Odd-layer short rectangular flat wire winding stator assembly and motor
Through the design of the odd-layer short-moment flat wire winding stator assembly, the motor's branch balance and harmonic weakening are achieved, solving the problems of high motor manufacturing cost and poor operating reliability, and improving the motor's NVH performance and efficiency.
Patent Information
- Application Number
- CN202422617756.2
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-10-29
- Publication Date
- 2025-10-03
- Estimated Expiration
- 2034-10-29
AI Technical Summary
It is difficult to adjust the number of slot layers and parallel branches in the stator winding of traditional flat wire motors, resulting in high motor manufacturing costs and poor operating reliability, especially the serious impact of the 5th and 7th harmonics.
A stator assembly with odd-numbered layers of short-length flat wire windings is designed. It adopts an odd-numbered slot-layer structure and the hairpin coils have the same span. Through same-layer twist welding and cross-layer connection, branch balance is achieved and harmonics are weakened. The three-phase stator winding is arranged with an electrical angle of 120°.
It effectively weakens the 5th and 7th harmonics of the motor, improves the NVH vibration and noise problems, improves the motor's operating reliability and efficiency, and reduces production costs.
Smart Images
Figure CN223414670U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to a flat wire motor winding arrangement, in particular to an odd-numbered layer short-moment flat wire winding stator assembly and a motor. Background Art
[0002] As new energy vehicles increasingly demand higher range, NVH, and space efficiency, flat wire motors, with their high copper fill rate, high efficiency, and high space utilization, have become a key solution for promoting lightweight and efficient development in new energy vehicles. Flat wire motor winding arrangements offer a variety of options, a key component of motor design, and each arrangement has varying impacts on motor performance, efficiency, and thermal management.
[0003] The magnetic field of traditional full-pitch winding motors contains a large number of harmonics, which can seriously affect the reliability of motor operation. The current common method is to adjust the stator winding arrangement to achieve the reduction of the 5th and 7th harmonics. However, the components of the flat wire motor stator winding are hairpin coils. Compared with the loose wire winding, the flat wire winding stator is difficult to adjust the number of slot layers and the number of parallel branches. At the same time, each adjustment of the flat wire winding increases the manufacturing cost.
[0004] Therefore, how to design a stator assembly that can achieve a balance between motor manufacturing cost and operational reliability is a technical problem that needs to be solved. Utility Model Content
[0005] The purpose of the present invention is to provide a stator assembly with odd-numbered layers of short-moment rectangular wire windings and a motor in order to overcome the defects of the prior art, such as poor motor operation reliability or high motor manufacturing cost.
[0006] The purpose of the utility model can be achieved through the following technical solutions:
[0007] According to one aspect of the present invention, a stator assembly with an odd-numbered layer of short rectangular wire windings is provided. The stator assembly includes a stator core and a stator winding. The stator core is provided with a plurality of stator slots, each of the stator slots being provided with N slot layers, where N is an odd number and N≥5. The stator winding includes a plurality of hairpin coils, each of which spans one or two slot layers, and the hairpin coils in the same two or one slot layer have the same span. The stator winding includes three phases, and each phase includes at least two hairpin coils spanning two layers with a span of y and two spans of y-1. The hairpin coils connect all slot layers starting from any slot layer along the circumferential direction of the stator core. The first slot layer is connected to two hairpin coils by twist welding on the same layer and the winding direction is changed. The Nth slot layer is connected to two hairpin coils by a hairpin coil spanning one layer and the winding direction is changed. After all stator slots are arranged, one end of the last hairpin coil is led out.
[0008] As a preferred technical solution, the stator winding of each phase includes a first branch and a second branch; the second branch is the first branch moved one stator slot along the first circumferential direction of the stator core.
[0009] As a preferred technical solution, the span Among them, Z is the number of stator slots, and P is the number of poles of the rotor that matches the stator assembly.
[0010] As a preferred technical solution, the sum of the number of stator slots spanned by the same-layer twist welding and the hairpin coil spanning one layer is 2y.
[0011] As a preferred technical solution, the first layer and the Nth layer are respectively the notch layer and the bottom layer, or the first layer and the Nth layer are respectively the bottom layer and the notch layer.
[0012] As a preferred technical solution, the stator slots are numbered in sequence, and the circumferential direction of the stator core is the direction of increasing stator slot numbers or the direction of decreasing stator slot numbers.
[0013] As a preferred technical solution, the hairpin coil includes an I-Pin hairpin coil, and the I-Pin hairpin coil is connected to the two ends of the stator winding leading into and leading out of the stator core.
[0014] As a preferred technical solution, the stator winding of each phase includes 2 hairpin coils with a span of y-1 across two layers, N-3 hairpin coils with a span of y across two layers, and 1 hairpin coil with a span of y-1 or y+1 across one layer.
[0015] As a preferred technical solution, the three phases of the stator winding are arranged with one phase rotated 120 electrical degrees in two directions.
[0016] According to another aspect of the present invention, a motor with an odd-numbered layer of short-moment flat wire windings is provided, comprising a stator assembly with an odd-numbered layer of short-moment flat wire windings.
[0017] Compared with the prior art, the present invention has the following beneficial effects:
[0018] 1) The utility model adopts same-layer twist welding and cross-layer hairpin coil connection on the first and Nth layers of the stator core, respectively. This can achieve branch balance and no circulating current while weakening the 5th and 7th harmonics of the motor, thereby improving the NVH vibration and noise problems of the motor, enhancing operational reliability, reducing harmonic losses, and improving efficiency.
[0019] 2) The utility model has fewer types of card-issuing coils, low production costs, and is easy to manufacture, thereby improving the product's cost-effectiveness. BRIEF DESCRIPTION OF THE DRAWINGS
[0020] Figure 1 This is a schematic diagram of the overall structure of the utility model;
[0021] Figure 2 This is a schematic diagram of the arrangement of one phase and one branch of the stator winding of the stator assembly embodiment 1 of the present utility model;
[0022] Figure 3 This is a schematic diagram of the arrangement of one phase of the stator winding of the stator assembly embodiment 1 of the present utility model;
[0023] Figure 4 This is a schematic diagram of the arrangement of one phase and one branch of the stator winding of the stator assembly embodiment 2 of the present utility model;
[0024] Figure 5 This is a schematic diagram of the arrangement of one phase and one branch of the stator winding of the stator assembly embodiment 3 of the present utility model;
[0025] Figure 6 This is a schematic diagram of the slot layer arrangement in the stator slot of the present invention. DETAILED DESCRIPTION
[0026] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the embodiments described are 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 should fall within the scope of protection of the present invention.
[0027] like Figure 1 As shown, the present invention provides an odd-layer short-moment rectangular wire winding stator assembly, the stator assembly includes a stator core and a stator winding, the stator core is provided with Z stator slots, and the stator slots are evenly distributed along the circumferential direction of the stator core; each stator slot is provided with N slot layers, and N layers of rectangular wires (N = 2*n+1, n ≥ 2) are arranged in the N slot layers, as shown in FIG. Figure 6 As shown, the 1st and Nth layers are defined as the slot opening layer and the bottom slot layer, respectively, or the 1st and Nth layers are defined as the bottom slot layer and the slot opening layer, respectively. The stator winding includes multiple hairpin coils, each of which spans one or two slot layers. That is, the two straight conductor segments of the hairpin winding coil are located in the stator slots of two different slot layers or in the stator slots of the same slot layer. The hairpin coils located in the same two or one slot layer have the same span. Among all layers except the slot opening layer and the bottom slot layer, only two layers must use short-pitch hairpin coils spanning two layers, and the remaining cross-layer hairpin coils are full-pitch hairpin coils spanning two layers. The slot opening layer or the bottom slot layer uses short-pitch or long-pitch hairpin coils spanning one layer. The corresponding bottom slot layers or slot layers are connected by same-layer twist welding (hereinafter referred to as same-layer twisting). The sum of the number of stator slots spanned by the same-layer twist welding and the hairpin coil spanning one layer is twice the full-pitch span.
[0028] The stator winding includes three phases. The stator winding of each phase is connected to the first layer layer by layer along the direction of increasing circumferential stator slot number from the starting point of the Nth layer, that is, the incoming line position, through at least one hairpin coil with a span of y and one span of y-1 across two layers. At the first layer, it is wound in the same direction of decreasing circumferential stator slot number through the same layer twist, that is, in the reverse direction to the Nth layer, and is wound along the direction of increasing circumferential stator slot number through the same layer span, and then circulated P / 2 times. At this time, the end point is the outgoing line position. When the layer where the starting position is located is set as the same layer twist, When winding on a layer or its adjacent layer, the P / 2nd loop has one less cross-layer hairpin coil compared to the previous loop. When the starting layer is set to a same-layer spanning layer, the P / 2nd loop has no same-layer spanning connection compared to the previous loop. When the starting layer is a spanning layer, the P / 2nd loop has one less cross-layer hairpin coil compared to the previous loop. This means that any end connection of the U1 and U2 branches can be disconnected to form a lead-out line based on the location of the input and output interfaces, allowing for flexible layout. The three phases of the stator winding are arranged with one phase rotated 120° in either direction. Each phase of the stator winding includes two hairpin coils with a span of y-1, N-3 hairpin coils with a span of y, and one cross-layer hairpin coil with a span of y-1 or y+1. Z is the number of stator slots, and P is the number of rotor poles that mate with the stator assembly. In this case, except for the same span, all layers have only (N-1) / 2 types of hairpin winding line types. Furthermore, there are two types of I-Pin hairpin windings at the input and output positions, meaning the total number of hairpin winding line types is (N-1) / 2+3.
[0029] The stator winding includes a first branch and a second branch. The second branch is the first branch moved one stator slot along the first circumferential direction of the stator core. The second branch has the same hairpin winding rule as the first branch.
[0030] Example 1
[0031] This embodiment provides an odd-layer short-moment flat wire winding stator assembly, which includes a stator core and a stator winding. The stator core is provided with 48 stator slots; each stator slot is provided with 5 slot layers, and the number of poles of the rotor matched with the stator assembly is 8. Assuming that the conductor edge of the 5th layer of slot 2, that is, the position numbered x0=1, is the starting point, and the position number is increased by 1 after each conductor edge is connected, the hairpin winding is first connected to the first layer layer by layer along the direction of increasing circumferential stator slot number from the starting point, that is, the incoming line position, through a short-distance hairpin coil spanning 5 slots and a full-distance hairpin coil spanning 6 slots, and then twisted in the same layer along the direction of decreasing circumferential stator slot number, that is, in the reverse direction, to the 5th layer in the same pattern, and wound along the direction of decreasing circumferential stator slot number through the same layer span, and then circulated P / 2 times until the number x1=40 is reached. At this time, x1 The position is the end point, that is, the outgoing line position, so the P / 2th cycle has no same-layer span connection compared with the previous cycle winding; for the first branch U2 in the two parallel branches of the U-phase winding, the winding direction starting from the starting point is along the direction of increasing the circumferential stator slot number, that is, the same as the first branch, until the first-layer same-layer twist position. At this time, the twist direction is opposite to that of the first branch U1, that is, it still reaches the next slot number along the direction of increasing slot number, and then realizes reverse winding through the same-layer twist, that is, winding back to the 5th layer in the direction of decreasing slot number, and winding along the circumferential stator slot number increasing direction through the same-layer span to cycle in sequence.
[0032] like Figure 2 and Figure 3 As shown in FIG, the arrangement of the two branches of the U-phase winding in the stator slot is described. 2(5) represents the fifth conductor layer of slot 2. Similarly, 8(4) represents the fourth conductor layer of slot 8. Similarly, the specific wiring method of the first branch U1 of the U-phase winding is as follows:
[0033] 2(5)-8(4)-13(3)-19(2)-25(1)-20(1)-14(2)-8(3)-3(4)-45(5)-38(5)-44(4)-1(3)-7(2)-13(1)-8(1)-2(2)-44(3)-39(4)-33(5)-26(5)-32(4)-37(3)-43(2)-1(1)-44(1)-38(2)-32(3)-27(4)-21(5)-14(5)-20(4)-25(3)-31(2)-37(1)-32(1)-26(2)-20(3)-15(4)-9(5)
[0034] Similarly, the specific wiring method of the second branch U2 of the U-phase winding is as follows:
[0035] 3(5)-9(4)-14(3)-20(2)-26(1)-31(1)-25(2)-19(3)-14(4)-8(5)-15(5)-21(4)-26(3)-32(2)-38(1)-43(1)-37(2)-31(3)-26(4)-20(5)-27(5)-33(4)-38(3)-44(2)-2(1)-7(1)-1(2)-43(3)-38(4)-32(5)-39(5)-45(4)-2(3)-8(2)-14(1)-19(1)-13(2)-7(3)-2(4)-44(5)
[0036] Example 2
[0037] This embodiment provides an odd-numbered layer short-term rectangular wire winding stator assembly, the stator assembly includes a stator core and a stator winding, the stator core is provided with 48 stator slots; each stator slot is provided with 5 slot layers, and the number of poles of the rotor matched with the stator assembly is 8. Figure 4 As shown in FIG, the arrangement of the two branches of the U-phase winding in the stator slot is described. 2(5) represents the fifth conductor layer of slot 2. Similarly, 8(4) represents the fourth conductor layer of slot 8. Similarly, the specific wiring method of the first branch U1 of the U-phase winding is as follows:
[0038] 2(5)-8(4)-13(3)-21(2)-25(1)-32(1)-26(2)-20(3)-15(4)-9(5)-14(5)-20(4)-25(3)-31(2)-37(1)-44(1)-38(2)-32(3)-27(4)-21(5)-26(5)-32(4)-37(3)-43(2)-1(1)-8(1)-2(2)-44(3)-39(4)-33(5)-38(5)-44(4)-1(3)-7(2)-13(1)-20(1)-14(2)-8(3)-3(4)-45(5)
[0039] Similarly, the specific wiring method of the second branch U2 of the U-phase winding is as follows:
[0040] 3(5)-9(4)-14(3)-20(2)-26(1)-19(1)-13(2)-7(3)-2(4)-44(5)-39(5)-45(4)-2(3)-8(2)-14(1)-7(1)-1(2)-43(3)-38(4)-32(5)-27(5)-33(4)-38(3)-44(2)-2(1)-43(1)-37(2)-31(3)-26(4)-20(5)-15(5)-21(4)-26(3)-32(2)-38(1)-31(1)-25(2)-19(3)-14(4)-8(5)
[0041] Example 3
[0042] This embodiment provides an odd-numbered layer short-term rectangular wire winding stator assembly, the stator assembly includes a stator core and a stator winding, the stator core is provided with 48 stator slots; each stator slot is provided with 5 slot layers, and the number of poles of the rotor matched with the stator assembly is 8. Figure 5 As shown in FIG, the arrangement of the two branches of the U-phase winding in the stator slot is described. 2(5) represents the fifth conductor layer of slot 2. Similarly, 8(4) represents the fourth conductor layer of slot 8. Similarly, the specific wiring method of the first branch U1 of the U-phase winding is as follows:
[0043] 25(1)-20(1)-14(2)-8(3)-3(4)-45(5)-38(5)-44(4)-1(3)-7(2)-13(1)-8(1)-2(2)-44(3)-39(4)-33(5)-26(5)-32(4)-37(3)-43(2)-1(1)-44(1)-38(2)-32(3)-27(4)-21(5)-14(5)-20(4)-25(3)-31(2)-37(1)-32(1)-26(2)-20(3)-15(4)-9(5)-2(5)-8(4)-13(3)-19(2)
[0044] Similarly, the specific wiring method of the second branch U2 of the U-phase winding is as follows:
[0045] 26(1)-31(1)-25(2)-19(3)-14(4)-8(5)-15(5)-21(4)-26(3)-32(2)-38(1)-43(1)-37(2)-31(3)-26(4)-20(5)-27(5)-33(4)-38(3)-44(2)-2(1)-7(1)-1(2)-43(3)-38(4)-32(5)-39(5)-45(4)-2(3)-8(2)-14(1)-19(1)-13(2)-7(3)-2(4)-44(5)-3(5)-9(4)-14(3)-20(2)
[0046] Example 4
[0047] This embodiment provides an odd-layer short-moment flat wire winding stator assembly. Based on any flat wire winding stator assembly in Embodiments 1 to 3, the two branches are connected in series by connecting copper bars at the ends to achieve the terminal performance of the final branch.
[0048] Example 5
[0049] This embodiment provides an odd-layer short-moment flat wire winding motor, including any flat wire winding stator assembly in Embodiments 1 to 4.
[0050] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any person skilled in the art can easily conceive of various equivalent modifications or substitutions within the technical scope disclosed in the present invention, and such modifications or substitutions should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be based on the scope of protection of the claims.
Claims
1. A stator assembly with odd-numbered layers of short rectangular wire windings, comprising a stator core and a stator winding, characterized in that: The stator core is provided with a plurality of stator slots, each of which is provided with N slot layers, where N is an odd number and N≥5; the stator winding includes a plurality of hairpin coils, each of which spans one or two slot layers, and the hairpin coils located in the same two or one slot layer have the same span; the stator winding includes three phases, and each phase of the stator winding includes at least two hairpin coils spanning two layers with a span of y and two spans of y-1; the hairpin coils connect all slot layers starting from any slot layer along the circumferential direction of the stator core; the first slot layer is connected to two hairpin coils by twist welding on the same layer and the winding direction is changed; the Nth slot layer is connected to two hairpin coils by a hairpin coil spanning one layer and the winding direction is changed; after all stator slots are arranged, one end of the last hairpin coil is led out.
2. The odd-layer short rectangular wire winding stator assembly according to claim 1, characterized in that: The stator winding of each phase includes a first branch and a second branch; the second branch is the first branch moved one stator slot along the first circumferential direction of the stator core.
3. The odd-layer short rectangular wire winding stator assembly according to claim 1, characterized in that: The span Among them, Z is the number of stator slots, and P is the number of poles of the rotor that matches the stator assembly.
4. The odd-layer short-length rectangular wire winding stator assembly according to claim 1, characterized in that: The sum of the stator slots spanned by the twist welding on the same layer and the hairpin coil spanning one layer is 2y.
5. The odd-layer short rectangular wire winding stator assembly according to claim 1, characterized in that: The first layer and the Nth layer are respectively the notch layer and the bottom layer, or the first layer and the Nth layer are respectively the bottom layer and the notch layer.
6. The odd-layer short rectangular wire winding stator assembly according to claim 1, characterized in that: The stator slots are numbered in sequence, and the circumferential direction of the stator core is the direction in which the stator slot numbers increase or the direction in which the stator slot numbers decrease.
7. The odd-numbered layer short rectangular wire winding stator assembly according to claim 1, characterized in that: The hairpin coil includes an I-Pin hairpin coil, which is connected to the two ends of the stator winding leading into and leading out of the stator core.
8. The odd-layer short-length rectangular wire winding stator assembly according to claim 1, characterized in that: The stator winding of each phase includes 2 hairpin coils with a span of y-1 across two layers, N-3 hairpin coils with a span of y across two layers, and 1 hairpin coil with a span of y-1 or y+1 across one layer.
9. The odd-layer short rectangular wire winding stator assembly according to claim 1, characterized in that: The three phases of the stator winding are arranged with one phase rotated 120 degrees in electrical angle in two directions.
10. An odd-number-layer short-moment flat wire winding motor, characterized in that: The invention comprises the stator assembly with odd-numbered layers of short rectangular wire windings as described in any one of claims 1 to 9.