Modular hairpin wire winding and stator structure

Abstract

The application provides a modular hairpin wire winding comprising four types of hairpin wires and two flat wires, the modular hairpin wire winding forms a phase unit of at least one phase winding, the phase unit is arranged only along a part of circumference of a stator core, each phase unit can be regarded as a modular structure, the wiring design is simplified, and the wiring cost is reduced. And the assembly difficulty is reduced.

Description

Technical Field

[0001] The present application relates to a wiring method for a hairpin winding, and more particularly to a wiring method for a modular hairpin winding. Background Art

[0002] The stator of a three-phase induction motor has three symmetrically arranged coil windings. When three-phase alternating current (AC) is applied to these coil windings, they generate a rotating magnetic field at the same frequency as the AC, driving the rotor. In recent years, flat-wire windings, a type of copper wire known as hairpin windings, have become increasingly common. Compared to traditional windings with round cross-sections, flat-wire windings (also known as rectangular wire) allow for higher current carrying capacity and offer improved heat dissipation, enabling the motor to operate at high power density and efficiency.

[0003] To assemble a hairpin winding, multiple flat copper wires are first bent sequentially into hairpin conductors. Next, according to the winding layout, the hairpin conductors are radially stacked and circumferentially arranged into a ring shape. The open ends of these conductors are then inserted axially into the slots of the stator core. Finally, the open ends of the hairpins are twisted, cut flat, and welded to form the flat wire winding.

[0004] Existing hairpin conductor units can be categorized by structure as Hair-pin (also known as U-pin), I-pin, X-pin, and S-winding. Furthermore, considering the complex assembly process and the high precision required for forming hairpins, simplifying the winding method would greatly reduce design complexity. Utility Model Content

[0005] The technical problem to be solved by this application is to provide a modular hairpin winding installed on a stator core to form any phase winding of a three-phase winding. Each phase winding has at least one phase unit. The modular hairpin winding includes a plurality of flat wires connected in series to form each phase unit.

[0006] The stator core includes a yoke and a plurality of teeth arranged along the circumference of the yoke to form N slots, each of which is used to accommodate L+2 layers of flat wires, wherein N is a multiple of 12, and N and L are positive integers;

[0007] The flat wire conductors of each phase unit include a first hairpin, a second hairpin, a third hairpin, 2L fourth hairpins, and two conductors. Each of the first hairpin, the second hairpin, the third hairpin, and the fourth hairpin has a crown, two extensions, one end of which extends from the two ends of the crown, and two welding sections extending from the other end of the extension.

[0008] The crown of the first hairpin line spans six slot distances, and the two extension sections of the first hairpin line are arranged on the first layer of the slot body;

[0009] The crown of the second hairpin line spans seven slot distances, and the two extension sections of the second hairpin line are arranged at the L+2th layer of the slot body;

[0010] The crown of the third hairpin line spans five slot distances, and the two extension sections of the third hairpin line are arranged at the L+2th layer of the slot body;

[0011] The crown portion of each fourth hairpin line spans five slot distances, the two extension sections of the fourth hairpin line are arranged on the 2nd to L+1th layers of the slot body, and the two extension sections of the same fourth hairpin line span adjacent layers of the slot body;

[0012] The two wires each have a connecting section disposed on the first layer of the slot, and each connecting section extends outward to form a welding section, wherein:

[0013] The two welding sections of the first hairpin line are respectively connected to one of the welding sections of the two fourth hairpin lines of the second layer of the tank body.

[0014] The welding section of each of the two wires is respectively connected to one of the welding sections of the two fourth hairpin wires of the second layer of the tank body.

[0015] The two welding sections of the second hairpin line are respectively connected to one of the welding sections of the fourth hairpin line adjacent to it on the L+1th layer of the tank body,

[0016] The two welding sections of the third hairpin line are respectively connected to one of the welding sections of the fourth hairpin line adjacent to it on the L+1th layer of the tank body,

[0017] One of the welding sections of the remaining fourth hairpin lines is connected to another welding section of the fourth hairpin line whose extension section is located at the same adjacent layer of the trough.

[0018] The aforementioned conductor routing allows the hairpin windings constituting each phase unit to be arranged only along a portion of the circumference of the stator core. Each phase unit can be considered a modular structure, thereby simplifying the wiring design and easing assembly difficulty.

[0019] Furthermore, let the connecting sections of the two wires be respectively arranged in the n1th slot and the n1+6th slot, where n1 is a positive integer, then,

[0020] The two extension sections of the first hairpin line are respectively disposed at the n1+1th groove and the n1+7th groove.

[0021] The two extension sections of the second hairpin line are respectively disposed at the n1+5th groove and the n1+12th groove.

[0022] The two extension sections of the third hairpin line are respectively disposed at the n1+6th slot and the n1+11th slot.

[0023] One of the extension sections of the fourth hairpin line is located at the n1th groove, the n1+1th groove, the n1+6th groove or the n1+7th groove.

[0024] Furthermore, the two welding sections of the fourth hairpin line are both bent toward the crown.

[0025] One of the welding sections of the first hairpin line is bent toward the crown, and the other welding section is bent away from the crown.

[0026] One of the welding sections of the second hairpin line is bent toward the crown, and the other welding section is bent away from the crown.

[0027] One of the welding sections of the third hairpin line is bent toward the crown, and the other welding section is bent away from the crown.

[0028] Each of the welding sections spans two and a half slots from the crown.

[0029] The present application also relates to a stator structure, comprising the aforementioned modular hairpin winding, for constructing at least one phase unit of any phase winding of a three-phase winding.

[0030] The details of other functions and embodiments of the present application are described below with reference to the drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments recorded in this application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0032] Figure 1 、 Figure 2 、 Figure 3 A schematic diagram of the appearance of a portion of a three-phase motor stator structure;

[0033] Figure 4A 、 Figure 4B 、 Figure 4C 、 Figure 5 Schematic diagram of a hairpin conductor unit;

[0034] Figure 6A 、 Figure 6B It is a schematic diagram of the conductor;

[0035] Figure 7A、 Figure 7B 、 Figure 7C 、 Figure 7D This is a schematic diagram of the connection of each conductor of a phase unit of the winding;

[0036] Figure 8A 、 Figure 8B 、 Figure 8C These are the wiring diagrams for the U-phase winding, V-phase winding, and W-phase winding respectively.

[0037] Explanation of symbols

[0038] 6~18: slot body 100: stator core

[0039] 101: Yoke 102: Tooth

[0040] 200: Hairpin winding 210: Phase unit

[0041] 300: Neutral flat cable U1, U2, U3, U4: Hairpin cable

[0042] I1, I2: Wires A1, A2: Extension

[0043] A3, A4: connecting section B1, B2, B3, B4: welding section

[0044] C1, C2, C3, C4: Crown X, Y, Z, T: Groove distance DETAILED DESCRIPTION

[0045] The positional relationships described in the following embodiments include up, down, left, and right. Unless otherwise specified, they are based on the directions of the components shown in the drawings.

[0046] The motor structure related to this application includes an inner rotor and an outer stator. The complete stator structure is an annular structure. However, in order to clearly identify the concept of this application, only a part of the stator structure is shown in this embodiment. Figures 1 to 3 , shows a portion of a stator structure, which includes a stator core 100 and a hairpin winding 200 .

[0047] The stator core 100 is composed of multiple core units stacked axially. Each core unit includes an annular yoke 101 and multiple teeth 102 arranged circumferentially around the yoke 101. Radially extending slots (6-18) are formed between adjacent pairs of teeth 102. The hairpin winding 200 comprises multiple rectangular conductors arranged axially and inserted into the slots of the stator core 100.

[0048] In this embodiment, the stator core 100 has N slots, and each slot is used to accommodate L+2 layers of rectangular wires, wherein N is a multiple of 12, and N and L are positive integers.

[0049] In this embodiment, the hairpin winding 200 constructs a first phase winding, a second phase winding and a third phase winding of the three-phase winding, and any phase winding has at least one phase unit 210 (such as Figure 7D As shown in FIG, the phase units 210 of the first phase winding, the second phase winding, and the third phase winding are periodically arranged in sequence along the circumference of the stator core 100.

[0050] In this embodiment, each phase winding comprises multiple phase units 210, arranged at equal angles along the circumference of the stator core 100. In one embodiment, the phase units 210 are connected in parallel. In another embodiment, the multiple phase units 210 of the same phase winding are connected in series using wires. The welded sections B4 of the phase units 210 of the first, second, and third phase windings can be connected using a neutral flat cable 300. In other embodiments, each phase winding may comprise only one phase unit 210, with the three phase units 210 arranged at equal angles along the circumference of the stator core 100.

[0051] The phase windings of this embodiment are all composed of one or more identical phase units 210. The hairpin winding 200 constituting each phase unit 210 is arranged only along a portion of the circumference of the stator core 100. Each phase unit can be regarded as a modular structure, which helps to simplify the wiring design and assembly difficulty.

[0052] The span (or slot pitch) described below refers to the distance between two extensions of the same conductor in a motor winding within the stator core. This is typically expressed as the number of slots in the stator core. For example, if two extensions are located in slots n0+1 and n0+6, respectively, where n0 is a positive integer, the distance between these extensions is defined as 5 slots.

[0053] The term "crown portion" used in the following text is used to define the bend between two extensions of the same hairpin line, and does not mean that the bend is crown-shaped. The aforementioned slot distance is also used to define the distance between the two ends of the crown.

[0054] See also Figure 4A 、 Figure 4B 、 Figure 4C 、 Figure 5 、 Figure 6A 、 Figure 6B , illustrating the type of wires used by each phase unit 210.

[0055] Figure 4A 、 Figure 4B 、 Figure 4CThe first, second, and third hairpins U1, U2, and U3 are shown. Each hairpin comprises a crown C1, C2, and C3, two extensions A1 and A2, one end extending from the distal ends of the crown, and two welding sections B1 and B2 extending from the other ends of the extensions A1 and A2, respectively. The extensions A1 and A2 are mounted in the slot, and the welding sections B1 and B2 connect to the welding sections B1 and B2 of adjacent conductors to form a complete loop. To facilitate assembly between the corresponding conductors, the welding sections B1 and B2 of each conductor can be bent relative to the extensions A1 and A2.

[0056] The crowns C1 , C2 , and C3 of the first hairpin line U1 , the second hairpin line U2 , and the third hairpin line U3 respectively span the X, Y, and Z slot distances, where X=7, Y=5, and Z=6.

[0057] One of the weld segments B1 and B2 of the first, second, and third hairpin lines U1, U2, and U3 bends toward the crowns C1, C2, and C3, while the other bends away from the crowns C1, C2, and C3. In this embodiment, each weld segment is spaced from the crown by a T-slot distance, where T = 2.5.

[0058] Figure 5 The fourth hairpin U4 also has a crown C4, two extensions A1 and A2, and two welded sections B1 and B2. It differs from the aforementioned hairpins U1, U2, and U3 in that the crown C4 spans a slot distance Y, where Y = 5. The two welded sections B1 and B2 are bent toward the crown C4. The two extensions A1 and A2 of the same fourth hairpin U4 span adjacent layers of the slot. When multiple fourth hairpins U4 are assembled in the same slot, the welded sections B1 and B2 of all fourth hairpins U4 are aligned side by side.

[0059] Figure 6A 、 Figure 6B Wires I1 and I2 are shown, each with connecting segments A3 and A4 mounted in a slot. Each end of each connecting segment A3 and A4 extends outward to form welding segments B3 and B4. One welding segment B3, located adjacent to the hairpin's welding segment B1, is used to connect adjacent wires within a phase unit 210. The other welding segment B4, located adjacent to the hairpin's crowns C1, C2, and C3, is connected to another phase unit 210 of the same phase winding via an external conductor, or to a phase unit 210 of a different phase winding via a neutral flat cable 300.

[0060] Please also refer to, Figure 7A 、 Figure 7B 、 Figure 7C 、 Figure 7DIn this embodiment, each phase unit 210 includes a first hairpin U1 , a second hairpin U2 , a third hairpin U3 , 2L fourth hairpins U4 , a wire I1 , and a wire I2 .

[0061] like Figure 7A As shown, the two extension sections A1 and A2 of the first hairpin line U1 are respectively arranged on the first layer of the trough body;

[0062] like Figure 7D As shown, the two extension segments A1 and A2 of the second hairpin line U2 are respectively arranged at the L+2th layer of the trough body;

[0063] like Figure 7D As shown, the two extension segments A1 and A2 of the third hairpin line U3 are respectively arranged at the L+2th layer of the trough body;

[0064] like Figure 7B 、 Figure 7C As shown, the two extension segments A1 and A2 of the fourth hairpin line U4 are arranged on the 2nd to L+1th layers of the tank body.

[0065] like Figure 7A As shown, the connecting sections A3 and A4 of the conductor I1 and the conductor I2 are arranged in the first layer of the tank.

[0066] If the connecting segment A3 of the conductor I1 is arranged in the n1th slot, and the connecting segment A4 of the conductor I2 is arranged in the n1+6th slot, where n1 is a positive integer, the connection of the conductors can be expressed as follows:

[0067] An extension segment A1 of a fourth hairpin U4 is located in the second layer, in the n1th slot. The welding segment B1 corresponding to the extension segment A1 (of the fourth hairpin U4) is connected to the welding segment B3 of the conductor I1.

[0068] An extension segment A1 of one of the fourth hairpin wires U4 is located in the second layer, in the n1+6th slot. The welding segment B1 corresponding to the extension segment A1 (of the fourth hairpin wire U4) is connected to the welding segment B3 of the wire I2.

[0069] The two extension segments A1 and A2 of the first hairpin line U1 are located in the n1+1th slot and the n1+7th slot respectively.

[0070] An extension segment A1 of a fourth hairpin U4 is located in the second layer, in the n1+1th slot. The welding segment B1 corresponding to the extension segment A1 (of the fourth hairpin U4) is connected to the welding segment B1 of the first hairpin U1.

[0071] An extension segment A1 of one of the fourth hairpin lines U4 is located in the second layer, in the n1+7th slot, and a welding segment B1 corresponding to the extension segment A1 (of the fourth hairpin line U4) is connected to the welding segment B2 of the first hairpin line U1.

[0072] The two extension segments A1 and A2 of the second hairpin line U2 are respectively arranged at the n1+5th slot and the n1+12th slot.

[0073] An extension segment A2 of a fourth hairpin U4 is located at the L+1th layer and the n1+5th slot. The welding segment B2 corresponding to the extension segment A2 (of the fourth hairpin U4) is connected to the welding segment B1 of the second hairpin U2.

[0074] An extension segment A2 of one of the fourth hairpin lines U4 is located at the L+1th layer and the n1+12th slot, and the welding segment B2 corresponding to the extension segment A2 (of the fourth hairpin line U4) is connected to the welding segment B2 of the second hairpin line U2.

[0075] The two extension segments A1 and A2 of the third hairpin line U3 are respectively arranged at the n1+6th slot and the n1+11th slot.

[0076] An extension segment A2 of a fourth hairpin U4 is located at the L+1th layer and the n1+6th slot. The welding segment B2 corresponding to the extension segment A2 (of the fourth hairpin U4) is connected to the welding segment B1 of the third hairpin U3.

[0077] An extension segment A2 of one of the fourth hairpin lines U4 is located at the L+1th layer and the n1+11th slot, and the welding segment B2 corresponding to the extension segment A2 (of the fourth hairpin line U4) is connected to the welding segment B2 of the third hairpin line U3.

[0078] The remaining fourth hairpins U4 are connected in such a way that one welding section B2 of one fourth hairpin U4 is connected to another welding section B1 of another fourth hairpin U4. The extension section A2 of one fourth hairpin U4 and the extension section A1 of the other fourth hairpin U4 are located in adjacent layers of the same slot. In this way, all the wires are serially connected to form a phase unit 210.

[0079] See also Figures 8A to 8C Based on the aforementioned embodiment, the wiring diagram for the U-phase winding, V-phase winding, and W-phase winding of a three-phase motor stator is shown. The wiring diagrams for the U-phase winding, V-phase winding, and W-phase winding are essentially identical, but are arranged in an offset arrangement along the circumference of the stator core 100. Each phase unit 210 is connected in series to form a complete loop around the stator core.

[0080] In this embodiment, each phase winding includes four phase units 210 , and each slot is provided with eight layers of extension segments, ie, N=48, L=6.

[0081] Matching 7A to 7D Taking the phase unit 210 arranged between slots 6 and 18 of the U-phase winding as an example, the wiring method of this phase unit 210 is described. The solid lines in the figure represent the physical conductors, and the dashed lines represent the wiring method of the welding segments. The connecting segment A3 of the conductor I1 is located in the 1st layer and the 18th slot and serves as the current input terminal. The connecting segment A4 of the conductor I1 is located in the 1st layer and the 12th slot and serves as the current output terminal. The following describes the wiring method of each conductor based only on the physical structure:

[0082] The extension section A1 of the No. 1 hairpin line is located at the 2nd layer and the 13th groove, and the extension section A2 is located at the 3rd layer and the 18th groove.

[0083] The extension section A1 of the No. 2 hairpin line is located at the 4th layer and the 13th groove, and the extension section A2 is located at the 5th layer and the 18th groove.

[0084] The extension section A1 of the No. 3 hairpin line is located at the 6th floor and the 13th groove, and the extension section A2 is located at the 7th floor and the 18th groove.

[0085] The extension section A1 of the No. 4 hairpin line is located at the 8th floor and the 13th groove, and the extension section A2 is located at the 8th floor and the 6th groove.

[0086] The extension section A2 of the No. 5 hairpin line is located at the 7th floor and the 11th groove, and the extension section A1 is located at the 6th floor and the 6th groove.

[0087] The extension section A2 of the No. 6 hairpin line is located at the 5th layer and the 11th groove, and the extension section A1 is located at the 4th layer and the 6th groove.

[0088] The extension section A2 of the No. 7 hairpin line is located at the 3rd layer and the 11th groove, and the extension section A1 is located at the 2nd layer and the 6th groove.

[0089] The extension section A2 of the No. 8 hairpin line is located at the 1st layer and the 11th groove, and the extension section A1 is located at the 1st layer and the 7th groove.

[0090] The extension section A1 of the No. 9 hairpin line is located at the 2nd layer and the 17th groove, and the extension section A2 is located at the 3rd layer and the 12th groove.

[0091] The extension section A1 of the No. 10 hairpin line is located at the 4th layer and the 17th groove, and the extension section A2 is located at the 5th layer and the 12th groove.

[0092] The extension section A1 of the No. 11 hairpin line is located at the 6th floor and the 17th groove, and the extension section A2 is located at the 7th floor and the 12th groove.

[0093] The extension section A1 of the No. 12 hairpin line is located at the 8th layer and the 12th groove, and the extension section A2 is located at the 8th layer and the 7th groove.

[0094] The extension section A2 of the No. 13 hairpin line is located at the 7th floor and the 12th groove, and the extension section A1 is located at the 6th floor and the 7th groove.

[0095] The extension section A2 of the No. 14 hairpin line is located at the 5th layer and the 12th groove, and the extension section A1 is located at the 4th layer and the 7th groove.

[0096] The extension section A2 of the No. 15 hairpin line is located at the 3rd layer and the 12th groove, and the extension section A1 is located at the 2nd layer and the 7th groove.

[0097] The connecting section A4 of the wire I2 is located at the 1st layer and the 12th slot and serves as the current output terminal.

[0098] Among them, the No. 4 hairpin line is the second hairpin line U2, the No. 8 hairpin line is the first hairpin line U1, the No. 12 hairpin line is the third hairpin line U3, and the remaining hairpin lines are the fourth hairpin line U4.

[0099] In this embodiment, the first layer is adjacent to the inner surface of the stator core, and the eighth layer is adjacent to the outer surface of the stator core. However, the first layer and the eighth layer can also be defined as the inner surface and the outer surface of the stator core, respectively.

[0100] The embodiments and / or implementation methods described above are only used to illustrate the preferred embodiments and / or implementation methods for realizing the technology of the present application, and do not impose any form of limitation on the implementation methods of the technology of the present application. Any person skilled in the art may make slight changes or modifications to other equivalent embodiments without departing from the scope of the technical means disclosed in the content of the present application, but they should still be regarded as technologies or embodiments that are essentially the same as those of the present application.

Claims

1. A modular hairpin winding for installation on a stator core to form any phase winding of a three-phase winding, wherein any phase winding has at least one phase unit, wherein the modular hairpin winding comprises a plurality of flat wires connected in series to form each phase unit. The stator core includes a yoke and a plurality of teeth arranged along the circumference of the yoke to form N slots, each of which is used to accommodate L+2 layers of flat wire conductors, wherein: N is a multiple of 12, and N and L are positive integers; The flat wire conductors of each phase unit include a first hairpin conductor, a second hairpin conductor, a third hairpin conductor, 2L fourth hairpin conductors, and two conductors. Each of the first hairpin conductor, the second hairpin conductor, the third hairpin conductor, and the fourth hairpin conductor has a crown, two extension segments, one end of each extending from two ends of the crown, and two welding segments extending from the other end of each extension segment. The crown of the first hairpin line spans six slot distances, and the two extension sections of the first hairpin line are arranged on the first layer of the slot body; The crown of the second hairpin line spans seven slot distances, and the two extension sections of the second hairpin line are arranged at the L+2th layer of the slot body; The crown of the third hairpin line spans five slot distances, and the two extension sections of the third hairpin line are arranged at the L+2th layer of the slot body; The crown portion of each fourth hairpin line spans five slot distances, the two extension sections of the fourth hairpin line are arranged on the 2nd to L+1th layers of the slot body, and the two extension sections of the same fourth hairpin line span adjacent layers of the slot body; The two wires each have a connecting section disposed on the first layer of the slot, and each connecting section extends outward to form a welding section. in, The two welding sections of the first hairpin line are respectively connected to one welding section of the two fourth hairpin lines of the second layer of the tank body. The welding section of each of the two wires is respectively connected to one of the welding sections of the two fourth hairpin wires of the second layer of the tank body. The two welding sections of the second hairpin line are respectively connected to one of the welding sections of the fourth hairpin line adjacent to it on the L+1th layer of the trough body, The two welding sections of the third hairpin line are respectively connected to one of the welding sections of the fourth hairpin line adjacent to it on the L+1th layer of the tank body, One of the welding sections of the remaining fourth hairpin lines is connected to another welding section of the fourth hairpin line whose extension section is located at the same adjacent layer of the trough.

2. The modular hairpin winding according to claim 1, characterized in that Let the connecting sections of the two wires be respectively arranged in the n1th slot and the n1+6th slot, where n1 is a positive integer, then, The two extension sections of the first hairpin line are respectively disposed at the n1+1th groove and the n1+7th groove. The two extension sections of the second hairpin line are respectively disposed at the n1+5th groove and the n1+12th groove. The two extension sections of the third hairpin line are respectively disposed at the n1+6th slot and the n1+11th slot. One of the extension sections of the fourth hairpin line is located at the n1th groove, the n1+1th groove, the n1+6th groove or the n1+7th groove.

3. The modular hairpin winding according to claim 1, characterized in that The two welding sections of the fourth hairpin line are both bent toward the crown. One of the welding sections of the first hairpin line is bent toward the crown, and the other welding section is bent away from the crown. One of the welding sections of the second hairpin line is bent toward the crown, and the other welding section is bent away from the crown. One of the welding sections of the third hairpin line is bent toward the crown, and the other welding section is bent away from the crown. Each of the welding sections spans two and a half slots from the crown.

4. A stator structure, characterized in that: The modular hairpin winding according to any one of claims 1 to 3 is used to construct at least one phase unit of any phase winding of a three-phase winding.

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