current group coil of the even-numbered unit motor through the interlayer conductive connection hole 3 24. The winding completion line of the 2nth layer of the even-numbered unit motor is connected to the winding start line of the next odd-numbered unit motor through the interlayer conductive connection hole 3. After the current phase coil is connected, it is connected to the adjacent phase coil through the interlayer conductive connection hole in a delta connection.

[0111] C. When k > 1 and the in-phase coils of k unit motors are connected in parallel, the winding start line of the odd-numbered unit motor is connected to the winding start line of the even-numbered unit motor. After all the winding completion lines of the unit motors are connected together, they are connected to the winding start line of the adjacent phase coil through the interlayer conductive connection hole three.

[0112] In this embodiment, a preferred configuration of n=1, k=1, and m=3 is used to illustrate the specific case where a delta connection is used between single-group winding coils in the conductive layer. Figure 6 ,7 and Figure 9 As shown, in this embodiment, the conductive connection between the windings of adjacent conductive layers 31 is achieved through interlayer conductive connection hole 1 25 and interlayer conductive connection hole 26; the corner connection between adjacent phase lines is achieved through interlayer conductive connection hole 3 24; interlayer conductive connection hole 1 25, interlayer conductive connection hole 26 and interlayer conductive connection hole 3 24 are integrally formed with the conductive layer 31, and there is no need to weld between the phase lines.

[0113] In this embodiment, taking U-group coil as an example, the odd-numbered conductive layer (such as conductive layer 1) starts from the winding start line of U-group and is wound from the outside to the inside in a group of coils (the designed number of turns can be an integer or a fraction). Each turn needs to be connected to the even-numbered conductive layer (such as conductive layer 2) through the interlayer conductive connection hole 2 at the non-lead end, and then connected to the odd-numbered conductive layer (such as conductive layer 1) through the interlayer conductive connection hole 1 at the lead end. This cycle continues until the group of coils is wound. If 2n > 2, then conductive layer 2 is conductively connected to the next odd-numbered conductive layer (i.e., conductive layer 3) through the interlayer conductive connection hole 1 at the lead end. Conductive layer 3 continues to be wound in the same way as above until all 2n layers are wound.

[0114] In this embodiment, the phase lead can be in either an odd-numbered conductive layer or an even-numbered conductive layer.

[0115] All the aforementioned connecting wires and various wound wires, including the corner wires 22, are integrally formed and connected inside the armature winding, eliminating the need for cross-wire connections. Phase leads are directly led out from the corner wires, and the phase leads, corner wires, and interlayer conductive connection holes 24 are all located on the same side of the motor, without occupying more motor space. This simplifies the manufacturing process and facilitates the miniaturization / micro-miniaturization of the motor. The leads are equipped with solder pads for soldering connecting wires and connecting them to the drive controller.

[0116] In this embodiment, one phase of the lead wire or lead wire is located on both sides of the coil joint. It can be soldered on the pad first, and the two separate A-phase coils on both sides can be connected by soldering (there is a solder point at the coil joint). At the same time, it can be connected to the drive controller through a unified connecting wire from the pad. Alternatively, the two separate A-phase lead wires can be connected by soldering the connecting wires to their respective pads, and the connecting wires on both sides can be connected to the drive controller. In this case, there is no solder point at the coil joint.

[0117] Example 4

[0118] The difference between this embodiment and Embodiment 1 is that in this embodiment, n=1, k=2, and m=3 are preferably used to describe the specific connection method in which the single-group winding coils in the conductive layer are connected in a star configuration and the unit motors are connected in series. Figure 12 and Figure 13As shown, the completed winding line of the 2nth layer of the odd-numbered unit motor is connected to the starting winding line of the even-numbered unit motor through the interlayer conductive connection hole two. The completed winding line of the 2nth layer of the even-numbered unit motor is connected to the starting winding line of the next odd-numbered unit motor through the interlayer conductive connection hole two, until the coil of the last unit motor of the current phase is completed. Finally, the completed winding lines of all phases are connected together to form the neutral line.

[0119] Example 5

[0120] The difference between this embodiment and Embodiment 1 is that in this embodiment, n=1, k=2, and m=3 are preferably used to describe the specific connection method of star connection between single winding coils in the conductive layer and parallel connection between unit motors. Figure 12 and Figure 14 As shown, the winding start line of the odd-numbered unit motor is connected to the winding start line of the even-numbered unit motor, and the winding completion lines of all unit motors are connected together to form the neutral line.

[0121] Example 6

[0122] The difference between this embodiment and the previous embodiment is that: in this embodiment, as... Figure 11 As shown, the fill rate of conductors in both odd-numbered and even-numbered conductive layers is between 50% and 85%, which effectively improves the electrical load capacity of the motor and further enhances the output torque and torque density of the motor.

[0123] The preferred embodiments of the present invention have been described in detail above. However, the present invention is not limited to the specific details in the above embodiments. Within the scope of the technical concept of the present invention, various equivalent transformations can be made to the technical solutions of the present invention, and these equivalent transformations all fall within the protection scope of the present invention.

Claims

1. A flexible stator with complementary interface misalignment, characterized in that: The planar full-pitch flexible windings are rolled and spliced ​​together to form the shape. The planar full-pitch flexible winding includes 2n conductive layers and 2n+1 flexible insulating layers stacked alternately; wherein, the top and bottom surfaces of the conductive layers both have flexible insulating layers; The 2n conductive layers include odd-numbered conductive layers that are staggered from bottom to top and left to right, and even-numbered conductive layers; The planar full-pitch flexible winding includes an overlapping region and two misaligned regions located on both sides of the overlapping region; when the planar full-pitch flexible winding is rolled and spliced, the two misaligned regions can overlap and complement each other. The coils of the odd-numbered conductive layers and the coils of the even-numbered conductive layers are arranged in a continuous series loop from the outside to the inside. The coils of the odd-numbered conductive layers are electrically connected to the coils of the even-numbered conductive layers through the interlayer conductive connection holes at the ends. The coils of the even-numbered conductive layers are also electrically connected to the next odd-numbered conductive layer through the interlayer conductive connection holes at the ends.

2. The interface misalignment complementary flexible stator according to claim 1, characterized in that: The formula for calculating the length L of each misaligned region is: ； in: ； In the formula, D is the outer diameter, inner diameter, or median of the innermost radial conductive layer in the interface misaligned complementary flexible stator. A c The circular angle of the misaligned region in the interface misaligned complementary flexible stator; a is a constant, ranging from 0.8 to 1.2; A p It is the circumferential mechanical angle between the neutral lines of the two sides of a single winding coil, corresponding to the circumferential mechanical angle of a rotor pole.

3. The interface misalignment complementary flexible stator according to claim 1, characterized in that: The end span of the coil edge located in the misaligned area is greater than the end span of the coil edge located in the overlapping area of ​​the same group of coils, so that all interlayer conductive connection holes for conductive connection between odd-numbered conductive layer coils and even-numbered conductive layer coils are located in the overlapping area.

4. The interface misalignment complementary flexible stator according to claim 1, characterized in that: The circumferential mechanical angle between the neutral lines of the two sides of the coil side of a single winding coil in the conductive layer is 0.8 to 1.2 times the circumferential mechanical angle corresponding to a rotor pole.

5. The interface misalignment complementary flexible stator according to claim 1, characterized in that: Each conductive layer contains k×m single-group winding coils, each of which is a multi-turn coil; where k is the number of unit motors and m is the number of motor phases; the single-group winding coils in the conductive layer are connected by star or delta connection.

6. The interface misalignment complementary flexible stator according to claim 5, characterized in that: In the conductive layer, the single-group winding coils are connected by a star connection, and the specific connection method is as follows: A. When k=1 and 2n=2, each phase coil starts from the phase lead of the odd-numbered conductive layer and is wound from the outside to the inside, with each single winding coil as a unit. Each turn is first connected to the even-numbered conductive layer through the interlayer conductive connection hole at the non-lead end, and then connected to the odd-numbered conductive layer through the interlayer conductive connection hole at the lead end. This cycle continues until the phase coil is wound. When 2n>2, the even-numbered conductive layer is conductively connected to the next odd-numbered conductive layer through the interlayer conductive connection hole at the phase lead end, and so on, until all 2n conductive layers are wound. B. When k > 1 and the in-phase coils of k unit motors are connected in series, the completed winding line of the 2nth layer of the odd-numbered unit motor is connected to the starting winding line of the even-numbered unit motor through the interlayer conductive connection hole two. The completed winding line of the 2nth layer of the even-numbered unit motor is connected to the starting winding line of the next odd-numbered unit motor through the interlayer conductive connection hole two, until the coil of the last unit motor of the current phase is completed. Finally, the completed winding lines of all phases are connected together to form the neutral line. C. When k > 1 and the in-phase coils of k unit motors are connected in parallel, the winding start line of the odd-numbered unit motor is connected to the winding start line of the even-numbered unit motor, and the winding completion lines of all unit motors are connected together to form the neutral line.

7. The interface misalignment complementary flexible stator according to claim 5, characterized in that: In the conductive layer, the single-group winding coils are connected using a corner connection. The specific connection method is as follows: A. When k=1 and 2n=2, the odd-numbered conductive layers start from the winding start line of the current phase coil and are wound from the outside to the inside, taking a single group of winding coils as the unit. Each turn needs to be connected to the even-numbered conductive layer through the interlayer conductive connection hole at the non-lead end, and then connected to the odd-numbered conductive layer through the interlayer conductive connection hole at the lead end. This cycle continues until the current phase coil is wound. When 2n>2, the even-numbered conductive layers are conductively connected to the next odd-numbered conductive layer through the interlayer conductive connection hole at the lead end. This cycle continues until all 2n layers are wound. B. When k > 1 and the coils of k unit motors are connected in series, the winding completion line of the 2nth layer of the odd-numbered unit motor is connected to the winding start line of the current group coil of the even-numbered unit motor through the interlayer conductive connection hole three. The winding completion line of the 2nth layer of the even-numbered unit motor is connected to the winding start line of the next odd-numbered unit motor through the interlayer conductive connection hole three. After the current phase coil is connected, it is connected to the winding start line of the adjacent phase through the interlayer conductive connection hole delta connection. C. When k > 1 and the in-phase coils of k unit motors are connected in parallel, the winding start line of the odd-numbered unit motor is connected to the winding start line of the even-numbered unit motor. After all the winding completion lines of the unit motors are connected together, they are connected to the winding start line of the adjacent phase coil through the interlayer conductive connection hole three.

8. The interface misalignment complementary flexible stator according to claim 1, characterized in that: Controlling the fill rate of the conductors in the odd-numbered and even-numbered conductive layers within their respective conductive layers. between.

9. The interface misalignment complementary flexible stator according to claim 1, characterized in that: The total thickness of the two misaligned regions after they are combined and complement each other is equal to the thickness of the overlapping region.

10. A lightweight, high torque density permanent magnet motor, characterized in that: It includes a coaxially arranged interface misaligned complementary flexible stator, rotor, housing and shaft; wherein, there is an air gap between the interface misaligned complementary flexible stator and the rotor.

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