Even-layer flat wire motor stator winding structure
Through the even-number flat-line motor stator winding structure, the problems of high insulation risks, increased costs and insufficient space utilization of flat-line motor stator windings are solved, and safety performance improvement and cost reduction are achieved.
Patent Information
- Application Number
- CN202422444899.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-10-10
- Publication Date
- 2025-08-15
- Estimated Expiration
- 2034-10-10
AI Technical Summary
The existing flat wire motor stator winding structures have problems such as high insulation risks, increased costs, insufficient space utilization and complex winding.
The stator winding structure of even-number flat wire motor is adopted, including stator core, star point bronze medal, three-phase winding and card sending coil. The number of layers formed by the three-phase winding in the winding trough is even. The jumper wire is braided on the innermost layer and the outermost layer through a specific winding method, and the intermediate layer is inserted into the wire, reducing the risk of welding points and insulation pressure resistance, and optimizing the winding path.
It effectively reduces the risk of insulation voltage resistance, saves materials, reduces welding points, improves the safety performance and space utilization efficiency of the motor, and reduces the cost of the motor.
Smart Images
Figure CN223230956U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to the technical field of motors, in particular to a stator winding structure of an even-number-layer flat wire motor. Background Art
[0002] With the rapid development of the new energy vehicle industry, flat-wire motors offer a higher slot fill rate than traditional round-wire motors, effectively increasing motor power density. The primary difference between flat-wire motors and round-wire motors lies in the shift from multiple thin wires in the stator winding to a few thick rectangular conductors. This specific flat-wire structure complicates stator manufacturing, necessitating critical design considerations such as coil structure, winding method, lead wire connection, and insulation.
[0003] In the flat wire motor winding method, the wires are mainly introduced from the innermost or outermost side of the same slot and exit from the innermost or outermost side of different slots. Since the lead wires need to be bent toward the outside of the motor stator, they may rub against the star point or accidentally touch the paint coating of other windings, resulting in increased insulation risks. If customized copper plates are used for connection, this will lead to a larger size and space, resulting in increased cost of the flat wire motor.
[0004] Currently, flat wire stators mainly use a busbar structure to connect the three-phase lead wires. Each phase requires a busbar for cross-connection. The three-phase busbar and the neutral busbar are placed at the end of the winding. A certain distance must be maintained between the busbars. However, this will cause the internal space to become larger, increasing the cost of the flat wire stator and even the entire motor.
[0005] Depending on customer needs and motor design requirements, multiple parallel connections, wave winding, and lap winding methods are sometimes necessary. This leads to complex wiring, multiple jumper wires, difficulty inserting flat wires, and difficulty welding the three-phase outlets. Therefore, a flat wire motor stator winding structure is urgently needed. Utility Model Content
[0006] The purpose of the utility model is to provide a stator winding structure of an even-numbered-layer flat wire motor to solve the problems raised in the above-mentioned background technology.
[0007] In order to solve the above technical problems, the present invention provides the following technical solutions: a stator winding structure of an even-layer flat wire motor, comprising a stator core, a star point copper plate, a three-phase winding, a three-phase lead wire and a hairpin coil, wherein the three-phase winding is inserted into the stator core, the star point copper plate is connected to the star point end, the number of poles of the flat wire winding is 8, the number of slots per pole per item of the stator core is 2, and the number of layers L formed by the three-phase winding in the winding slot is an even number greater than 2.
[0008] Preferably, the number of parallel branches of the three-phase winding is 1, the three-phase winding is wound in one circumferential direction, and the winding close to the outermost layer of the outer diameter of the core is wound by connecting wires across different slots.
[0009] Preferably, the hairpin coils of the middle two layers of windings span from layer N to layer N+1, and the inter-slot conductors are connected in the form of a span of y or y+1 between the hairpins.
[0010] Preferably, the three-phase lead wires are four-layer flat wires in a continuously wound form.
[0011] The beneficial effects of the utility model are as follows: the stator winding structure of the three-phase flat wire motor adopts a full-pitch winding, the wires are output at the welding end, the voltage between the turns is evenly distributed, and the wires are input in the middle layer, which effectively reduces the risk of insulation withstand voltage and improves the safety performance of the motor. Through a specific winding method, the cross-bridge wires are woven in the innermost and outermost layers, which effectively avoids the problems of too many cross-bridge wires and welding difficulties, and also reduces the axial end space, saves materials, and saves motor costs. BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Figure 1 is a schematic diagram of the stator winding structure;
[0013] Figure 2 This is the main view of the stator winding structure;
[0014] Figure 3 It is a schematic diagram of the stator winding hairpin coil;
[0015] Figure 4 This is a schematic diagram of the wiring method of the welding end of one phase;
[0016] Figure 5 This is a schematic diagram of the wiring method of a single-phase braided end.
[0017] The reference numerals in the figure are: stator winding braided end 1; stator core 2; three-phase lead wire 3; star point copper plate 4; three-phase winding 5; hairpin coil 6. DETAILED DESCRIPTION
[0018] In the following description, numerous specific details are provided to provide a more thorough understanding of the present invention. However, it will be apparent to those skilled in the art that the present invention can be practiced without one or more of these details. In other instances, certain technical features known in the art are not described to avoid confusion with the present invention.
[0019] Example 1
[0020] Reference Figures 1 to 3Through a specific winding method, the jumper wire can be woven into the winding, effectively reducing the end height, saving materials, reducing the risk of welding points and insulation withstand voltage, and effectively improving the safety performance of the motor. This solution includes a stator core 2, a star point copper plate 4, a three-phase winding 5, a three-phase lead wire 3, and a hairpin coil 6. The three-phase winding 5 is inserted into the stator core 2, and the star point copper plate 4 is connected to the star point end. The three-phase winding 5 has 8 poles, and the stator core 2 has 2 slots per pole. The number of layers L formed by the three-phase winding 5 in the winding slot is an even number greater than 2. It is possible to weave the jumper wire into the winding, effectively reducing the end height, saving materials, reducing the risk of welding points and insulation withstand voltage, and effectively improving the safety performance of the motor.
[0021] The number of parallel branches of the three-phase winding 5 is 1. The three-phase winding 5 is wound in one circumferential direction. The outermost winding close to the outer diameter of the stator core 2 is wound by wiring across different slots. The hairpin coils 6 of the two middle layers of windings span from N layers to N+1 layers, where N is an integer and the wire embedding position is located in adjacent layers. The three-phase winding 5 does not change the order of embedding the slots. The connections between the hairpin coils 6 can be made in the form of a span of y or y+1 to connect the inter-slot conductors. The three-phase lead wire 3 is a four-layer flat wire in a continuously stacked form. The three-phase incoming wire enters from the middle slot, which can effectively prevent the conductor from hitting the stator when it is bent, causing the paint to crack. No jumper wires need to be welded, which saves material and increases the available axial space.
[0022] The stator winding structure of the three-phase flat wire motor is as follows: the three-phase winding 5 enters the wire through the middle layer, and the jumper wire is introduced at the innermost and outermost sides, and is bent toward the middle layer at the welding end, and finally goes out the outermost side. The current is introduced through the middle layer lead-in wire, flows through the three-phase winding 5, flows out from the outermost side, and is connected and fixed to the winding braiding end 1 through the star point copper plate 4; the three-phase lead-out wire motor stator structure, in which the A phase takes the outermost current lead-out wire as the starting point, and is connected to a number of hairpin coils 6 in the clockwise or counterclockwise direction of the stator core 2 in sequence until it is connected to the three-phase lead-out wire; the innermost and outermost jumper wires are placed in the stator core 2 with specific hairpin coils 6, and the two middle layers are woven together, which solves the problem of too many jumper wires. By overlapping the winding, the end height is effectively reduced, saving the use of materials.
[0023] Example 2
[0024] Reference Figures 4 and 5, place the stator core 2 on the paper inserting machine and push the folded insulation paper into the stator core slots one by one. Next, place the stator core 2 with the insulation paper inserted. Using the stator winding end 1 as the reference surface, manually insert the wires. Insert the hairpin coils 6 into the stator core slots one by one according to the winding diagram, inserting the wire from the outermost layer to the innermost layer. Near the outer diameter of the stator core 2, there are hairpin coils 6 with two spans. Through a specific winding method, the large-span hairpin coil 6 is superimposed on the small-span hairpin coil 6, effectively reducing the end height.
[0025] Example 3
[0026] Next, the flat-wire motor stator winding, with the insulating paper and hairpin coils 6 inserted, is placed on a flaring and twisting machine. First, the fourth layer of hairpin coils 6 are flared to the designated position, followed by the third and second layers. Finally, the first layer of hairpin coils 6 is flared. Finally, all the hairpin coils 6 are inserted into the twisting die slot, completing the stator end twisting. The twisted stator is then trimmed and welded.
[0027] As described above, although the present invention has been shown and described with reference to specific preferred embodiments, it should not be interpreted as limiting the present invention itself. Various changes may be made to it in form and detail without departing from the spirit and scope of the present invention as defined in the appended claims.
Claims
1. An even-layer flat wire motor stator winding structure, characterized in that: It includes a stator core, a star point copper plate, a three-phase winding, a three-phase lead wire and a hairpin coil. The three-phase winding is inserted in the stator core. The star point copper plate is connected to the star point end. The number of poles of the flat wire winding is 8. The number of slots per pole and item of the stator core is 2. The number of layers L formed by the three-phase winding in the winding slot is an even number greater than 2.
2. The stator winding structure of an even-layer flat wire motor according to claim 1, characterized in that: The number of parallel branches of the three-phase winding is 1, the three-phase winding is wound in one circumferential direction, and the winding close to the outermost layer of the outer diameter of the core is wound by connecting wires across different slots.
3. The stator winding structure of an even-layer flat wire motor according to claim 1, characterized in that: The hairpin coils of the middle two layers of windings span from layer N to layer N+1, and the inter-slot conductors are connected in the form of a span of y or y+1 between the hairpins.
4. The stator winding structure of an even-layer flat wire motor according to claim 1, characterized in that: The three-phase lead wires are four-layer flat wires in a continuously stacked form.