Six-phase flat wire wave winding structure and stator assembly

Abstract

The utility model discloses a six-phase flat wire wave winding structure and a stator assembly, comprising two groups of three-phase wave windings which are arranged at an interval of 180 degrees in the circumferential direction, each phase wave winding comprises two coil ring groups which are arranged at a staggered position of one magnetic pole in the circumferential direction, and each coil ring group comprises at least one coil ring. The coil ring comprises P single coils which are uniformly distributed, and P is the number of pole pairs; each single coil comprises two supporting feet which are bent in opposite directions in the circumferential direction, the supporting feet of the P single coils are sequentially connected in series in the circumferential direction to form a coil ring, and the supporting feet located at the two ends of the coil ring form connecting feet. Wherein the connecting pin located on the innermost side or the outermost side of one coil ring group is reversely bent in a deflection manner and is connected with the connecting pin located on the innermost side or the outermost side of the other coil ring group in a welding manner side by side. The six-phase flat wire wave winding structure and the stator assembly have the advantages that the structural design is reasonable, the types of hairpins can be reduced, the assembly difficulty can be reduced, and the like.

Description

Technical Field

[0001] The utility model relates to the technical field of flat wire motors, in particular to a six-phase flat wire wave winding structure and a stator assembly. Background Art

[0002] In recent years, miniaturization and high speed have become the main development trends of new energy electric vehicle motors. Compared with traditional permanent magnet motors, the windings of flat wire motors have the characteristics of high copper full rate, which can greatly improve the torque density and power density of the motor; the winding end length of the flat wire motor is relatively short, which can further improve the utilization rate of the vehicle space; the large contact area between the wires effectively enhances the heat dissipation capacity of the motor. Therefore, flat wire motors have good application prospects in new energy electric vehicles.

[0003] Compared to three-phase motors, six-phase motors can offset specific harmonics, reduce torque ripple, and improve NVH performance. As the number of motor phases increases, the motor's fault tolerance is enhanced, resulting in higher operational reliability. Existing technologies typically employ multi-layer wave windings, with each phase winding located on a different layer of the stator slots. The lead-out wire ends of each phase are welded, while the non-lead-out wire ends are U-shaped. However, as the number of motor phases increases, the flat wire winding process becomes more difficult, making it difficult to ensure a consistent span of the U-shaped coils, and thus increasing manufacturing costs. Utility Model Content

[0004] In view of the above-mentioned deficiencies in the existing technology, the technical problem to be solved by the present invention is: how to provide a six-phase flat wave winding structure and stator assembly with a reasonable structural design, which can reduce the types of hairpins and help reduce assembly difficulty and manufacturing costs.

[0005] In order to solve the above technical problems, the present invention adopts the following technical solutions:

[0006] A six-phase flat line wave winding structure includes two groups of three-phase wave windings arranged 180° apart in the circumferential direction, each phase of the wave winding includes two coil ring groups arranged with one magnetic pole position offset in the circumferential direction, each coil ring group includes at least one coil ring, and the coil ring includes P single coils evenly distributed along the circumferential direction, where P is the number of pole pairs; the single coil includes two legs that deflect and bend in opposite directions in the circumferential direction, and the legs of the P single coils are connected in series in sequence along the circumferential direction to form the coil ring, and the legs at both ends of the coil ring form connecting legs; the innermost or outermost connecting leg on one of the coil ring groups is deflected and bends in the opposite direction, and is welded side by side with the innermost or outermost connecting leg on the other coil ring group.

[0007] In the above structure, the innermost or outermost connecting pin on one coil ring is reversed and bent to the connecting pin of the other coil ring and welded side by side, so that the two can be connected in series without the need for additional jumpers. In the assembled state, it is only necessary to deflect the connecting pin that needs to be reversed outward by one layer and then bend it in the reverse direction, which facilitates subsequent automated welding operations, thereby improving assembly efficiency and quality. At the same time, the above structure constitutes a six-phase winding, with an electrical angle difference of 60 degrees between each phase. It can operate with either single winding or double winding. The motor has a wider high-efficiency area, and the heat generated by the entire machine is greatly reduced, which makes the harmonic components lower and the noise reduced.

[0008] Furthermore, in each coil ring group, the coil rings are arranged in at least two layers radially side by side, and the two adjacent layers of the coil rings are connected by welding radially side by side connecting pins, and the two connecting pins are respectively located in the Nth layer and the N+1th layer of the winding, where N is an even number.

[0009] In this way, the coil rings of two adjacent layers are welded together through the connecting pins located at the Nth layer and the N+1th layer of the winding, thereby realizing the series connection of the coil rings of two adjacent layers without the need for jumpers.

[0010] Furthermore, the single coil includes a hairpin conductor, the hairpin conductor includes a hairpin body that is bent in a U-shape as a whole, the hairpin body includes two legs arranged parallel to each other and a head connected to one end of the two legs, and the other ends of the two legs are bent in opposite directions along the width direction of the hairpin body to form the legs.

[0011] Furthermore, the single coil includes two hairpin conductors arranged side by side in the thickness direction, the hairpin conductor includes a hairpin body that is bent in a U-shape as a whole, the hairpin body includes two legs arranged parallel to each other and a head connected to one end of the two legs, the other end of the two legs is a connecting section, and the connecting sections on the two hairpin conductors are deflected and bent in opposite directions in the width direction of the hairpin body, wherein two connecting sections are close to each other and welded together, and the other two connecting sections are deflected in opposite directions to form the legs.

[0012] Furthermore, the single coil also includes an O-shaped conductor arranged side by side with the hairpin conductor in the thickness direction, the O-shaped conductor includes a hairpin body bent in a U shape, the hairpin body includes two legs arranged parallel to each other and a head connected to one end of the two legs, the other ends of the two legs are deflected toward the middle in the width direction of the hairpin body to form a connecting section, and the two connecting sections of the O-shaped conductor are respectively welded to two connecting sections close to each other on the two hairpin conductors.

[0013] Furthermore, the pitch of the hairpin conductor is Y-1, where Y is the pole pitch.

[0014] A stator assembly comprises a stator core and the above-mentioned six-phase flat wave winding structure, wherein the six-phase flat wave winding structure is mounted on the stator core.

[0015] In summary, the six-phase flat-line wave winding structure and stator assembly of the present invention have the advantages of reasonable structural design, can reduce the types of hairpins, and are conducive to reducing assembly difficulty and manufacturing costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 This is a schematic diagram of the overall structure of Example 1.

[0017] Figure 2 This is a schematic diagram of the structure of the two outermost coil rings of a phase winding in Example 1.

[0018] Figure 3 and Figure 4 They are Figure 2 Schematic diagram of the structure of the two coil rings.

[0019] Figure 5 This is a schematic diagram of the structure of a two-layer coil ring for a single-phase winding.

[0020] Figure 6 Schematic diagram of the structure of the phase winding of Example 1.

[0021] Figures 7 to 9 Schematic diagram of the structure of the hairpin conductor in Example 2. DETAILED DESCRIPTION

[0022] The present invention will be further described in detail below with reference to the embodiments.

[0023] Example 1: A six-phase flat wave winding motor, such as Figure 1 As shown, it includes a stator assembly, which includes a stator core 1 and two groups of three-phase wave windings 2 arranged 180° apart in the circumferential direction. The stator core 1 includes a main body that is generally cylindrical. A plurality of stator core slots that are radially open inward are arranged circumferentially on the inner ring of the stator core 8. The lower end of the stator core slot is the insertion side (or crown side), and the upper end is the connection side.

[0024] In this embodiment, Figures 2 to 4As shown, the number of pole pairs P=4, each phase of the wave winding includes two coil ring groups 3 that are circumferentially offset by one magnetic pole position, each coil ring group 3 includes at least one coil ring 4, the coil ring 4 includes four single coils 5 evenly distributed along the circumference, the single coil 5 includes two legs 6 that are deflected and bent in opposite directions in the circumference, the legs 6 of the four single coils 5 are sequentially connected in series along the circumference to form the coil ring 4, and the legs 6 at both ends of the coil ring 4 form connecting legs 7; the outermost connecting leg 7 on one of the coil ring groups 3 is deflected and bent in the opposite direction, and is welded side by side with the outermost connecting leg 7 on the other coil ring group 3. As shown Figure 2 As shown, one connecting leg 7 indicated by a solid line is deflected in the opposite direction and bent to the outside of the connecting leg 7 indicated by a dotted line, and then the connecting legs 7 indicated by the dotted line are placed side by side and welded together.

[0025] In this embodiment, the single coil 5 includes a hairpin conductor, which includes a hairpin body that is bent in a U-shape as a whole. The hairpin body includes two legs 51 arranged parallel to each other and a head 52 connected to one end of the two legs 51. The other ends of the two legs 51 are bent in opposite directions along the width direction of the hairpin body to form the support foot 6.

[0026] like Figure 5 As shown, in each coil ring group 3, the coil rings 4 are arranged radially side by side in two layers. Adjacent layers of coil rings 4 are welded together via radially parallel connecting legs 7. The two connecting legs are located in the Nth and N+1th layers of the winding, respectively, where N is an even number. In this embodiment, each stator core slot has four leg portions, and the connecting legs are located in the second and third layers of the winding from the inside out.

[0027] Figure 6 The figure shows two phase windings arranged 180° apart in the circumferential direction. The power supply connection lines for the two phase windings are located at opposite ends of the stator's radial direction. In any phase winding, the outermost connection pins 7 on one coil ring 4 are deflected and bent in opposite directions and welded side by side to the outermost connection pins 7 on the other coil ring 4 in the same phase, as shown by the symbols A and B in the figure.

[0028] In this embodiment, the outermost connecting pin on one coil ring is deflected in the opposite direction and bent to the connecting pin of the other coil ring and welded side by side, so that the two can be connected in series without the need for additional jumpers. In the assembled state, it is only necessary to deflect the connecting pin that needs to be bent in the opposite direction outward by one layer and then bend it in the opposite direction, which facilitates subsequent automated welding operations, thereby improving assembly efficiency and quality. At the same time, the above structure forms a six-phase winding, with an electrical angle difference of 60 degrees between each phase. It can operate with either single winding or double winding, and the motor has a wider high-efficiency area, significantly reduces the heat generated by the entire machine, reduces harmonic components, and reduces noise.

[0029] Example 2: The main difference between this example and Example 1 is the structure of the single coil. Specifically, the single coil includes two hairpin conductors arranged side by side in the thickness direction. The hairpin conductor includes a hairpin body that is bent in a U-shape as a whole. The hairpin body includes two legs 51 arranged parallel to each other and a head 52 connected to one end of the two legs 51. The other ends of the two legs 51 are connecting sections 53. The connecting sections 53 on the two hairpin conductors are bent in opposite directions in the width direction of the hairpin body. Figure 7 and Figure 8 As shown, two connecting sections 53 are close to each other and welded together, and the other two connecting sections 53 are deflected in opposite directions to form the supporting feet.

[0030] The single coil further includes an O-shaped conductor arranged side by side with the hairpin conductor in the thickness direction. The O-shaped conductor includes a hairpin body bent in a U-shape. The hairpin body includes two legs 51 arranged parallel to each other and a head 52 connected to one end of the two legs. The other ends of the two legs 51 are deflected toward the middle in the width direction of the hairpin body to form a connecting section 53. Figure 9 As shown, the two connecting sections of the O-shaped conductor are respectively connected to the two connecting sections on the two hairpin conductors that are close to each other by welding.

[0031] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent replacements, and improvements made within the spirit and principles of the present invention shall be included in the scope of protection of the present invention.

Claims

1. A six-phase flat wave winding structure, characterized in that: It includes two groups of three-phase wave windings arranged 180° apart in the circumferential direction, and each phase of the wave winding includes two coil ring groups arranged with one magnetic pole position offset in the circumferential direction. Each coil ring group includes at least one coil ring, and the coil ring includes P single coils evenly distributed along the circumferential direction, where P is the number of pole pairs; the single coil includes two legs that deflect and bend in opposite directions in the circumferential direction, and the legs of the P single coils are connected in series in sequence along the circumferential direction to form the coil ring, and the legs at both ends of the coil ring form connecting legs; the innermost or outermost connecting leg on one of the coil ring groups is deflected and bends in the opposite direction, and is welded side by side with the innermost or outermost connecting leg on the other coil ring group.

2. The six-phase flat wave winding structure according to claim 1, characterized in that: In each coil ring group, the coil rings are arranged in at least two layers radially side by side, and the two adjacent layers of coil rings are connected by welding through radially side by side connecting pins, and the two connecting pins are respectively located in the Nth layer and the N+1th layer of the winding, where N is an even number.

3. The six-phase flat wave winding structure according to claim 1 or 2, characterized in that: The single coil includes a hairpin conductor, which includes a hairpin body that is bent in a U-shape as a whole. The hairpin body includes two legs arranged parallel to each other and a head connected to one end of the two legs. The other ends of the two legs are bent in opposite directions along the width direction of the hairpin body to form the legs.

4. The six-phase flat wave winding structure according to claim 1 or 2, characterized in that: The single coil includes two hairpin conductors arranged side by side in the thickness direction, and the hairpin conductors include a hairpin body that is bent in a U-shape as a whole. The hairpin body includes two legs arranged parallel to each other and a head connected to one end of the two legs. The other ends of the two legs are connecting sections. The connecting sections on the two hairpin conductors are deflected and bent in opposite directions in the width direction of the hairpin body, wherein two connecting sections are close to each other and welded together, and the other two connecting sections are deflected in opposite directions to form the legs.

5. The six-phase flat wave winding structure according to claim 4, characterized in that: The single coil also includes an O-shaped conductor arranged side by side with the hairpin conductor in the thickness direction. The O-shaped conductor includes a hairpin body bent in a U shape. The hairpin body includes two legs arranged parallel to each other and a head connected to one end of the two legs. The other ends of the two legs are deflected toward the middle in the width direction of the hairpin body to form a connecting section. The two connecting sections of the O-shaped conductor are respectively welded to two connecting sections close to each other on the two hairpin conductors.

6. The six-phase flat wave winding structure according to any one of claims 3 to 5, characterized in that: The pitch of the hairpin conductor is Y-1, where Y is the pole pitch.

7. A stator assembly, characterized in that: The invention comprises a stator core and a six-phase flat wave winding structure according to any one of claims 1 to 6, wherein the six-phase flat wave winding structure is installed on the stator core.

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