Stator of flat wire motor
By designing a multi-layer structure of three-phase flat-line motor stator, the problem of insufficient motor power density in a narrow space is solved, and the effect of high power output and magnetic circuit balance in a small space is achieved.
Patent Information
- Application Number
- CN202421062391.5
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-05-15
- Publication Date
- 2025-01-14
- Estimated Expiration
- 2034-05-15
AI Technical Summary
In new energy vehicle motors, existing flat line motor stators are difficult to meet the needs of smaller axial lengths and more slots in a narrow space environment, resulting in insufficient power density.
A flat wire motor stator including iron core and three-phase flat wire winding is designed. The number of winding poles is 12, the number of core winding ducts is 72, and there are 2 branches per phase, using I-shaped and U-shaped conductors. The conductor forms a multi-layer structure in the winding trough, and through specific conductor insertion and welding methods, the magnetic circuit balance and simple structure are ensured.
Provides greater power in a smaller axial space, has few types of conductors, simple structure and balanced magnetic circuits, and is suitable for space-constrained motor applications.
Smart Images
Figure CN222356077U_ABST
Abstract
Description
Technical Field
[0001] The present application relates to the field of motors, and in particular to a stator of a flat wire motor using flat wires as windings. Background Art
[0002] Taking the motor of new energy vehicles as an example, the motor stator using flat wire as winding has a higher copper full rate, which can improve the power density of the motor.
[0003] The applicant has proposed a winding method suitable for a 6-pole 48-slot stator. However, in certain scenarios, such as when the space left for the motor inside a vehicle is relatively narrow, it is necessary to use a motor stator with a smaller axial length and a larger number of slots. Utility Model Content
[0004] The purpose of the present application is to overcome or at least alleviate the deficiencies of the above-mentioned prior art and to provide a stator for a flat wire motor.
[0005] The present application provides a stator of a flat wire motor, comprising an iron core and a flat wire winding, wherein the flat wire winding has a three-phase winding, the number of poles of the flat wire winding is 12, the number of winding slots of the iron core is 72, the flat wire winding of each phase comprises two branches, each of the branches comprises two I-shaped conductors and a plurality of U-shaped conductors, each of the I-shaped conductors has one leg, each of the U-shaped conductors has two legs, and the I-shaped conductors are arranged at the inlet and outlet ends of each branch, wherein:
[0006] The number of layers of the flat wire winding formed in the winding slot is M, where M is an integer greater than 2.
[0007] A U-shaped conductor with one leg inserted into the first layer has its other leg also inserted into the first layer, and the pitch of the U-shaped conductor in the first layer is 5 or 7,
[0008] A U-shaped conductor with one leg inserted into the Mth layer has another leg also inserted into the Mth layer, and the pitch of the U-shaped conductor in the Mth layer is 6,
[0009] In the remaining layers, the legs of the U-shaped conductor are inserted into the two adjacent layers.
[0010] In at least one embodiment, adjacent legs of two adjacent U-shaped conductors are welded together, and the pitches between the welded legs are all 6.
[0011] In at least one embodiment, within each pole and each phase, the conductor fills two consecutive winding slots.
[0012] In at least one embodiment, the pitch of the U-shaped conductors inserted in the 2nd to M-1th layers is 6.
[0013] In at least one embodiment, the conductor extends into three consecutive winding slots per pole per phase, and,
[0014] The middle slot of three consecutive winding slots is the Kth slot, and the Kth slot is fully filled.
[0015] M is an even number, and the K-1th slot and the K+1th slot are occupied from the 1st to the M / 2th layers and from the M / 2+1th to the Mth layers respectively, or the K-1th slot and the K+1th slot are occupied from the M / 2+1th to the Mth layers and from the 1st to the M / 2th layers respectively.
[0016] In at least one embodiment, the pitch of the U-shaped conductors inserted into the M / 2th and M / 2+1th layers is 5 or 7,
[0017] The pitches of the U-shaped conductors inserted into the other layers except the 1st layer, the Mth layer, the M / 2th layer, and the M / 2+1th layer are all 6.
[0018] In at least one embodiment, the direction of each branch is:
[0019] While winding around the stator core in the circumferential direction, it crosses layers in the radial direction; in the process of crossing layers and winding around, the winding direction in the circumferential direction is changed after encountering the radial innermost layer or the radial outermost layer.
[0020] In at least one embodiment, the first layer is the radially innermost layer, the Mth layer is the radially outermost layer, or
[0021] The first layer is the radially outermost layer, and the Mth layer is the radially innermost layer.
[0022] In at least one embodiment, the two branches are connected in series or in parallel.
[0023] In at least one embodiment, the incoming end and the outgoing end of the branch are both located at the crown end, and the incoming end and the outgoing end are both located at the same layer, or
[0024] The incoming line end and the outgoing line end of the branch circuit are both located at the welding end, and the incoming line end and the outgoing line end are located at two adjacent layers.
[0025] The stator of the flat wire motor according to the present application has a large number of slots and can therefore provide greater power in a smaller axial space. The flat wire motor also has fewer types of conductors, a simple structure, and a balanced magnetic circuit. BRIEF DESCRIPTION OF THE DRAWINGS
[0026] Figure 1 FIG. 1 is a schematic diagram of a partial structure of a stator of a flat wire motor according to a first embodiment of the present application.
[0027] Figure 2 It is a schematic diagram of the winding path of a certain phase of the stator of the flat wire motor according to the first embodiment of the present application.
[0028] Figure 3 yes Figure 2 A schematic diagram of the branch road routing direction.
[0029] Figure 4 yes Figure 3 A schematic diagram showing the two branches combined.
[0030] Figure 5 1 is a schematic diagram of a winding path of a stator of a flat wire motor according to a second embodiment of the present application.
[0031] Figure 6 yes Figure 5 A schematic diagram of the branch road routing direction.
[0032] Figure 7 1 is a schematic diagram of the winding path of the stator of the flat wire motor according to the third embodiment of the present application.
[0033] Figure 8 FIG. 4 is a schematic diagram showing a partial structure of a stator of a flat wire motor according to a fourth embodiment of the present application.
[0034] Fig. 9 This is a schematic diagram of the winding path of a branch of a certain phase of the stator of a flat wire motor according to the fourth embodiment of the present application. DETAILED DESCRIPTION
[0035] The exemplary embodiments of the present application are described below with reference to the accompanying drawings. It should be understood that these specific descriptions are only used to teach those skilled in the art how to implement the present application, and are not intended to exhaust all possible methods of the present application, nor to limit the scope of the present application.
[0036] First embodiment
[0037] Reference Figures 1 to 4 The stator of the flat wire motor according to the first embodiment of the present application (hereinafter referred to as the stator) is introduced. The stator includes an iron core and a winding, and the winding is inserted into a winding slot (hereinafter referred to as the slot) of the iron core.
[0038] The number of poles of the winding in the present application is 12, the number of winding slots of the core is 72, and the winding of each phase includes 2 branches. Each branch includes multiple conductors, also known as hairpins or PINs, and specifically, the conductors of each branch include 2 I-shaped hairpins and multiple U-shaped hairpins. The U-shaped hairpin has two legs, which are connected at one end to form a crown end and separated at the other end to form a welding end. The I-shaped hairpin has only one leg, and one I-shaped hairpin is set at the incoming and outgoing ends of each branch.
[0039] Figure 2The wiring sequence of one phase of the winding of the stator of the first embodiment of the present application is shown. Each column in the figure represents a winding slot, and the winding slot that is not inserted in the phase portion is omitted and not shown; each row in the figure represents a layer in the slot. It should be understood that the layer mentioned here is an abstract concept. The layer only exists when the wire is inserted. When the wire is not inserted in the slot, there is no layer structure. Depending on the actual design structure of the motor, the first layer can be the radial innermost layer or the radial outermost layer. The numbers in the unshaded spaces in the figure represent the wiring sequence of the windings of the first branch, and the numbers in the shaded spaces represent the wiring sequence of the windings of the second branch.
[0040] To show clarity, Figure 3 The wiring sequence of the two branches is shown separately in the figure. The number 1 represents the incoming terminal of the branch winding, which is represented by the letter A or B in the figure, where A represents the incoming terminal of the first branch and B represents the incoming terminal of the second branch. The number 96 represents the outgoing terminal of the branch winding, which is represented by the letter a or b in the figure, where a represents the outgoing terminal of the first branch and b represents the outgoing terminal of the second branch. The solid line in the figure represents the crown end of the conductor, and the dotted line represents the welding end of the conductor. The incoming terminal and the outgoing terminal in this embodiment are both located at the crown end, refer to Figure 1 .
[0041] Figure 4 The routing sequence of the two branches is combined in one diagram to facilitate observation of the relationship between the two branches.
[0042] Reference Figure 2 In this embodiment, the conductor of each branch extends into two consecutive winding slots in each pole and fills up the two consecutive winding slots.
[0043] The number of slots occupied by each branch in each layer is equal to the number of poles, 12. For the slot occupied by the phase conductor, the number of layers occupied by the two branches in the slot is equal, both 4.
[0044] The above-mentioned wire insertion method makes the magnetic circuit formed by the winding balanced.
[0045] Reference Figure 3 and Figure 4 , in the 1st and 8th layers, the two legs of the U-shaped hairpin are inserted into the same layer; and the pitch (number of slots between the two legs) of the U-shaped hairpin in the 1st layer is 5 or 7, and the pitch of the U-shaped hairpin in the 8th layer is 6. In the layers other than the 1st and 8th layers, the two legs of the U-shaped hairpin are respectively inserted into two adjacent layers, such as the 2nd and 3rd layers, the 4th and 5th layers, and the 6th and 7th layers; and the pitch of these U-shaped hairpins is 6.
[0046] The winding direction of each branch is: while winding around the stator core in the circumferential direction, it crosses layers in the radial direction; in the process of winding across layers, when encountering the radial innermost layer or radial outermost layer, that is, the 1st layer or the 8th layer, the winding direction in the circumferential direction is changed. For example, the direction from small to large slot numbers is defined as clockwise, and the opposite direction is counterclockwise. Figure 2 The first branch starts from the incoming line end and gradually extends from the 1st layer to the 8th layer in a clockwise direction (i.e. the order of numbers 1, 2, 3, 4, 5, 6, 7, and 8 in the figure). Then the branch changes the winding direction and gradually extends from the 8th layer back to the 1st layer in a counterclockwise direction.
[0047] Along the extension direction of the branch, adjacent legs of adjacent hairpins are connected by welding, and the pitch between the two welding ends is 6.
[0048] The inlet and outlet ends of each branch are located at two adjacent poles, and the circumferential distance between the inlet and outlet ends is small, so that the busbar at the end can have a simple structure and a small size.
[0049] Second embodiment
[0050] Reference Figure 5 and Figure 6 A second embodiment of the present application is introduced, which is a variation of the first embodiment. The same or similar features as those of the first embodiment are denoted by the same or similar reference numerals, and detailed description of these features is omitted.
[0051] The main difference between this embodiment and the first embodiment is that the slots into which the two branches of each phase extend are three consecutive slots, but the three slots are not fully occupied; only the middle slot is fully occupied, and the middle slot is defined as slot K, while the K-1th slot and the K+1th slot occupy the 1st to 4th layers and the 5th to 8th layers respectively. Or from another perspective, for the 1st to 4th layers, the two branches of each phase occupy two consecutive half slots; for the 5th to 8th layers, the two branches of each phase occupy two consecutive half slots; these two groups of consecutive half slots are staggered by one slot in the circumferential direction.
[0052] This variation brings about a change in the pitch of some conductors, specifically, the pitch of the U-shaped hairpins inserted into the 4th and 5th layers is 7.
[0053] Third embodiment
[0054] Reference Figure 7 The third embodiment of the present application is introduced, which is a variation of the first embodiment and the second embodiment. The main difference between this embodiment and the second embodiment is that the circumferential staggered directions of the two groups of half slots occupied by the two branches of each phase are different.
[0055] This modification makes the pitch of the U-shaped hairpins inserted into the 4th and 5th layers modified to 5.
[0056] Fourth embodiment
[0057] Reference Figure 8 and Fig. 9 The fourth embodiment of the present application is introduced, which is another variation of the first embodiment.
[0058] In this embodiment, the inlet and outlet terminals are both located at the welding terminal, which is equivalent to connecting the inlet and outlet terminals of the same branch of the original crown terminal in the first embodiment together, for example Fig. 9 Connect the unshaded numbers 1 and 96 together at the crown end; at the same time, open one of the original welded pairs, i.e. Fig. 9 The unshaded numbers 96 and 95 in the figure serve as the new incoming and outgoing terminals, respectively.
[0059] It should be understood that the above-mentioned embodiments and some aspects or features thereof may be appropriately combined.
[0060] Of course, the present application is not limited to the above-mentioned embodiments, and those skilled in the art can make various modifications to the above-mentioned embodiments of the present application under the guidance of the present application without departing from the scope of the present application. For example:
[0061] (i) The number of layers formed by the winding in the slot is not limited to 8 layers, but can be expanded to other numbers of layers, and is not limited to an even number of layers, but can also be an odd number of layers.
[0062] (ii) As an extension of the fourth embodiment, the incoming and outgoing ends of the branch circuit may also be located at other layers.
Claims
1. A stator of a flat wire motor, comprising an iron core and a flat wire winding, wherein the flat wire winding has a three-phase winding, the number of poles of the flat wire winding is 12, the number of winding slots of the iron core is 72, the flat wire winding of each phase comprises two branches, each of the branches comprises two I-shaped conductors and a plurality of U-shaped conductors, each of the I-shaped conductors has one leg, each of the U-shaped conductors has two legs, the I-shaped conductors are arranged at the inlet and outlet ends of each branch, characterized in that: The number of layers of the flat wire winding formed in the winding slot is M, where M is an integer greater than 2. A U-shaped conductor with one leg inserted into the first layer has its other leg also inserted into the first layer, and the pitch of the U-shaped conductor in the first layer is 5 or 7, A U-shaped conductor with one leg inserted into the Mth layer has another leg also inserted into the Mth layer, and the pitch of the U-shaped conductor in the Mth layer is 6, In the remaining layers, the legs of the U-shaped conductor are inserted into the two adjacent layers.
2. The stator of the flat wire motor according to claim 1, characterized in that: Adjacent legs of two adjacent U-shaped conductors are welded together, and the pitches between the welded legs are all 6.
3. The stator of the flat wire motor according to claim 1, characterized in that: In each pole and phase, the conductor fills two consecutive winding slots.
4. The stator of the flat wire motor according to claim 3, characterized in that: The pitch of the U-shaped conductors inserted in the 2nd to M-1th layers is 6.
5. The stator of the flat wire motor according to claim 1, characterized in that: In each pole and phase, the conductor extends into three consecutive winding slots, and, The middle slot of three consecutive winding slots is the Kth slot, and the Kth slot is fully filled. M is an even number, and the K-1th slot and the K+1th slot are occupied from the 1st to the M / 2th layers and from the M / 2+1th to the Mth layers respectively, or the K-1th slot and the K+1th slot are occupied from the M / 2+1th to the Mth layers and from the 1st to the M / 2th layers respectively.
6. The stator of the flat wire motor according to claim 5, characterized in that: The pitch of the U-shaped conductors inserted into the M / 2 and M / 2+1 layers is 5 or 7. The pitches of the U-shaped conductors inserted into the other layers except the 1st layer, the Mth layer, the M / 2th layer, and the M / 2+1th layer are all 6.
7. The stator of the flat wire motor according to claim 1, characterized in that: The direction of each branch is: While winding around the stator core in the circumferential direction, it crosses layers in the radial direction; in the process of crossing layers and winding around, the winding direction in the circumferential direction is changed after encountering the radial innermost layer or the radial outermost layer.
8. The stator of the flat wire motor according to any one of claims 1 to 7, characterized in that: The first layer is the radially innermost layer, and the Mth layer is the radially outermost layer, or The first layer is the radially outermost layer, and the Mth layer is the radially innermost layer.
9. The stator of the flat wire motor according to any one of claims 1 to 7, characterized in that: The two branches are connected in series or in parallel.
10. The stator of the flat wire motor according to any one of claims 1 to 7, characterized in that: The incoming and outgoing terminals of the branch are both located at the crown end, and the incoming and outgoing terminals are both located at the same level, or The incoming line end and the outgoing line end of the branch circuit are both located at the welding end, and the incoming line end and the outgoing line end are located at two adjacent layers.