Flat wire centrally-arranged motor stator for electric motorcycle

Abstract

The utility model discloses a motor stator with a built-in flat wire for an electric motorcycle, which relates to the technical field of electric motorcycles and comprises a stator core, slot insulation and flat wire windings, 48 slots are uniformly distributed along the circumferential direction of the stator core, six layers of flat wire windings are arranged in each slot, the flat wire windings are divided into three phases, namely, an A phase, a B phase and a C phase, and the A phase, the B phase and the C phase are connected with the slot insulation. Each phase of flat wire winding is composed of four branches which are connected in parallel or connected in series on the same layer. According to the utility model, the flat wire winding is divided into three phases, each phase of flat wire winding consists of four branches, and the four branches can be connected in parallel or in series on the same layer, so that the winding with one or two or four branches is formed, and the winding is suitable for electric motorcycles with different rotating speeds, powers and voltage grades; the flat wire centrally-mounted motor stator is wide in application range, high in power density, low in noise, low in energy consumption and low in temperature rise.

Description

Technical Field

[0001] The utility model relates to the technical field of electric motorcycles, in particular to a flat wire mid-mounted motor stator for electric motorcycles. Background Art

[0002] With the widespread popularity of electric vehicles and the continuous improvement of relevant national regulations, the demand for greater power, more energy saving, higher power density, lighter weight, and quieter operation is becoming increasingly demanding. The flat wire mid-mounted motor for electric motorcycles is a special motor design with the following main features and advantages:

[0003] Flat Wire Design: Flat wire motors use flat copper wire for their stator windings, rather than traditional round copper wire. This design improves the motor's slot fill rate and the number of effective conductors, thereby increasing the motor's efficiency and power density.

[0004] Mid-mounted: A mid-mounted motor is located in the center of the vehicle. This layout optimizes weight distribution, improving handling and stability. It also directly drives the rear wheels, eliminating the need for a drive chain or belt and reducing energy loss.

[0005] Efficient heat dissipation: Flat wire motors are usually equipped with efficient heat dissipation systems, such as water cooling or oil cooling, to ensure that the motor can maintain good temperature control at high power output.

[0006] High torque output: Flat-wire mid-mounted motors are generally able to provide higher torque output due to their design features, which makes electric motorcycles perform well in acceleration and climbing.

[0007] Low maintenance requirements: Since the mid-mounted motor directly drives the rear wheel, the clutch and gearbox of traditional motorcycles are eliminated, reducing maintenance requirements.

[0008] Environmental protection and energy saving: Compared with traditional fuel motorcycles, electric motorcycles have the characteristics of zero emissions and low noise, and are more environmentally friendly and energy-saving.

[0009] At present, the common practice in the industry is to use round wire concentrated winding motors, which have small reluctance torque, low efficiency, rich harmonics, high noise, low slot fill rate, and high winding temperature, and can no longer meet the needs of future high-performance electric vehicles; and conventional flat wire motors have a single number of parallel branches in the windings, resulting in poor applicability of the motors. Utility Model Content

[0010] In view of this, the purpose of the present utility model is to provide a flat wire mid-mounted motor stator for electric motorcycles to solve the current common practice in the industry of using round wire concentrated winding motors, which have small reluctance torque, low efficiency, rich harmonics, high noise, low slot fill rate, and high winding temperature, and can no longer meet the needs of future high-performance electric vehicles; and the conventional flat wire motor has a single number of parallel branches of the winding, resulting in poor applicability of the motor.

[0011] To achieve the above objectives, the present invention is implemented through the following technical solutions:

[0012] A flat-wire mid-mounted motor stator for electric motorcycles includes a stator core, slot insulation, and flat-wire windings. The stator core is evenly distributed with 48 slots along the circumference, each slot containing six layers of flat-wire windings. The flat-wire windings are divided into three phases: A, B, and C. Each phase of the flat-wire winding consists of four branches, which are connected in parallel or in series within the same layer to form a winding with one, two, or four branches. Each branch consists of six hairpin coils with a span of 8 or six with a span of 6 (including two cross-layer hairpin coils).

[0013] As an optimal technical solution of the present invention, both sides of the hairpin coil on the welding side are twisted by 2.5 slot pitches, thereby realizing a short-span winding with a span of 5.

[0014] As a preferred technical solution of the present invention, in phase A, the first branch is 24a-30b, 35a-43b, 48a-6b, 11a-19b, 24c-30d, 35c-43d, 48c-6d, 11c-19d, 24e-30f, 35e-43f, 48e-6f, and 11e-19f.

[0015] As a preferred technical solution of the present utility model, in phase A, the second branch is 24f-18e, 13f-5e, 48f-42e, 37f-29e, 24d-18c, 13d-5c, 48d-42c, 37d-29c, 24b-18a, 13b-5a, 48b-42a, 37b-29a;

[0016] As a preferred technical solution of the present utility model, in phase A, the third branch is 23a-31b, 36a-42b, 47a-7b, 12a-18b, 23c-31d, 36c-42d, 47c-7d, 12c-18d, 23e-31f, 36e-42f, 47e-7f, and 12e-18f;

[0017] As a preferred technical solution of the present utility model, in phase A, the fourth branch is 25f-17e, 12f-6e, 1f-41e, 36f-30e, 25d-17c, 12d-6c, 1d-41c, 36d-30c, 25b-17a, 12b-6a, 1b-41a, 36b-30a;

[0018] As an optimal technical solution of the present invention, if the number of parallel winding branches is 1, the same-layer bridge wires 19f-24f, 29a-23a, and 18f-25f are added; 24a is led out as the A-phase power lead; 30a is the neutral point lead, which is welded together with the B-phase and C-phase neutral point lead wires.

[0019] As an optimal technical solution of the present invention, if the number of parallel winding branches is 2, the same-layer bridge wires 19f-24f and 18f-25f are added; 24a and 23a are connected in parallel to form the A-phase power lead wires; 30a and 29a are neutral point lead wires, which are welded together with the B-phase and C-phase neutral point lead wires.

[0020] As an optimal technical solution of the present invention, if the number of parallel winding branches is 4, 24a, 24f, 23a, and 25f are connected in parallel to form the A-phase power lead wire; 19f, 29a, 18f, and 30a are neutral point lead wires, which are welded together with the B-phase and C-phase neutral point lead wires.

[0021] The utility model is divided into three phases by a flat wire winding, and each phase flat wire winding is composed of four branches. These four branches can be connected in parallel or in series on the same layer to form a winding with one, two or four branches, so as to be suitable for electric motorcycle models with different speeds, powers and voltage levels, and provide a flat wire mid-mounted motor stator with wide applicability, high power density, low noise, low energy consumption and low temperature rise.

[0022] Other advantages, objectives, and features of the present invention will be described in detail in the following description and, to some extent, will be apparent to those skilled in the art upon examination and study of the following or may be learned from practice of the present invention. The objectives and other advantages of the present invention may be realized and obtained through the following description. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 This is a schematic diagram of the appearance and structure of the stator of the flat wire mid-mounted motor for an electric motorcycle of the present invention;

[0024] Figure 2 This is a front structural diagram of the stator of the flat wire mid-mounted motor for an electric motorcycle of the present invention;

[0025] Figure 3This is a schematic top view of the structure of the stator of the flat wire mid-mounted motor for an electric motorcycle of the present invention;

[0026] Figure 4 It is a schematic diagram of the structure of the side wire winding distribution of the utility model;

[0027] In the figure: stator core 1, flat wire winding 2, slot insulation 3. DETAILED DESCRIPTION

[0028] To make the purpose, technical solutions, and advantages of the embodiments of the present invention more clear, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Generally, the components of the embodiments of the present invention described and shown in the drawings herein can be arranged and designed in various different configurations.

[0029] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but rather merely represents selected embodiments of the present invention. All other embodiments derived by persons of ordinary skill in the art based on the embodiments of the present invention without creative effort are also within the scope of protection of the present invention.

[0030] It should be noted that similar reference numerals and letters denote similar items in the following drawings, and therefore, once an item is defined in one drawing, it does not need to be further defined or explained in subsequent drawings.

[0031] In the above description of the present invention, it should be noted that the terms "one side" and "the other side" and the like indicate positions or locations based on the positions or locations shown in the accompanying drawings, or the positions or locations in which the product of the present invention is typically placed when in use. These terms are intended solely to facilitate the description of the present invention and simplify the description, and are not intended to indicate or imply that the device or component referred to must have a specific orientation, be constructed, or operate in a specific orientation. Therefore, they should not be construed as limitations on the present invention. Furthermore, the terms "first" and "second" and the like are used solely for distinction and should not be construed as indicating or implying relative importance.

[0032] Furthermore, the term "identical" and similar terms do not necessarily require that the components be absolutely identical; slight variations are permitted. The term "perpendicular" simply refers to the positional relationship between components being more perpendicular than "parallel," not that the structure must be perfectly vertical; rather, it can be slightly tilted. Example 1

[0033] See also Figure 1-4, a technical solution provided by the utility model: a flat wire mid-mounted motor stator for an electric motorcycle, comprising a stator core 1, slot insulation 3 and a flat wire winding 2. The stator core 1 is provided with 48 slots evenly distributed along the circumference, and each slot is provided with 6 layers of flat wire windings 2. The flat wire windings are divided into 3 phases, namely phase A, phase B, and phase C. Each phase of the flat wire winding 2 is composed of 4 branches. These 4 branches are connected in parallel or in series on the same layer to form a winding with 1, 2 or 4 branches, so as to be suitable for electric motorcycle models with different speeds, power and voltage levels.

[0034] In this embodiment, each branch consists of six hairpin coils with a span of 8 and six hairpin coils with a span of 6 (including two cross-layer hairpin coils). Both sides of the hairpin coils on the welding side are twisted by 2.5 slots, thereby achieving a short-span winding with a span of 5, reducing winding harmonics.

[0035] In this embodiment, the slot insulation is 2-3 mm higher than the iron core, and the straight section at the end of the hairpin coil is flush with the slot insulation or 0-1 mm higher than the slot insulation.

[0036] Among them, in this embodiment, the gap between the copper wires at the crown end is 0.3-0.6mm; the gap between the copper wires at the welding end is 0.5-1mm; the straight section of the hairpin copper wire welding part is 7-10mm; and the distance between the layers at the welding end is not less than 2mm.

[0037] In this embodiment, the slot insulation is 2-3 mm higher than the iron core, and the straight section at the end of the hairpin coil is flush with the slot insulation or 0-1 mm higher than the slot insulation.

[0038] In this embodiment, the stator core has 48 slots evenly distributed along the circumferential direction, each slot has 6 layers of flat wire windings, and the rotor has 8 poles.

[0039] In this embodiment, each phase flat wire winding consists of four branches, which can be connected in parallel or in series within the same layer to form a winding with one, two, or four branches. Each branch consists of six hairpin coils with a span of 8 and six with a span of 6 (including two hairpin coils across layers). Both sides of the hairpin coils on the welding side are twisted by 2.5 slots, thus achieving a short-pitch winding with a span of 5.

[0040] The bridge lines with 2 or 1 parallel branches are connected on the same layer.

[0041] Taking phase A as an example, in phase A, the first branch is 24a-30b, 35a-43b, 48a-6b, 11a-19b, 24c-30d, 35c-43d, 48c-6d, 11c-19d, 24e-30f, 35e-43f, 48e-6f, and 11e-19f.

[0042] Taking phase A as an example, in phase A, the second branch is 24f-18e, 13f-5e, 48f-42e, 37f-29e, 24d-18c, 13d-5c, 48d-42c, 37d-29c, 24b-18a, 13b-5a, 48b-42a, 37b-29a;

[0043] Taking phase A as an example, in phase A, the third branch is 23a-31b, 36a-42b, 47a-7b, 12a-18b, 23c-31d, 36c-42d, 47c-7d, 12c-18d, 23e-31f, 36e-42f, 47e-7f, and 12e-18f;

[0044] Taking phase A as an example, in phase A, the fourth branch is 25f-17e, 12f-6e, 1f-41e, 36f-30e, 25d-17c, 12d-6c, 1d-41c, 36d-30c, 25b-17a, 12b-6a, 1b-41a, 36b-30a;

[0045] If the number of parallel winding branches is 1, add bridge wires 19f-24f, 29a-23a, and 18f-25f on the same layer; 24a is the power lead wire of phase A; 30a is the neutral point lead wire, which is welded together with the neutral point lead wires of phases B and C.

[0046] If the number of parallel winding branches is 2, add bridge wires 19f-24f and 18f-25f on the same layer; 24a and 23a are connected in parallel to form the A-phase power lead wires; 30a and 29a are neutral point lead wires, which are welded together with the B-phase and C-phase neutral point lead wires.

[0047] If the number of parallel winding branches is 4, then 24a, 24f, 23a, and 25f are connected in parallel to form the A-phase power lead wires; 19f, 29a, 18f, and 30a are the neutral point lead wires, which are welded together with the B-phase and C-phase neutral point lead wires.

[0048] Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of the utility model and are not limiting. Although the utility model is described in detail with reference to the preferred embodiments, ordinary technicians in this field should understand that the technical solution of the utility model can be modified or replaced by equivalents without departing from the purpose and scope of the technical solution of the utility model, which should be included in the scope of the claims of the utility model.

Claims

1. A flat wire mid-mounted motor stator for an electric motorcycle, characterized by: The invention comprises a stator core (1), slot insulation (3) and a flat wire winding (2), wherein the stator core (1) is provided with 48 slots evenly distributed along the circumference, and each slot is provided with 6 layers of flat wire winding (2), and the flat wire winding is divided into 3 phases, namely phase A, phase B and phase C. Each phase flat wire winding (2) is composed of 4 branches, and the 4 branches are connected in parallel or in series in the same layer to form a winding with 1, 2 or 4 branches, and each branch is composed of 6 hairpin coils with a span of 8 or 6 spans of 6.

2. The flat wire mid-mounted motor stator for an electric motorcycle according to claim 1, characterized in that: Both sides of the hairpin coil on the welding side are twisted by 2.5 slot pitches, thereby realizing a short-pitch winding with a span of 5.

3. The flat wire mid-mounted motor stator for an electric motorcycle according to claim 1, characterized in that: In phase A, the first branch is 24a-30b, 35a-43b, 48a-6b, 11a-19b, 24c-30d, 35c-43d, 48c-6d, 11c-19d, 24e-30f, 35e-43f, 48e-6f, and 11e-19f.

4. The flat wire mid-mounted motor stator for an electric motorcycle according to claim 1, characterized in that: In phase A, the second branch is 24f-18e, 13f-5e, 48f-42e, 37f-29e, 24d-18c, 13d-5c, 48d-42c, 37d-29c, 24b-18a, 13b-5a, 48b-42a, and 37b-29a.

5. The flat wire mid-mounted motor stator for an electric motorcycle according to claim 1, characterized in that: In phase A, the third branch is 23a-31b, 36a-42b, 47a-7b, 12a-18b, 23c-31d, 36c-42d, 47c-7d, 12c-18d, 23e-31f, 36e-42f, 47e-7f, and 12e-18f.

6. The flat wire mid-mounted motor stator for an electric motorcycle according to claim 1, characterized in that: In phase A, the fourth branch is 25f-17e, 12f-6e, 1f-41e, 36f-30e, 25d-17c, 12d-6c, 1d-41c, 36d-30c, 25b-17a, 12b-6a, 1b-41a, and 36b-30a.

7. The flat wire mid-mounted motor stator for an electric motorcycle according to claim 1, characterized in that: If the number of parallel winding branches is 1, add bridge wires 19f-24f, 29a-23a, and 18f-25f on the same layer; 24a is the power lead wire of phase A; 30a is the neutral point lead wire, which is welded together with the neutral point lead wires of phases B and C.

8. The flat wire mid-mounted motor stator for an electric motorcycle according to claim 1, characterized in that: If the number of parallel winding branches is 2, add bridge wires 19f-24f and 18f-25f on the same layer; 24a and 23a are connected in parallel to form the A-phase power lead wires; 30a and 29a are neutral point lead wires, which are welded together with the B-phase and C-phase neutral point lead wires.

9. The flat wire mid-mounted motor stator for an electric motorcycle according to claim 1, characterized in that: If the number of parallel winding branches is 4, then 24a, 24f, 23a, and 25f are connected in parallel to form the A-phase power lead wires; 19f, 29a, 18f, and 30a are the neutral point lead wires, which are welded together with the B-phase and C-phase neutral point lead wires.

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