Flat wire motor stator structure of six-layer full-pitch six-phase winding

Abstract

The utility model relates to a flat wire motor stator structure of a six-layer full-pitch six-phase winding, which comprises windings, a stator iron core and a neutral point copper bar, the windings comprise a plurality of I-shaped and U-shaped flat wire conductors, and two sets of windings in all notches on the stator iron core are arranged at intervals in the same phase; the welding end structure of the U-shaped flat wire conductor comprises two supporting legs, the span of the two supporting legs is 3, and the two supporting legs are twisted in the same direction or opposite directions along the circumferential direction; the in-groove straight line segments of the I-shaped flat wire conductors are located on the outermost side or the innermost side of the groove openings, and the multiple I-shaped flat wire conductors are led out of the multiple adjacent grooves in a concentrated mode. According to the utility model, the winding structure adopts an integral pitch winding structure, so that the peak output capability of the motor can be effectively improved. The winding structure is a six-phase two-set winding structure, so that the redundancy in design is provided, and the reliability of the system is enhanced; the winding structure has few types of hairpins, so that the types and investment of forming equipment are greatly reduced.

Description

Technical Field

[0001] The utility model belongs to the technical field of motor stator structures, and in particular relates to a flat wire motor stator structure with six-layer, full-pitch, six-phase windings. Background Art

[0002] At present, more and more flat wire motors are being used in the domestic new energy vehicle industry. The winding arrangement and connection method of flat wire motors are one of the difficulties in designing such motors. The existing coil arrangement method generally has the following problems:

[0003] 1) There is a problem of asymmetric winding lines, which will lead to differences in back electromotive force, resistance, inductance, etc., and reduce motor performance; it will cause circulating currents between different branch windings, increase the additional loss of the motor, and cause local overheating of the motor.

[0004] 2) There are many special-shaped coils. The existence of special-shaped coils will increase the difficulty of coil manufacturing and is not conducive to mass production.

[0005] 3) There are many types of coils and the arrangement is complex; a large number of bus bars and busbars are required to connect the branches and center points of each phase winding, which will lead to the height of the winding ends and increase the axial length of the motor.

[0006] 4) Existing flat wire motors generally have only one set of windings. If a phase winding fails, the motor cannot continue to operate, posing a huge safety hazard. Utility Model Content

[0007] In order to solve the above technical problems, the purpose of the present invention is to provide a flat wire motor stator structure with six layers of full-pitch six-phase windings, which can make the motor run more smoothly, with high system stability and strong safety.

[0008] In order to achieve the above-mentioned purpose of the utility model, the utility model adopts the following technical solutions:

[0009] A flat wire motor stator structure with six layers of full-pitch six-phase windings, comprising a winding, a stator core and a neutral point copper bar, wherein the stator core is provided with a plurality of slots evenly distributed along the circumference; the winding is arranged in the slots, and the winding comprises a plurality of flat wire conductors in an "I" shape and a "U" shape, wherein the U"-shaped flat wire conductor comprises a crown end, a straight line segment in the slot and a welding end, and the corresponding U"-shaped flat wire conductors are connected by the welding end, and the two straight line segments in the slot of the U"-shaped flat wire conductor are respectively inserted in different slots, and each slot has six layers of flat wire conductors, and the winding is a six-layer short-distance connection, comprising two sets of windings; the neutral point copper bar connects the neutral points of the two sets of windings, and the two sets of winding structures are connected. The three-phase interface is directly connected to the winding, and the two sets of windings in all slots on the stator core are arranged with the same phase interval; the welding end structure of the "U"-shaped flat wire conductor is two legs, the span of the two legs is L, and the two legs are twisted in the same direction or opposite directions along the circumferential direction; wherein, L=3; the straight line section in the slot of the "I"-shaped flat wire conductor is located at the outermost or innermost side of the slot, and multiple "I"-shaped flat wire conductors are concentratedly led out from multiple adjacent slots; one end of the "I"-shaped flat wire conductor is connected to the windings in other slots, and the torsional span of one end of the "I"-shaped flat wire conductor is 3, and the other end of the "I"-shaped flat wire conductor is connected to the neutral point copper bus or the three-phase interface.

[0010] As a preferred solution: the span of the slot where the two straight segments in the slot of the "U"-shaped flat wire conductor are located is X, Y or Z, where X=5, Y=6, and Z=7; the two straight segments in the slot are in the same layer or adjacent layers.

[0011] As a preferred solution: the two sets of windings are arranged symmetrically at 90° or 180°; the two sets of windings constitute a six-phase winding structure.

[0012] As a preferred solution: the two sets of windings are formed by combining different numbers of "I"-shaped and "U"-shaped flat wire conductors, and the neutral points of the two sets of windings are connected by a neutral point copper bar to achieve a "Y"-shaped connection.

[0013] As a preferred solution: an in-slot insulation structure is further provided between the winding and the inner wall of the slot of the stator core.

[0014] Compared with the prior art, the beneficial effects of the present invention are:

[0015] The winding structure of this utility model adopts a full-pitch winding structure, which can effectively improve the peak output capacity of the motor. The winding structure adopts a six-phase winding structure design, which can better balance the load, reduce the impact of phase imbalance, and improve system stability. The winding structure is a six-phase two-set winding structure, providing design redundancy. When a phase winding fails, the other set of windings can continue to operate, enhancing system reliability. The two sets of windings in the winding structure are evenly arranged on the circumference, and the spacing within the same slot is well-uniformed, which can effectively reduce the impact of circulating current. The winding structure has a very small number of types of hairpins, which greatly reduces the types of molding equipment and investment. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The drawings in the specification, which constitute a part of this application, are used to provide a further understanding of this application. The illustrative embodiments of this application and their descriptions are used to explain this application and do not constitute a limitation on this application.

[0017] Figure 1 This is a schematic diagram of the structure of a conductor according to an embodiment of the present utility model;

[0018] Figure 2 This is a schematic diagram of the structure of the conductor 2 according to an embodiment of the present utility model;

[0019] Figure 3 This is a schematic diagram of the third structure of the conductor in an embodiment of the present utility model;

[0020] Figure 4 This is a schematic diagram of the structure of the conductor 4 according to an embodiment of the present utility model;

[0021] Figure 5 This is a schematic diagram of the arrangement of two sets of windings of the utility model;

[0022] Figure 6 This is a schematic diagram of the stator structure of a motor according to an embodiment of the present utility model;

[0023] Figure 7 This is a schematic diagram of the stator winding structure of an embodiment of the present utility model;

[0024] Figure 8 This is a schematic diagram of the stator winding structure of one set of windings in one phase of an embodiment of the present invention;

[0025] Figure 9 This is a schematic diagram of the stator winding and stator arrangement of one set of windings in one phase of an embodiment of the present invention;

[0026] Figure 10 This is a planar expansion diagram of the slot arrangement of an embodiment of the present utility model;

[0027] Figure 11 This is a schematic diagram of the connection of one set of windings in one phase of an embodiment of the present invention;

[0028] Figure 12 This is a schematic diagram of the connection of another set of windings in one phase of an embodiment of the present utility model;

[0029] Figure 13 This is a schematic diagram of a star-connected circuit of two sets of windings according to an embodiment of the present invention. DETAILED DESCRIPTION

[0030] It should be noted that the following detailed descriptions are illustrative and intended to provide further explanation of the present application. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which the present application belongs.

[0031] It should be noted that the terms used herein are only for describing specific embodiments and are not intended to limit the exemplary embodiments according to the present application. As used herein, unless the context clearly indicates otherwise, the singular form is also intended to include the plural form. In addition, it should be understood that when the terms "comprise" and / or "include" are used in this specification, they indicate the presence of features, steps, operations, devices, components and / or combinations thereof.

[0032] In addition, in the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "clockwise", "counterclockwise" and the like to indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention.

[0033] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of the technical features being referred to. Thus, a feature specified as "first" or "second" may explicitly or implicitly include one or more of such features. In the description of this utility model, unless otherwise specified, "plurality" means two or more, unless expressly limited otherwise.

[0034] In this utility model, unless otherwise specified or limited, the terms "installed," "connected," "connect," "fixed," etc. should be understood in a broad sense. For example, they can refer to fixed connection, detachable connection, or integral connection; mechanical connection or electrical connection; direct connection or indirect connection through an intermediate medium; and internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in this utility model based on specific circumstances.

[0035] In the present invention, unless otherwise expressly specified or limited, a first feature being "above" or "below" a second feature may include the first and second features being in direct contact, or may include the first and second features being in contact not directly but through another feature between them. Moreover, a first feature being "above," "above," and "above" a second feature may include the first feature being directly above or obliquely above the second feature, or may simply mean that the first feature is higher in level than the second feature. A first feature being "below," "below," and "below" a second feature may include the first feature being directly below or obliquely below the second feature, or may simply mean that the first feature is lower in level than the second feature.

[0036] The present invention will be further described below with reference to the accompanying drawings and embodiments:

[0037] The following describes in detail the specific structure of the winding of one of the two sets of six-phase windings and its distribution structure in the stator.

[0038] like Figures 1 to 13As shown, a flat wire motor stator structure with six layers of full-pitch six-phase windings includes windings, a stator core 1 and a neutral point copper bar. The stator core 1 is provided with a plurality of slots evenly distributed along the circumference; the windings are arranged in the slots, and the windings 2 include a plurality of flat wire conductors in "I" shape and "U" shape. The U"-shaped flat wire conductor includes a crown end, a straight line segment in the slot and a welding end. The corresponding U"-shaped flat wire conductors are connected through the welding end. The two straight line segments in the slot of the U"-shaped flat wire conductor are respectively inserted in different slots, and each slot has 6 layers of flat wire conductors. It is characterized in that: the windings are 6 layers of short-distance connection, including two sets of windings; the neutral point copper bar connects the neutral points of the two sets of windings, and the three-phase interface of the two sets of winding structures is directly connected by the windings. The two sets of windings in all slots on the stator core 1 are arranged with equal phase spacing. The welded ends of the U-shaped flat wire conductors are structured as two legs with a span of L, twisting in the same or opposite directions along the circumferential direction, where L = 3. The straight segments of the I-shaped flat wire conductors in the slots are located at the outermost or innermost sides of the slots, and multiple I-shaped flat wire conductors are concentrated and led out from multiple adjacent slots. One end of the I-shaped flat wire conductor is connected to the windings in other slots, and the twist span of one end of the I-shaped flat wire conductor is 3. The other end of the I-shaped flat wire conductor is connected to the neutral point copper busbar or three-phase interface. An in-slot insulation structure 3 is also provided between the winding 2 and the inner wall of the slot of the stator core 1.

[0039] The two windings are arranged symmetrically at 90° or 180°, forming a six-phase winding structure. The two windings are formed by combining different numbers of "I"-shaped and "U"-shaped flat wire conductors, and the neutral points of the two windings are connected via a neutral point copper bar, achieving a "Y" connection.

[0040] A single hairpin with only one leg on one side is called an "I"-shaped line, and a single hairpin with legs on both sides is called a "U"-shaped line.

[0041] The two straight sides of the "U"-shaped line are named hairpin straight side A1 and hairpin straight side B1 respectively. Hairpin straight side A1 and hairpin straight side B1 can be located in adjacent layers or in the same layer; generally, hairpin straight side A1 is located in the outer layer, and hairpin straight side B1 is located in the inner layer.

[0042] The two legs of the "U"-shaped line are named hairpin leg A2 and hairpin leg B2 respectively; the straight edge A1 of the "U"-shaped hairpin is connected to the hairpin leg A2 and is located on the same layer; the straight edge B1 of the hairpin is connected to the hairpin leg B2 and is located on the same layer.

[0043] The only straight side of the “I”-shaped linear type is named as the hairpin straight side A3, and one leg of the linear type is named as the hairpin leg A4.

[0044] The slot distance between the two straight sides A1 and B1 of the "U"-shaped line is called the span, which is represented by X / Y / Z in the present invention, where X=5, Y=6, and Z=7.

[0045] The "U"-shaped linear hairpin legs A2 and B2 are led out through the hairpin straight edges A1 and B1, and the "I"-shaped linear hairpin leg A4 is led out through the hairpin straight edge A3; the groove distance between the end of the hairpin leg A2 and the hairpin straight edge A1, the end of the hairpin leg A4 and the hairpin straight edge A3, and the end of the hairpin leg B2 and the hairpin straight edge B1 is called the hairpin leg span, which is represented by L in the utility model, where L=3.

[0046] The specific structure of one of the two six-phase windings is as follows:

[0047] A single winding consists of two I-shaped wires and 23 U-shaped wires. The I-shaped wires have only one conductor configuration, a single-conductor configuration. The U-shaped wires have three conductor configurations, depending on the span of the hairpin's straight edge and legs: two, three, or four conductors. The three or four conductor configurations are used in both windings.

[0048] Each set of windings first goes from the 1st layer to the 6th layer, and then returns from the 6th layer to the 1st layer through a reverse cross-line (conductor three or four structure). The conductors are evenly distributed in each slot of each layer. The specific wiring structure of one set of windings of the stator structure of the present invention is as follows: the starting section (IN) of the winding is located at the crown end, that is, the straight edge A3 of the "I"-shaped hairpin is inserted in the first layer of slot No. 1, the straight edge A1 of the first hairpin is inserted in the second layer of slot No. 43, the straight edge B1 of the first hairpin is inserted in the first layer of slot No. 37, the straight edge A1 of the second hairpin is inserted in the second layer of slot No. 31, the straight edge B1 of the second hairpin is inserted in the first layer of slot No. 25, the straight edge A1 of the third hairpin is inserted in the second layer of slot No. 19, the straight edge B1 of the third hairpin is inserted in the first layer of slot No. 13, the straight edge B1 of the fourth hairpin is inserted in the second layer of slot No. 7, the straight edge A1 of the fourth hairpin is inserted in The 3rd layer of slot 1, the 5th hairpin straight edge A1 is inserted in the 4th layer of slot 43, the 5th hairpin straight edge B1 is inserted in the 3rd layer of slot 37, the 6th hairpin straight edge A1 is inserted in the 4th layer of slot 31, the 6th hairpin straight edge B1 is inserted in the 3rd layer of slot 25, the 7th hairpin straight edge A1 is inserted in the 4th layer of slot 19, the 7th hairpin straight edge B1 is inserted in the 3rd layer of slot 13, the 8th hairpin straight edge B1 is inserted in the 4th layer of slot 7, the 8th hairpin straight edge A1 is inserted in the 5th layer of slot 1, the 9th hairpin straight edge A1 is inserted in the 6th layer of slot 43, the 9th hairpin straight edge B1 is inserted in the 5th layer of slot 37, the 10th hairpin straight edge A1 is inserted in the 6th layer of slot 31, the straight edge B1 of the tenth hairpin is inserted in the 5th layer of slot 25, the straight edge A1 of the eleventh hairpin is inserted in the 6th layer of slot 19, the straight edge B1 of the eleventh hairpin is inserted in the 5th layer of slot 13, the straight edge A1 of the twelfth hairpin is inserted in the 6th layer of slot 7, the straight edge B1 of the twelfth hairpin is inserted in the 6th layer of slot 2, the straight edge B1 of the thirteenth hairpin is inserted in the 5th layer of slot 8, the straight edge A1 of the thirteenth hairpin is inserted in the 6th layer of slot 14, the straight edge B1 of the fourteenth hairpin is inserted in the 5th layer of slot 20, the straight edge A1 of the fourteenth hairpin is inserted in the 6th layer of slot 26, the straight edge B1 of the fifteenth hairpin is inserted in the The 5th layer of the slot, the 15th hairpin straight edge A1 is inserted in the 6th layer of slot 38, the 16th hairpin straight edge A1 is inserted in the 5th layer of slot 44, the 16th hairpin straight edge B1 is inserted in the 4th layer of slot 2, the 17th hairpin straight edge B1 is inserted in the 3rd layer of slot 8, the 17th hairpin straight edge A1 is inserted in the 4th layer of slot 14, the 18th hairpin straight edge B1 is inserted in the 3rd layer of slot 20, the 18th hairpin straight edge A1 is inserted in the 4th layer of slot 26, the 19th hairpin straight edge B1 is inserted in the 3rd layer of slot 32, the 19th hairpin straight edge A1 is inserted in the 4th layer of slot 38, and the 20th hairpin straight edge A1 is inserted in the 3rd layer of slot 44.The 20th hairpin straight edge B1 is inserted in the second layer of slot 2, the 21st hairpin straight edge B1 is inserted in the first layer of slot 8, the 21st hairpin straight edge A1 is inserted in the second layer of slot 14, the 22nd hairpin straight edge B1 is inserted in the first layer of slot 20, the 22nd hairpin straight edge A1 is inserted in the second layer of slot 26, the 23rd hairpin straight edge B1 is inserted in the first layer of slot 32, and the 23rd hairpin straight edge A1 is inserted in the second layer of slot 38. The winding output section (OUT) is located at the crown end, that is, the "I"-shaped hairpin straight edge A3 is inserted in the first layer of slot 44.

[0049] Conductor 1 includes two "I"-shaped hairpins. Conductor 2 includes the first, second, third, fourth, fifth, sixth, seventh, eighth, ninth, tenth, eleventh, thirteenth, fourteenth, fifteenth, sixteenth, seventeenth, eighteenth, nineteenth, twentieth, twenty-first, twenty-second, and twenty-third "U"-shaped wires. Conductor 3 or 4 includes the twelfth "U"-shaped hairpin.

[0050] The winding structure of the utility model adopts a full-pitch winding structure, which can effectively improve the peak output capacity of the motor. The winding structure adopts a six-phase winding structure design, which can better balance the load, reduce the impact of phase imbalance, and improve system stability; the winding structure can more effectively offset high-order harmonics, making the torque pulsation smaller and the motor operation more stable; the winding structure is a six-phase two-set winding structure, which provides design redundancy. When a phase winding fails, the other set of windings can continue to work, enhancing the reliability of the system; the two sets of windings in the winding structure are evenly arranged on the circumference, and the spacing in the same slot is well-uniformed, which can effectively reduce the impact of circulating current; the winding structure has very few types of card types, which greatly reduces the types and investment of molding equipment.

[0051] Throughout this specification, reference to terms such as "one embodiment," "some embodiments," "examples," "specific examples," or "some examples" means that the specific features, structures, materials, or characteristics described in conjunction with that embodiment or example are included in at least one embodiment or example of the present invention. In this specification, schematic representations of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.

[0052] Although the embodiments of the present invention have been shown and described above, it can be understood that the above embodiments are illustrative and cannot be understood as limiting the present invention. Ordinary technicians in this field can change, modify, replace and modify the above embodiments within the scope of the present invention without departing from the principles and purpose of the present invention. Any simple modifications, equivalent changes and modifications made to the above embodiments based on the technical essence of the present invention are still within the scope of the technical solution of the present invention.

Claims

1. A flat wire motor stator structure with six layers of uniform pitch six-phase windings, comprising a winding, a stator core (1) and a neutral point copper bar, wherein the stator core (1) is provided with a plurality of slots evenly distributed along the circumference; the winding is arranged in the slots, and the winding (2) comprises a plurality of flat wire conductors in an "I" shape and a "U" shape, wherein the U"-shaped flat wire conductor comprises a crown end, a straight line segment in the slot and a welding end, and the corresponding U"-shaped flat wire conductors are connected by the welding end, and the two straight line segments in the slot of the U"-shaped flat wire conductor are respectively inserted in different slots, and each slot has six layers of flat wire conductors, characterized in that: The winding is a 6-layer short-distance connection, including two sets of windings; the neutral point copper bar connects the neutral points of the two sets of windings, the three-phase interfaces of the two sets of winding structures are directly connected by the windings, and the two sets of windings in all slots on the stator core (1) are arranged with the same phase interval; the welding end structure of the "U"-shaped flat wire conductor is two legs, the span of the two legs is L, and the two legs are twisted in the same direction or opposite directions along the circumferential direction; wherein L=3; the straight line section in the slot of the "I"-shaped flat wire conductor is located at the outermost or innermost side of the slot, and multiple "I"-shaped flat wire conductors are concentrated and drawn out from multiple adjacent slots; one end of the "I"-shaped flat wire conductor is connected to the windings in other slots, and the twisting span of one end of the "I"-shaped flat wire conductor is 3, and the other end of the "I"-shaped flat wire conductor is connected to the neutral point copper bar or the three-phase interface.

2. The flat wire motor stator structure with six layers of uniform pitch six-phase windings according to claim 1, characterized in that: The span of the slot where the two straight segments of the U-shaped flat conductor are located is X, Y or Z, where X=5, Y=6, and Z=7; the two straight segments are in the same layer or adjacent layers.

3. The flat wire motor stator structure with six layers of uniform pitch six-phase windings according to claim 1, characterized in that: The two sets of windings are arranged symmetrically at 90° or 180°; the two sets of windings constitute a six-phase winding structure.

4. The flat wire motor stator structure with six layers of uniform pitch six-phase windings according to claim 1, characterized in that: Two sets of windings are formed by combining different numbers of "I"-shaped and "U"-shaped flat wire conductors, and the neutral points of the two sets of windings are connected by a neutral point copper bar to achieve a "Y" shape connection.

5. The flat wire motor stator structure with six layers of uniform pitch six-phase windings according to claim 1, characterized in that: An in-slot insulation structure (3) is also provided between the winding (2) and the inner wall of the slot of the stator core (1).

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