Flat wire motor coil winding structure

Abstract

The utility model discloses a coil winding structure of a flat wire motor, which comprises a motor stator and a coil winding, 45 tooth crowns are arranged along the inner circumference of the motor stator in an inward extending manner, the inner circumference of the motor stator is divided into 45 tooth grooves by the tooth crowns, the coil winding comprises a first phase winding, a second phase winding and a third phase winding, each of the first phase winding, the second phase winding and the third phase winding comprises a power supply end and a plurality of coil units, the coil units are connected end to end on a tooth crown, and a first ring layer and a second ring layer are formed on the end surface of the motor stator; the first ring layer and the second ring layer comprise a plurality of welding ends and connecting ends which protrude out of the end face of the motor stator, the heights of the welding ends and the connecting ends relative to the end face of the motor stator are the same, and a connecting unit is arranged between the first ring layer and the second ring layer. The heights of the welding ends are the same, so that the welding ends can be made into the end face of the motor stator to form a whole circle of consistent welding spots so as to realize automatic production.

Description

Technical Field

[0001] The utility model relates to the field of winding structures, in particular to a flat wire motor coil winding structure. Background Art

[0002] Flat wire motors are widely used in many fields due to their advantages such as high efficiency, high power density, and good heat dissipation performance. Due to their extremely high slot fill rate, they can output greater power and torque in the same volume.

[0003] When winding the wires of existing flat-wire motors, the weld end often has inconsistent heights. This results in an irregular shape and position of the weld head. This makes it difficult for welding equipment to accurately align the welded area during automated welding, significantly increasing the difficulty of the welding operation. For example, laser welding requires precise focus positioning. An uneven weld end can cause the focus to deviate from the optimal welding position, affecting the welding effect. Furthermore, securing the uneven winding weld end requires a more complex fixture design to accommodate the varying shapes and positions of the weld head. This not only increases the manufacturing cost and design difficulty of the fixture, but also reduces its versatility and replacement efficiency, impacting the flexibility of automated production. Utility Model Content

[0004] In order to solve the above problems, the utility model provides a flat wire motor coil winding structure, including a motor stator and a coil winding, 45 tooth crowns are extended inward along the inner circumference of the motor stator, and the tooth crowns divide the inner circumference of the motor stator into 45 tooth slots, and the coil winding includes a first phase winding, a second phase winding and a third phase winding, and the first phase winding, the second phase winding and the third phase winding are respectively introduced into the tooth slots from one side of the motor stator, and the first phase winding, the second phase winding and the third phase winding each include a power supply end and a plurality of coil units, and the coil units are connected end to end on the tooth crown, and are connected end to end at the tooth crown. A first coil layer and a second coil layer are formed on the end face of the motor stator, the power end is introduced into the tooth slot and connected to the coil unit, the first coil layer and the second coil layer include several welding ends and connecting ends protruding from the end face of the motor stator, and the welding ends and the connecting ends are at the same height relative to the end face of the motor stator. A connecting unit is provided between the first coil layer and the second coil layer, and the connecting unit includes a first lead-out portion, a first bent portion and a first introduction portion connected in sequence, the first lead-out portion is used to be connected to the coil unit of the first coil layer and led out from the tooth slot, and the first lead-out portion is used to be introduced into the tooth slot and connected to the coil unit of the second coil layer.

[0005] Furthermore, the coil unit includes a first main body portion configured in the tooth slot, having a first welding portion at both ends of the first main body portion, and a first connecting portion is provided in the first main body portion. The first connecting portion is connected at one end of the motor stator to form a connecting end, adjacent coil units are connected together through the first welding portion, and adjacent first welding portions form a welding end at the other end of the motor stator, and the shape of the first main body portion is roughly U-shaped.

[0006] Furthermore, the welding portion is bent in opposite directions relative to two sides of the first main body portion.

[0007] Furthermore, the number of teeth slots between the first main body parts in the coil unit is 4, and the number of teeth slots between the first main body parts of different coil units is 3.

[0008] Furthermore, a commutation unit is included in the first phase winding, the second phase winding and the third phase winding, and the commutation unit includes a second main body portion, with second welding portions at both ends of the second main body portion, the second welding portion is connected to the first welding portion to form a welding end at one end of the motor stator, and a second connecting portion is provided in the second main body portion, the second connecting portion is provided at the other end of the electronic stator, and the second welding portion is bent in the same direction relative to both sides of the second main body portion.

[0009] Furthermore, the second ring layer is arranged around the outside of the first ring layer, and is integrally formed between the first lead-out portion, the first bent portion and the first introduction portion. A third welding portion is respectively provided on the first lead-out portion and the first introduction portion, and the third welding portion is respectively connected to the first welding portion of the first ring layer and the first welding portion of the second ring layer.

[0010] Furthermore, the position of the tooth groove of the second circle layer where the first introduction portion is located is the same as the position of the tooth groove of the first circle layer where the power supply end is located.

[0011] Furthermore, the second connecting portion and the first bent portion protrude on the same side of the motor stator and are at the same height relative to the end surface of the motor stator.

[0012] Furthermore, the coil unit of the second coil layer is provided with a terminal, which is connected to the first welding portion. The terminal of the first phase winding, the second phase winding and the third phase winding are at the same height relative to the end face of the motor stator and are connected to each other through special-shaped wires.

[0013] Compared with the prior art, the beneficial effects of the present invention are:

[0014] The present application divides the three-phase windings on the 45-pole stator into a first layer and a second layer, which are wound on the teeth of the stator, and passes the first layer and the second layer through a connecting unit, so that the first layer and the second layer have welding ends and connecting ends with the same height relative to the end face of the motor stator on the end face of the motor stator. Since the heights of the welding ends are the same, the welding ends can be made into the end face of the motor stator to form a whole circle of consistent welding points to realize automated production. In addition, since the heights of the connecting ends are the same, special-shaped wire connection can be used to achieve that only the center connection point of the winding needs to be welded with three joints, and even the tail ends of the first phase winding, the second phase winding and the third phase winding can be pulled together to achieve a welding point connection.

[0015] Additional aspects and advantages of the present invention will be given in part in the following description, and in part will become apparent from the following description, or will be learned through practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] In order to more clearly illustrate the embodiments of the present invention 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 of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative labor.

[0017] Figure 1 It is a schematic diagram of the overall structure of the utility model;

[0018] Figure 2 This is a top view of the overall structure of the utility model;

[0019] Figure 3 A schematic structural diagram of any one of the first phase winding, the second phase winding or the third phase winding of the present invention;

[0020] Figure 4 This is a schematic structural diagram of the coil unit of the present invention;

[0021] Figure 5 This is a schematic structural diagram of the reversing unit of the present invention;

[0022] Figure 6 This is a schematic structural diagram of the connection unit of the present invention;

[0023] Figure 7 This is a schematic structural diagram of the overall assembly of the first phase winding, the second phase winding and the third phase winding of the present invention;

[0024] Figure 8 This is a wiring diagram of the first phase winding, the second phase winding or the third phase winding of the present invention.

[0025] The reference numerals and names in the figures are as follows:

[0026] Motor stator 10, tooth crown 11, tooth slot 12, first phase winding 21, second phase winding 22, third phase winding 23, power supply end 100, coil unit 200, first coil layer 110, second coil layer 120, welding end 130, connecting end 140, connecting unit 300, first lead-out portion 310, first bent portion 320, first introduction portion 330, first main body 210, first connecting portion 210a, first welding portion 220, commutating unit 230, second main body 231, second connecting portion 231a, second welding portion 232, third welding portion 340, terminal 150, special-shaped wire 160. DETAILED DESCRIPTION

[0027] The following is a clear and complete description of the technical solutions in the embodiments of the present invention. Obviously, the embodiments described are only a part of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0028] The present invention will be described in more detail. It should be understood that the specific embodiments described herein are intended only to explain the present invention and are not intended to limit the present invention. It should be noted that when an element is described as being "fixed to" another element, it may be directly on the other element, or one or more intervening elements may be present therebetween. When an element is described as being "connected to" another element, it may be directly connected to the other element, or one or more intervening elements may be present therebetween.

[0029] In the description of the present invention, it should be noted that the directions or positional relationships indicated by directional words such as "front, back, up, down, left, right", "lateral, vertical, vertical, horizontal" and "top, bottom" are usually based on the directions or positional relationships shown in the accompanying drawings. They are only for the convenience of describing the present invention and simplifying the description. Unless otherwise stated, these directional words do not indicate or imply that the device or element referred to must have a specific direction or be constructed and operated in a specific direction. Therefore, they cannot be understood as limiting the scope of protection of the present invention. The directional words "inside and outside" refer to the inside and outside relative to the outline of each component itself. In the description of the present invention, it should be noted that the use of words such as "first" and "second" to limit components is only for the convenience of distinguishing the corresponding components. Unless otherwise stated, the above words have no special meaning and therefore cannot be understood as limiting the scope of protection of the present invention. In the description of the embodiments of the present application, the meaning of "multiple" is two or more, unless otherwise clearly and specifically defined.

[0030] Unless otherwise defined, all technical and scientific terms used in this specification have the same meanings as those commonly understood by those skilled in the art in the art of the present invention. The terms used in this specification are only for the purpose of describing specific embodiments and are not intended to limit the present invention.

[0031] In addition, the technical features involved in different embodiments of the present application described below can be combined with each other as long as they do not conflict with each other.

[0032] The preferred embodiment of the present invention is further described with reference to the accompanying drawings. Figure 1 、 Figure 2 、 Figure 3 and Figure 6 As shown, the flat wire motor coil winding structure includes a motor stator 10, and 45 tooth crowns 11 are extended inward along the inner circumference of the motor stator 10. The tooth crowns 11 are used to wind the coil winding. The tooth crowns 11 divide the inner circumference of the motor stator 10 into 45 tooth slots 12. The coil winding includes a first phase winding 21, a second phase winding 22 and a third phase winding 23 with the same structure. The first phase winding 21, the second phase winding 22 and the third phase winding 23 are respectively introduced into the tooth slots 12 from one side of the motor stator 10, so that they can be continuously wound on the tooth crowns 11. The first phase winding 21, the second phase winding 22 and the third phase winding 23 each include a power supply terminal 100 and a plurality of coil units 200. The coil units 200 are connected end to end on the tooth crowns 11 and are on the end face of the motor stator 10. A first coil layer 110 and a second coil layer 120 are formed, and the power supply end 100 is introduced into the tooth slot 12 and connected to the coil unit 200. The first coil layer 110 and the second coil layer 120 include several welding ends 130 and connecting ends 140 protruding from the end face of the motor stator 10. The welding ends 130 and the connecting ends 140 have the same height relative to the end face of the motor stator 10. A connecting unit 300 is connected between the first coil layer 110 and the second coil layer 120. The connecting unit 300 includes a first lead-out portion 310, a first bent portion 320 and a first introduction portion 330 connected in sequence. The first lead-out portion 310 is used to be connected to the coil unit 200 of the first coil layer 110 and led out from the tooth slot 12. The first lead-out portion 310 is used to be introduced into the tooth slot 12 and connected to the coil unit 200 of the second coil layer 120.

[0033] The specific wiring structure of this embodiment is now described with reference to the accompanying drawings. Figure 8As shown, any tooth slot 12 on the motor stator 10 can be marked as tooth slot 12 No. 1, and the numbering is sequentially clockwise or counterclockwise along the tooth slot 12 No. 1, and the last tooth slot 12 is tooth slot 12 No. 45, and the tooth slot 12 No. 1 is adjacent to the tooth slot 12 No. 45. Let's take the first phase winding 21 as an example. The copper wire constitutes the power supply end 100 of the first phase winding 21. After being introduced and led out from the tooth slot 12 No. 5, it is then introduced and led out from the tooth slot 12 No. 1 in a counterclockwise direction, and then passes through No. 41, No. 37, No. 32, No. 28, No. 23, No. 19, No. 14, No. 10, No. 6, No. 2, No. 42, 38, 33, No. 2 The introduction and extraction of No. 9, 24, 20, 15 and 11 are started from the tooth slot 12 No. 11 and then reintroduced to the tooth slot 12 No. 15 in a clockwise direction, passing through the tooth slots 12 No. 19, 28, 33, 37, 42, 1, 6 and 10 in sequence. The above winding method constitutes the first phase winding 21. Then, the first lead-out portion 310 of the connecting unit 300 is led out from the tooth slot 12 No. 10, forms the first bent portion 320, and then is introduced into the tooth slot 12 No. 5 from the outside of the first phase winding 21, and then passes through the same path as the first phase winding 21, and finally is led out from the tooth slot 12 No. 10.

[0034] In the present application, the three-phase windings on the 45-pole stator are all divided into a first coil layer 110 and a second coil layer 120 and are wound on the teeth of the stator, and the first coil layer 110 and the second coil layer 120 are connected through a connecting unit 300, so that the first coil layer 110 and the second coil layer 120 have a welding end 130 and a connecting end 140 with the same height relative to the end face of the motor stator 10 on the end face of the motor stator 10. Since the height of the welding end 130 is the same, the welding end 130 can be made into a consistent welding point on the end face of the motor stator 10 to realize automated production. In addition, since the height of the connecting end 140 is the same, the special-shaped wire 160 can be used for connection to achieve that only the center connection point of the winding needs to be welded with 3 joints, and even the tail ends of the first phase winding 21, the second phase winding 22 and the third phase winding 23 can be pulled together to achieve a welding point connection.

[0035] On the basis of the above embodiment, Figure 3 and Figure 4As shown, the coil unit 200 includes a first main body portion 210 configured in the tooth slot 12, and has a first welding portion 220 at both ends of the first main body portion 210. A first connecting portion 210a is provided in the first main body portion 210, and the first connecting portion 210a is connected at one end of the motor stator 10 to form a connecting end 140. Adjacent coil units 200 are connected together through the first welding portion 220, and adjacent first welding portions 220 form a welding end 130 at the other end of the motor stator 10. The first main body portion 210 is roughly U-shaped. When this embodiment is performed in a specific operation, it is only necessary to insert the first main body portion 210 and the first connecting portion 210a into the tooth slot 12 from one end of the motor stator 10. There is no need for a winding machine to insert a probe into the tooth slot 12 for winding. After the insertion is completed, the first welding portion 220 is extended from the other end of the motor stator 10, and then the adjacent first welding machine portions are welded together to form a welding end 130.

[0036] In some embodiments, combined Figure 3 and Figure 4 As shown, the first welding portion is bent in opposite directions relative to both sides of the first main body portion 210, so that the coil unit 200 is easily connected when it is set.

[0037] On the basis of the above embodiment, Figure 3 and Figure 4 As shown, the number of tooth slots 12 between the first main body parts 210 in the coil unit 200 is 4, and the number of tooth slots 12 between the first main body parts 210 of different coil units 200 is 3. For example, a coil unit 200 is configured between tooth slot 12 No. 1 and tooth slot 12 No. 41, and there are 4 tooth slots 12 adjacent to its first main body parts 210, namely No. 45, No. 44, No. 43 and No. 42, a total of 4 tooth slots 12, while tooth slot 12 No. 41 and tooth slot 12 No. 37 are the first main body parts 210 between different coil units 200, and there are 3 tooth slots 12 adjacent to its first main body parts 210, namely No. 40, No. 39 and No. 38, a total of 3 tooth slots 12. Therefore, under the premise of ensuring heat dissipation, the present application achieves that the fewer the number of slots across the slots, the lower the height of the welding end 130 and the connecting end 140 at the end of the motor stator 10 can be, thereby reducing the waste of copper wire.

[0038] On the basis of the above embodiment, Figure 5As shown, a commutation unit 230 is included in the first phase winding 21, the second phase winding 22 and the third phase winding 23. The commutation unit 230 includes a second main body 231, and a second welding portion 232 is provided at both ends of the second main body 231. The second welding portion 232 is connected to the first welding portion 220 at one end of the motor stator 10 to form a welding end 130. A second connecting portion 231a is provided in the second main body 231, and the second connecting portion 231a is provided at the other end of the electronic stator. The second welding portion 232 is bent in the same direction relative to both sides of the second main body 231. In this way, when the second welding portion 232 is connected to the first welding portion 220 of the coil unit 200, the connection mode of its winding will undergo an opposite change, for example, from counterclockwise connection to clockwise connection.

[0039] On the basis of the above embodiment, Figure 2 and Figure 6 As shown, the second ring layer 120 is arranged around the outside of the first ring layer 110, and is integrally formed between the first lead-out portion 310, the first bending portion 320 and the first introduction portion 330. A third welding portion 340 is respectively provided on the first lead-out portion 310 and the first introduction portion 330. The third welding portion 340 is respectively connected to the first welding portion 220 of the first ring layer 110 and the first welding portion 220 of the second ring layer 120, thereby connecting the first ring layer 110 and the second ring layer 120 together.

[0040] On the basis of the above embodiment, Figure 6 and Figure 8 As shown, the position of the tooth groove 12 of the second circle layer 120 where the first introduction part 330 is located is the same as the position of the tooth groove 12 of the first circle layer 110 where the power supply terminal 100 is located. In this embodiment, the power supply terminal 100 is configured in the No. 5 tooth groove 12 of the first circle layer 110, and the first introduction part 330 is also configured in the No. 5 tooth groove 12, so that the winding of the first circle layer 110 and the second circle layer 120 can be exactly the same, so that the distribution positions of the welding ends 130 and the connection ends 140 of the first circle layer 110 and the second circle layer 120 can also be the same, thereby achieving better automated production.

[0041] On the basis of the above embodiment, Figure 7 As shown, the second connecting portion 231a and the first bent portion 320 protrude on the same side of the motor stator 10 and have the same height relative to the end face of the motor stator 10, so that the height of the overall structure can be more consistent, which is convenient for subsequent installation.

[0042] On the basis of the above embodiment, Figure 7 and Figure 8As shown, a terminal 150 is provided on the coil unit 200 of the second coil layer 120, and the terminal 150 is connected to the first welding portion 220. The terminal 150 of the first phase winding 21, the second phase winding 22 and the third phase winding 23 are at the same height relative to the end face of the motor stator 10, and are connected to each other through the special-shaped wire 160. In this way, only the center connection point of the winding needs to be welded with 3 joints, and the tail ends of the first phase winding 21, the second phase winding 22 and the third phase winding 23 can be pulled together to realize a welding point connection.

[0043] The above exemplary embodiments are detailed, and the present invention may be implemented in other specific forms without departing from the spirit or essential characteristics of the present invention. Therefore, the embodiments should be considered in all respects as illustrative and non-restrictive, and the scope of the present invention is defined by the appended claims rather than the foregoing description, and it is intended that all changes that come within the meaning and range of equivalents of the claims be included within the present invention.

Claims

1. A flat wire motor coil winding structure, characterized in that: The invention comprises a motor stator (10) and a coil winding, wherein 45 tooth crowns (11) are provided along the inner circumference of the motor stator (10) and extend inwardly, and the tooth crowns (11) divide the inner circumference of the motor stator (10) into 45 tooth slots (12), and the coil winding comprises a first phase winding (21), a second phase winding (22) and a third phase winding (23), wherein the first phase winding (21), the second phase winding (22) and the third phase winding ( 23) are respectively introduced into the tooth slot (12) from one side of the motor stator (10), the first phase winding (21), the second phase winding (22) and the third phase winding (23) each include a power supply terminal (100) and a plurality of coil units (200), the coil units (200) are connected end to end on the tooth crown (11), and form a first coil layer (110) and a second coil layer (120) on the end face of the motor stator (10), the power supply terminal (1 00) is introduced into the tooth slot (12) and connected to the coil unit (200), the first coil layer (110) and the second coil layer (120) include a plurality of welding ends (130) and connecting ends (140) protruding from the end surface of the motor stator (10), the welding ends (130) and the connecting ends (140) are at the same height relative to the end surface of the motor stator (10), a connecting unit (300) is provided between the first coil layer (110) and the second coil layer (120), the connecting unit (300) includes a first lead-out portion (310), a first bent portion (320) and a first introduction portion (330) connected in sequence, the first lead-out portion (310) is used to be connected to the coil unit (200) of the first coil layer (110) and led outward from the tooth slot (12), the first lead-out portion (310) is used to be introduced into the tooth slot (12) and connected to the coil unit (200) of the second coil layer (120).

2. The flat wire motor coil winding structure according to claim 1, characterized in that: The coil unit (200) comprises a first main body (210) arranged in a tooth slot (12), a first welding portion (220) being provided at both ends of the first main body (210), a first connecting portion (210a) being provided in the first main body (210), the first connecting portion (210a) being connected at one end of the motor stator (10) to form a connecting end (140), adjacent coil units (200) being connected together via the first welding portion (220), and adjacent first welding portions (220) forming a welding end (130) at the other end of the motor stator (10), and the shape of the first main body (210) being substantially U-shaped.

3. The flat wire motor coil winding structure according to claim 2, characterized in that: The first welding portion (220) is bent in opposite directions relative to two sides of the first main body portion (210).

4. The flat wire motor coil winding structure according to claim 3, characterized in that: The number of tooth slots (12) between the first main body parts (210) in the coil unit (200) is four, and the number of tooth slots (12) between the first main body parts (210) of different coil units (200) is three.

5. The flat wire motor coil winding structure according to claim 4, characterized in that: A commutation unit (230) is included in the first phase winding (21), the second phase winding (22) and the third phase winding (23). The commutation unit (230) includes a second main body (231). Second welding parts (232) are provided at both ends of the second main body (231). The second welding part (232) is connected to the first welding part (220) at one end of the motor stator (10) to form a welding end (130). A second connecting part (231a) is provided in the second main body (231). The second connecting part (231a) is provided at the other end of the electronic stator. The second welding part (232) is bent in the same direction relative to both sides of the second main body (231).

6. The flat wire motor coil winding structure according to claim 5, characterized in that: The second ring layer (120) is arranged around the outside of the first ring layer (110), and is integrally formed between the first lead-out portion (310), the first bent portion (320) and the first introduction portion (330). A third welding portion (340) is respectively provided on the first lead-out portion (310) and the first introduction portion (330), and the third welding portion (340) is respectively connected to the first welding portion (220) of the first ring layer (110) and the first welding portion (220) of the second ring layer (120).

7. The flat wire motor coil winding structure according to claim 6, characterized in that: The position of the tooth groove (12) of the second ring layer (120) where the first introduction portion (330) is located is the same as the position of the tooth groove (12) of the first ring layer (110) where the power supply end (100) is located.

8. The flat wire motor coil winding structure according to claim 7, characterized in that: The second connecting portion (231a) and the first bent portion (320) protrude on the same side of the motor stator (10) and have the same height relative to the end surface of the motor stator (10).

9. The flat wire motor coil winding structure according to claim 1, characterized in that: The coil unit (200) of the second coil layer (120) is provided with a terminal (150), and the terminal (150) is connected to the first welding portion (220). The terminal (150) of the first phase winding (21), the second phase winding (22), and the third phase winding (23) are at the same height relative to the end face of the motor stator (10), and are connected to each other via a special-shaped wire (160).

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