Three-phase 48-slot 8-pole single-layer flat wire winding structure and motor

Abstract

The utility model discloses a three-phase 48-slot 8-pole single-layer flat wire winding structure and a motor, in the winding structure, a stator is provided with 48 slots, the number of three-phase 8-pole pole phase groups is equal to 1 / 2 of the slot number, the total number of the pole phase groups is 24, each phase comprises 8 pole phase groups, each pole phase group is composed of single-turn or multi-turn flat wire hairpin coils, each coil accounts for 2 slots, the span of each flat wire hairpin coil is 6 slots, and the flat wire hairpin coils are arranged in parallel. The structure aims to change the winding structure that the existing 48-slot 8-pole flat wire hairpin can only be made into even number of layers and the number of turns in the slot can only be even number, and the number of turns in the slot of the 48-slot 8-pole single-layer flat wire hairpin winding can be flexibly selected and matched, so that the power output of a new energy driving motor and a vehicle voltage platform are higher in adaptation degree, and the output coverage range of a high-efficiency area of the motor is wider; and the single-layer flat wire winding has the structural characteristics of simple structure, wider slot pole and turn ratio matching surface, fewer end welding spots, guide material saving, cost reduction and product reliability improvement.

Description

Technical Field

[0001] This application relates to the technical field of new energy vehicle drive, and specifically relates to a three-phase 48-slot 8-pole single-layer flat wire winding structure and an electric motor. Background Art

[0002] As shown in the Figure 1 accompanying drawings, the traditional 48-slot 8-pole flat wire hairpin motor winding is made into a hairpin shape by flat wire, and then the ends are twisted and welded to form a waveform structure. Each coil occupies 2 slots, the number of pole-phase groups is equal to the number of slots, and the number of turns of the winding in the slot can only form even numbers such as 2, 4, 6, 8, etc. There are many welding points at the winding ends, wasting working hours and increasing costs. Parameters such as the slot-pole and turn ratio matching of the winding cannot be flexibly adapted, resulting in a narrow coverage of the power output in the high-efficiency area of the new energy flat wire hairpin motor. In order to make the new energy vehicle drive power more adaptable to parameters such as the vehicle power demand and voltage platform, make the output range of the high-efficiency area of the new energy vehicle drive motor wider, and the vehicle cruising range farther, it is required that the number of turns of the flat wire hairpin in the slot can be flexibly selected to meet the power demand of the new energy vehicle. Therefore, it is necessary to improve the existing flat wire hairpin winding structure. Summary of the Utility Model

[0003] Aiming at the deficiencies of the existing technology, this application proposes a three-phase 48-slot 8-pole single-layer flat wire winding structure. The stator has 48 slots, the number of three-phase 8-pole pole-phase groups is equal to 1 / 2 of the number of slots, the total number of pole-phase groups is 24, each phase has 8 pole-phase groups, each pole-phase group is composed of a single-turn or multi-turn flat wire hairpin coil, each coil occupies 2 slots, and the span of each flat wire hairpin coil is 6 slots. The purpose of this structure is to change the winding structure of the existing 48-slot 8-pole flat wire hairpin that can only be made into an even number of layers and the number of turns in the slot can only be an even number. By flexibly selecting the number of turns of the 48-slot 8-pole single-layer flat wire hairpin winding in the slot, the power output of the new energy drive motor can be better adapted to the vehicle voltage platform, and the output coverage of the high-efficiency area of the motor is wider.

[0004] According to one aspect of the present application, a three-phase 48-slot 8-pole single-layer flat wire winding structure includes a stator core and a single-layer winding wound by three-phase parallel flat wires. The three phases are phase U, phase V, and phase W. There are 48 stator slots evenly distributed on the stator core. Each single-layer winding of each phase is connected by 8 pole-phase groups in a symmetric distribution structure. And each pole-phase group is connected by single-turn or multi-turn flat wire hairpin coils of the same phase belonging to the same magnetic pole. Each flat wire hairpin coil occupies two of the stator slots. The 8 pole-phase groups in the same phase are evenly and equidistantly distributed in the stator core, and all the pole-phase groups in the three-phase single-layer windings do not occupy the same stator slot. Each pole-phase group in each single-layer winding of each phase can be connected to the adjacent pole-phase groups at both ends in the same phase head-to-head and tail-to-tail. Each pole-phase group in the same phase generates a magnetic pole, and the magnetic pole polarities generated by two adjacent pole-phase groups in the same phase are opposite; since the three-phase 48-slot 8-pole single-layer flat wire winding structure is a single-layer structure in the stator slot, the number of turns of the flat wire hairpin coil in each slot of each phase can be arbitrarily selected as single-turn or multi-turn according to the needs of the motor.

[0005] Preferably, the flat wire hairpin coil is an open coil with an end "U" shape or "V" shape with a width span of 1 to 6 slots made by straightening and cutting a flat wire guide material. The end of each flat wire hairpin coil is twisted outward by a certain angle according to the size of the motor, and according to the number of turns of the flat wire hairpin coil in each stator slot, the twisting angle of the flat wire hairpin coil from the outside to the inside gradually decreases, so that a certain interval distance is formed between the ends of the flat wire hairpin coils of each layer of the winding, thereby making 8 flat wire hairpin coils with the same span in each layer of each phase. The flat wire hairpin coils are placed into the stator slots according to their respective phases. The two ends of the flat wire at the part where each pole-phase group extends out of the stator slot opening are bent outward or inward by 1 / 2 pole pitch dimension along the arc of the stator core and are connected to the flat wires at both ends of the adjacent pole-phase group in the same phase head-to-head and tail-to-tail. The flat wires at the ends of the three-phase windings are cross-connected phase by phase and layer by layer, and three-phase lead-out wires are reserved. After welding the remaining connection points, a three-phase 48-slot 8-pole single-layer flat wire winding structure is formed.

[0006] Preferably, the flat wire hairpin coil is an open coil with an end "U" shape or "V" shape having a width span of 1 to 6 slots, which is made by straightening and cutting a flat wire guide material. The end of each flat wire hairpin coil is twisted outward by a certain angle according to the size of the motor, and according to the number of turns of the flat wire hairpin coil in each stator slot, the twisting angle of the flat wire hairpin coil from the outside to the inside gradually decreases, so that a certain spacing distance is formed between the ends of the flat wire hairpin coils of each layer of winding, thereby making 8 flat wire hairpin coils with the same span in each phase and each layer. The flat wire hairpin coils are placed into the stator slots according to their respective phases. At both ends of the part where the pole phase group extends out of the stator slot opening, one flat wire is reserved for each end, which is bent outward along the arc of the stator core by a size of 1 / 2 pole pitch and is connected to the reserved flat wires at both ends of the adjacent pole phase group in the same phase by head-to-head and tail-to-tail connection. The remaining flat wires at both ends of the pole phase group are twisted inward to the center position of the flat wire hairpin coil and are sequentially connected to the remaining turns of the flat wire hairpin coil on the other side of the same-pole and same-phase winding, and three-phase lead-out wires are reserved, and after welding the remaining connection points, a three-phase 48-slot 8-pole single-layer flat wire winding structure is formed.

[0007] A motor includes a rotor and a three-phase 48-slot 8-pole single-layer flat wire winding structure, and the rotor is capable of rotating relative to the three-phase 48-slot 8-pole single-layer flat wire winding structure.

[0008] Compared with the traditional 48-slot 8-pole hairpin flat wire motor winding, the present application has the characteristics of a single-layer flat wire winding structure, which is simple in structure, has a wider matching surface of slot poles and turn ratios, fewer end soldering points, saves wire materials, reduces costs, and improves product reliability; the number of pole phase groups in the 48 slots and 8 poles of the present application is 1 / 2 of that of the traditional wave winding, and only one side of a winding is placed in each slot, avoiding the hidden danger of inter-turn breakdown, improving the fault tolerance ability of the new energy drive motor, having fewer winding coils, simple process, fewer welding points, reducing working hours, reducing costs, and the number of turns in the slot can be flexibly selected, making the external characteristics such as power output and back electromotive force of the winding and the voltage platform have a higher matching degree, improving the performance of the motor, and improving the working efficiency of the motor. Description of the Drawings

[0009] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly describe the drawings required to be used in the embodiments or the prior art. Obviously, the following drawings are only examples of the embodiments of the present invention, and those of ordinary skill in the art can obtain other drawings according to these drawings without creative efforts.

[0010] Figure 1 It is a schematic diagram of the developed structure of a traditional 48-slot 8-pole hairpin flat wire motor winding.

[0011] Figure 2It is a schematic diagram of the outward expansion structure of the winding welding end of a three-phase 48-slot 8-pole single-layer flat wire winding structure according to an embodiment of the present application.

[0012] Figure 3 It is a schematic diagram of the inward expansion structure of the winding welding end of a three-phase 48-slot 8-pole single-layer flat wire winding structure according to an embodiment of the present application. Detailed implementation manners

[0013] In order to make the content of the present application more clearly understood, the technical solutions in the embodiments of the present application will be clearly and completely described below in conjunction with the accompanying drawings in the embodiments of the present application. What is described is only a part of the embodiments of the present application, not all embodiments. All other implementation manners obtained by those of ordinary skill in the art without creative efforts belong to the scope protected by the present application.

[0014] As Figure 2 and Figure 3 shown, a three-phase 48-slot 8-pole single-layer flat wire winding structure includes a stator core and a single-layer winding wound by three-phase parallel flat wires. The three phases are the U phase, the V phase, and the W phase. There are 48 stator slots evenly distributed on the stator core. Each phase of the single-layer winding is connected by 8 pole-phase groups in a symmetric distribution structure. And each pole-phase group is connected by single-turn or multi-turn flat wire hairpin coils of the same phase under the same magnetic pole. Each flat wire hairpin coil occupies two stator slots. The 8 pole-phase groups in the same phase are evenly and equidistantly distributed in the stator core, and all the pole-phase groups in the three-phase single-layer winding do not occupy the same stator slot. In the single-layer winding, the number of three-phase 8-pole pole-phase groups is equal to 1 / 2 of the number of slots, and the total number of coils is 24. Compared with the traditional 48-slot 8-pole hairpin flat wire motor winding, the total number of coils is reduced by half; each pole-phase group in each phase of the single-layer winding can be connected to the adjacent pole-phase groups at both ends according to the connection of the same-phase head to head and tail to tail. Each pole-phase group in the same phase generates a magnetic pole, and the magnetic pole polarities generated by two adjacent pole-phase groups in the same phase are opposite; since the three-phase 48-slot 8-pole single-layer flat wire winding structure is a single-layer structure in the stator slot, the number of turns of the flat wire hairpin coil in each phase and each slot can be arbitrarily selected as single-turn or multi-turn according to the needs of the motor; in this design, the characteristics of the single-layer flat wire winding structure are simple structure, a wider matching surface of slot poles and turn ratios, fewer end joints, saving conductive materials, reducing costs, and improving product reliability; the number of pole-phase groups in the 48-slot 8-pole of the present application is 1 / 2 of the traditional wave winding. Only one side of a winding is placed in each slot, avoiding the hidden danger of inter-turn breakdown, improving the fault tolerance ability of the new energy drive motor, fewer winding coils, simple process, fewer welding points, reducing working hours, reducing costs, and the number of turns in the slot can be flexibly selected, making the external characteristics such as power output and back electromotive force of the winding and the voltage platform have a higher matching degree, improving the performance of the motor, and improving the working efficiency of the motor.

[0015] In one embodiment, in combination with Figure 2 , in an arrangement of this structure, the flat wire hairpin coil is an open coil with an end "U" shape or "V" shape having a width span of 1 to 6 slots, which is made by straightening and cutting a flat wire conductor. The end of the coil is twisted outward by a certain angle according to the size of the motor. According to the number of turns per slot, the twisting angle gradually decreases layer by layer, so that a certain spacing distance is formed between the ends of each layer of coils, and 8 open coils with the same span are made for each phase and each layer. The open coils are placed in the stator slots according to their respective phases. The two ends of the flat wire of the part where each pole-phase group extends out of the stator slot opening are bent outward or inward by a size of 1 / 2 pole pitch along the arc of the stator core, and the lead wires are reserved. They are connected to the adjacent coils of the same layer and the same phase with head-to-head and tail-to-tail connections. The ends of the three-phase windings are cross-connected phase by phase and layer by layer, and three-phase lead wires are left. After welding is completed, a 48-slot 8-pole single-layer flat wire winding is formed.

[0016] In one embodiment, with reference to Figure 3 , in another arrangement of this structure, the flat wire hairpin coil is an open coil with an end "U" shape or "V" shape having a width span of 1 to 6 slots, which is made by straightening and cutting a flat wire conductor. The end of the coil is twisted outward by a certain angle according to the size of the motor. According to the number of turns per slot, the twisting angle gradually decreases layer by layer, so that a certain spacing distance is formed between the ends of each layer of coils, and 8 open coils with the same span are made for each phase and each layer. The open coils are placed in the stator slots according to their respective phases. One flat wire is reserved at each of the two ends of the flat wire of the part where the pole-phase group extends out of the stator slot opening, and they are bent outward by a size of 1 / 2 pole pitch along the arc of the stator core, and are connected to the reserved flat wires at the two ends of the adjacent pole-phase groups in the same phase with head-to-head and tail-to-tail connections. The remaining coils are twisted inward to the center position of the coil, and are sequentially connected to the remaining turns of the coil on the other side of the same pole and the same phase winding, and three-phase lead wires are reserved. After welding is completed, a three-phase 48-slot 8-pole single-layer flat wire winding is formed.

[0017] A motor includes a rotor and a three-phase 48-slot 8-pole single-layer flat wire winding structure, and the rotor can rotate relative to the three-phase 48-slot 8-pole single-layer flat wire winding structure.

[0018] In addition, two identical hairpin winding motors are respectively compared with the traditional wave winding 48-slot 8-pole structure and the 48-slot 8-pole single-layer winding in this application. According to the single-layer 48-slot 8-pole flat wire winding structure, the number of windings is 1 / 2 of the number of stator slots. The copper consumption is less than that of the traditional 48-slot 8-pole wave winding, the winding resistance is small, the loss is low, and the efficiency is high; according to the number of slots per pole and per phase q = 48 / (2 * 4 * 3) = 2, the fundamental wave electromotive force and magnetomotive force synthesized by the two sides of a single coil are the largest.

[0019] The twisting angle described in this application should be understood in a broad sense, which can be a radial outward expansion, an axial upward expansion, or a twisting angle with a certain axial inclination. For those of ordinary skill in the art, the specific meanings of the above terms in this application can be understood according to the specific situation.

[0020] The above embodiments are only used to illustrate the technical solutions of the embodiments of the present application, rather than limiting them. Although the embodiments of the present application have been described in detail with reference to the foregoing embodiments, those of ordinary skill in the art should understand that without departing from the spirit and scope defined by the claims of the present application, they can still modify the technical solutions described in the foregoing embodiments, or perform equivalent replacements for some of the technical features.

Claims

1. A three-phase 48-slot 8-pole single-layer flat wire winding structure, comprising a stator core and a single-layer winding formed by three-phase parallel flat wire winding, wherein the three phases are U phase, V phase and W phase, and 48 stator slots are evenly distributed on the stator core, characterized in that: The single-layer winding of each phase is formed by 8 pole-phase groups connected in a symmetrically distributed structure, and each pole-phase group is formed by single-turn or multi-turn flat wire hairpin coils of the same phase under the same magnetic pole, each of the flat wire hairpin coils occupies two stator slots, and the 8 pole-phase groups in the same phase are evenly and equidistantly distributed in the stator core, and all the pole-phase groups in the three-phase single-layer winding do not occupy the same stator slot, and each pole-phase group in the single-layer winding of each phase can be connected with the adjacent pole-phase groups at both ends in the same phase head-to-head and tail-to-tail manner, and each pole-phase group in the same phase generates a magnetic pole, and the polarity of the magnetic poles generated by the two adjacent pole-phase groups in the same phase is opposite; since the three-phase 48-slot 8-pole single-layer flat wire winding structure is a single-layer structure in the stator slot, the number of turns of the flat wire hairpin coil in each slot of each phase can be arbitrarily selected as single turn or multi-turn according to the needs of the motor.

2. A three-phase 48-slot 8-pole single-layer flat wire winding structure according to claim 1, characterized in that: The flat wire hairpin coil is an open coil with a width span of 1 to 6 slots formed by straightening and cutting the flat wire guide. Each end of the flat wire hairpin coil is twisted outward at a certain angle according to the size of the motor, and according to the number of turns of the flat wire hairpin coil in each stator slot, the twisting angle of the flat wire hairpin coil layer by layer from outside to inside is gradually reduced, so that a certain spacing distance is formed between the ends of the flat wire hairpin coil of each layer of winding, thereby forming 8 per phase per layer. Flat wire hairpin coils with the same span are placed in the stator slots according to their respective phases, the flat wires at both ends of each pole-phase group extending out of the stator slot notch are bent outward or inward along the arc of the stator core by 1 / 2 of the pole pitch and connected head to head or tail to tail with the flat wires at both ends of the adjacent pole-phase group in the same phase, the flat wires at the ends of the three-phase windings are crossed with each other and connected phase by phase and layer by layer, and three-phase lead-out wires are reserved and the remaining connection points are welded to form a three-phase 48-slot 8-pole single-layer flat wire winding structure.

3. The three-phase 48-slot 8-pole single-layer flat wire winding structure according to claim 1, characterized in that: The flat wire hairpin coil is an open coil with a width span of 1 to 6 slots formed by straightening and cutting the flat wire guide. Each end of the flat wire hairpin coil is twisted outward at a certain angle according to the size of the motor, and according to the number of turns of the flat wire hairpin coil in each stator slot, the twisting angle of the flat wire hairpin coil is gradually reduced from the outside to the inside layer by layer, so that a certain spacing distance is formed between the ends of the flat wire hairpin coils of each layer of winding, thereby forming 8 flat wire hairpin coils with the same span per phase and per layer, and the flat wire hairpin coil is twisted outward at a certain angle according to the size of the motor, and the number of turns of the flat wire hairpin coil in each stator slot is gradually reduced from the outside to the inside, so that a certain spacing distance is formed between the ends of the flat wire hairpin coils of each layer of winding, thereby forming 8 flat wire hairpin coils with the same span per phase and per layer, and the flat wire hairpin coil is twisted outward at a certain angle according to the size of the motor. The coils are placed in the stator slots according to their respective phases, and one flat wire is reserved for each of the two ends of the flat wires extending out of the stator slot notch of the pole-phase group. The flat wires are bent outward along the arc of the stator core by 1 / 2 of the pole pitch and connected head to head and tail to tail with the reserved flat wires at both ends of the adjacent pole-phase group in the same phase, and the remaining flat wires at both ends of the pole-phase group are twisted inward to the center of the flat wire hairpin coil and connected in sequence with the remaining turns of the flat wire hairpin coil on the other side of the same-pole and same-phase winding, and three-phase lead-out wires are reserved. After the remaining connection points are welded, a three-phase 48-slot 8-pole single-layer flat wire winding structure is formed.

4. An electric motor, characterized in that: The invention comprises a rotor and a three-phase 48-slot 8-pole single-layer flat wire winding structure as claimed in any one of claims 1 to 3, wherein the rotor is rotatable relative to the three-phase 48-slot 8-pole single-layer flat wire winding structure.

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