Flat wire stator structure and flat wire motor
By distributing the leads of the three-phase coils at the bottom and opening of the slots in a 48-slot flat wire motor, and using a U-shaped hairpin with specific span and layering, the design problem of the three-phase connection structure was solved, the strength was improved and the radial envelope was optimized, and the high-efficiency design of the flat wire motor was achieved.
Patent Information
- Application Number
- CN202423138892.X
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-12-18
- Publication Date
- 2025-11-14
- Estimated Expiration
- 2034-12-18
AI Technical Summary
The three-phase leads and neutral point structure of the 48-slot flat wire motor are located on the same side of the welding end, making the three-phase connection structure design difficult, the strength not easy to guarantee, and the radial envelope has no advantage.
Three-phase coils are inserted into the stator slots with spans of n, n-1, and n+1. The leads are located at the bottom and top of the slots. The three-phase coils are equipped with two parallel first and second branches. U-shaped hairpins are inserted into the stator slots with specific spans and layers, and are welded at the top and bottom of the slots.
It improves the strength of the three-phase connection, simplifies the design of the three-phase output structure, reduces the radial envelope size, and provides a practical design scheme for a 48-slot flat wire stator structure.
Smart Images
Figure CN223553109U_ABST
Abstract
Description
Technical Field
[0001] This utility model belongs to the field of flat wire motor technology, and specifically relates to a flat wire stator structure and a flat wire motor. Background Technology
[0002] Flat wire motors, also known as hairpin motors, are characterized by stator windings made of flat copper wires. These flat copper wires are processed into a hairpin-like shape, inserted into the stator slots, and welded together at the other end.
[0003] 48-slot flat-wire motors have broad application prospects in the new energy vehicle field due to their advantages such as high power density, excellent heat dissipation performance, and low electromagnetic noise. Especially in hybrid and plug-in hybrid vehicles, flat-wire motors can significantly improve vehicle power performance and range. In addition, flat-wire motors are also suitable for industrial equipment and household appliances requiring high efficiency and low noise operation.
[0004] Despite the numerous advantages of 48-flat wire motors, their large-scale application still faces some challenges. For example:
[0005] (1) Its three-phase leads and neutral point structure are located on the same side of the welding end, and the three-phase connection structure is not easy to design and the strength is not easy to guarantee.
[0006] (2) Its setting of the same layer of card issuance does not have the advantage of radial envelope. Utility Model Content
[0007] To address the problems in the background art, this utility model proposes a flat wire stator structure and a flat wire motor.
[0008] To achieve the above objectives, the present invention adopts the following technical solution:
[0009] A flat wire stator structure includes a stator core and a three-phase coil, wherein a plurality of stator slots are uniformly formed on the end face of the stator core along the circumference of the stator core;
[0010] The three-phase coils are inserted into the stator slots with spans of n, n-1, and n+1, respectively, in a clockwise or counterclockwise direction, where n ≥ 6;
[0011] The leads of the three-phase coils are located at the bottom and opening of the stator slots;
[0012] The number of stator slots between adjacent lead-out lines located at the slot opening is 1 or 3.
[0013] Preferably, the number of stator slots is 48, and the span n = 6.
[0014] Preferably, the three-phase coil includes a U-phase coil, a V-phase coil, and a W-phase coil;
[0015] The U-phase coil, V-phase coil, and W-phase coil are each provided with two parallel first branches and second branches;
[0016] Along a clockwise or counterclockwise direction, both the first branch and the second branch include a number of U-shaped hairpins connected in sequence, and the U-shaped hairpins are inserted into the stator slots with spans n, n-1 and n+1.
[0017] Preferably, the first branch has 6 layers from the opening of the stator slot to the bottom of the slot;
[0018] In the first and second layers, the first branch starts from the slot opening of the stator slot and inserts the U-shaped hairpins in sequence according to the spans n, n, n, n-1, n, n, and n+1.
[0019] In the 3rd and 4th layers, the first branch starts from the U-shaped hairpin in the 2nd layer and inserts the U-shaped hairpins in sequence according to the spans n, n, n, n-1, n, n, and n+1.
[0020] On the 5th and 6th floors, the first branch starts from the U-shaped hairpin on the 4th floor and inserts the U-shaped hairpins in sequence according to the spans n, n, n, n-1, n, n, and n+1.
[0021] Preferably, the second branch has 6 layers from the opening of the stator slot to the bottom of the slot;
[0022] In the first and second layers, the second branch starts from the slot opening of the stator slot and inserts the U-shaped hairpins in sequence according to the spans n, n, n-1, n, n, n+1 and n.
[0023] In the 3rd and 4th layers, the second branch starts from the U-shaped hairpin in the 2nd layer and inserts the U-shaped hairpins in sequence according to the spans n, n, n-1, n, n, n+1 and n;
[0024] On the 5th and 6th floors, the second branch starts from the U-shaped hairpin on the 4th floor and inserts the U-shaped hairpins in sequence according to the spans n, n, n-1, n, n, n+1 and n.
[0025] Preferably, in the first branch, the lead wires are located at the beginning and end of the first branch, respectively;
[0026] In the second branch, the lead wires are located at the beginning and end of the two branches, respectively.
[0027] Preferably, the number of stator slots between the starting ends of the first branch and the second branch is n-1.
[0028] Preferably, the U-shaped hairpin is a flat copper hairpin, and the open ends of the U-shaped hairpin are welded sequentially in the first branch and the second branch.
[0029] Preferably, the number of stator slots located at the interval between adjacent lead-out lines at the slot opening is 3.
[0030] A flat wire motor, equipped with the aforementioned flat wire stator structure.
[0031] The beneficial effects of this utility model are:
[0032] 1. The lead wires of the three-phase coil of this utility model are distributed at the slot opening and the bottom of the stator slot, which reduces the radial envelope size, facilitates the design of the three-phase lead wire structure, and improves the strength of the three-phase connection.
[0033] 2. The three-phase coils of this utility model are inserted using U-shaped hairpins, which eliminates the need for reverse twisting and ensures that the lead-out positions are distributed at the bottom and opening of the slots, providing a practical and feasible solution for the design of a 48-slot flat wire stator structure.
[0034] Other features and advantages of this invention will be set forth in the description which follows, and will be apparent in part from the description, or may be learned by practicing the invention. The objectives and other advantages of this invention can be realized and obtained through the structures pointed out in the description and the accompanying drawings. Attached Figure Description
[0035] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.
[0036] Figure 1 A schematic diagram of a flat wire stator structure according to this utility model is shown;
[0037] Figure 2 A schematic diagram of the end face of the stator core of this utility model is shown;
[0038] Figure 3 A schematic diagram of the structure of the U-shaped hair clip of this utility model is shown;
[0039] Figure 4 The diagram shows the unfolded view of the three-phase coil of the 48-slot flat wire stator structure of this utility model;
[0040] Figure 5 The diagram shows the unfolded view of the first branch of the 48-slot flat wire stator structure of this utility model;
[0041] Figure 6 The diagram shows the unfolded view of the first branch of the 48-slot flat wire stator structure of this invention.
[0042] In the diagram: 1. Stator core; 101. Stator slot; 2. Three-phase coil; 3. U-shaped hairpin. Detailed Implementation
[0043] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.
[0044] A flat wire stator structure, such as Figure 1 As shown, it includes a stator core 1 and a three-phase coil 2, which is installed in the stator core 1. Specifically, in conjunction with Figure 2 It can be seen that a number of stator slots 101 are evenly opened on the end face of the stator core 1 along the circumference of the stator core 1; the three-phase coils 2 are inserted in the stator slots 101 with spans of n, n-1 and n+1 in the clockwise or counterclockwise direction, where n≥6. In addition, the leads of the three-phase coils 2 are located at the bottom and top of the stator slots 101, and the number of stator slots 101 between adjacent leads located at the top of the slots is 1 or 3.
[0045] It should be noted that, in Figure 1 and Figure 2 In the structure, the leads of the three-phase coil 2 are distributed at the slot opening and bottom of the stator slot 101, which reduces the radial envelope size, facilitates the design of the three-phase lead structure, and improves the strength of the three-phase connection.
[0046] The three-phase coil 2 includes unidirectional coils such as the U-phase coil, V-phase coil, and W-phase coil. Each of the three unidirectional coils is provided with two parallel first branches and second branches. In a clockwise or counterclockwise direction, the first branch and the second branch each include several U-shaped hairpins 3 connected in sequence. The U-shaped hairpins 3 are inserted into the stator slots 101 with spans n, n-1, and n+1.
[0047] It should be noted that there are a total of 6 branches in the three-phase coil 2. Each phase coil consists of two branches connected in parallel. The insertion scheme of each branch in the stator slot 101 directly determines the position of the lead wire.
[0048] like Figure 3As shown, the structure of the U-shaped hairpin 3 (flat copper hairpin) can be divided into a hairpin body, a bending section, and a welding section from bottom to top, all using flat copper conductors. The bending section of the U-shaped hairpin 3 bends outwards towards the hairpin body and is located at the U-shaped opening of the hairpin body. The welding section is connected to the bending section and remains parallel to the U-shaped body. During installation, the U-shaped body is inserted into the stator slot 101. The welding sections of adjacent U-shaped hairpins 3 can overlap, and then the overlapping positions are welded, so that the U-shaped hairpins 3 are connected sequentially to form a welding end. The other end of the corresponding U-shaped hairpin 3 serves as the closed end.
[0049] Furthermore, in Figure 1 In the first branch, from the opening to the bottom of the stator slot 101, there are 6 layers. In the first and second layers, the first branch starts from the opening of the stator slot 101 and inserts U-shaped hairpins 3 sequentially according to spans n, n, n, n-1, n, n, n, and n+1. In the third and fourth layers, the first branch starts from the U-shaped hairpins 3 in the second layer and inserts U-shaped hairpins 3 sequentially according to spans n, n, n, n-1, n, n, n, and n+1. In the fifth and sixth layers, the first branch starts from the U-shaped hairpins 3 in the fourth layer and inserts U-shaped hairpins 3 sequentially according to spans n, n, n, n-1, n, n, n, and n+1.
[0050] Furthermore, the second branch also has 6 layers from the opening to the bottom of the stator slot 101. In layers 1-2, the second branch starts from the opening of the stator slot 101 and inserts U-shaped hairpins 3 sequentially according to spans n, n, n-1, n, n, n, n+1, and n. In layers 3-4, the second branch starts from the U-shaped hairpins 3 in layer 2 and inserts U-shaped hairpins 3 sequentially according to spans n, n, n-1, n, n, n, n+1, and n. In layers 5-6, the second branch starts from the U-shaped hairpins 3 in layer 4 and inserts U-shaped hairpins 3 sequentially according to spans n, n, n-1, n, n, n+1, and n.
[0051] It should be noted that the insertion method of the first and second branches described above ensures that the current inlets of both branches are located at the slot opening and the current outlets are located at the slot bottom. In the first branch, the leads are located at the starting end (current inlet) and the ending end (current outlet) of the first branch, respectively. In the second branch, the leads are located at the starting end (current inlet) and the ending end (current outlet) of the second branch, respectively. Therefore, the insertion method described above ensures that the leads are distributed at the slot opening and the slot bottom.
[0052] Furthermore, the number of stator slots 101 between the starting ends of the first branch and the second branch is n-1.
[0053] It should be noted that by limiting the interval between the starting ends of the first and second branches, the entry and exit positions of the lead-in lines can be determined, making the pattern predictable.
[0054] Figure 1 The number of stator slots 101 can be set according to actual needs, as detailed below. Figures 4-6 This paper introduces a flat wire stator structure with 48 stator slots 101, a span n = 6, and 3 stator slots 101 spaced apart from adjacent lead wires at the slot opening.
[0055] like Figure 4 The diagram shown is a three-phase unfolded view of this flat wire stator structure. The numbers 1-48 represent the 48 stator slots 101. Solid lines indicate current inflow, and dashed lines indicate current outflow.
[0056] like Figure 5 The diagram shown is an unfolded view of the first branch in the unidirectional coil of this flat wire stator structure. The U-shaped hairpin 3 is inserted as follows:
[0057] 31(1)-25(2)-19(1)-13(2)-7(1)-1(2)-43(1)-38(2)-32(1)-26(2)-20(1)-14(2)-8(1)-2(2)-44(1)-37(2)-31(3)-25(4)-19(3)-13(4)-7(3)-1(4)-43(3)-38(4)- 32(3)-26(4)-20(3)-14(4)-8(4)-2(4)-44(3)-37(4)-31(5)-25(6)-19(5)-14(6)-8(5)-2(6)-44(5)-38(6)-32(5)-26(6)-20(5)-13(6)-7(5)-1(6)-43(5)-37(6).
[0058] In the above designations, 31(1) indicates that the U-shaped hairpin 3 is inserted into stator slot 101 of layer 1 (number 31), 25(2) indicates that the U-shaped hairpin 3 is inserted into stator slot 25 of layer 2, and so on. In the first branch, in layers 1-2, the first branch starts from the slot opening of stator slot 101 and inserts U-shaped hairpin 3 in sequence according to spans of 6, 6, 6, 5, 6, 6, 6 and 7. In layers 3-4, the first branch starts from the U-shaped hairpin 3 of layer 2 and inserts U-shaped hairpin 3 in sequence according to spans of 6, 6, 6, 5, 6, 6, 6 and 7. In layers 5-6, the first branch starts from the U-shaped hairpin 3 of layer 4 and inserts U-shaped hairpin 3 in sequence according to spans of 6, 6, 6, 5, 6, 6, 6 and 7.
[0059] like Figure 5 The diagram shown is an unfolded view of the second branch in the unidirectional coil of this flat wire stator structure. The U-shaped hairpin 3 is inserted as follows:
[0060] 37(1)-31(2)-25(1)-19(2)-13(1)-7(2)-1(1)-44(2)-38(1)-32(2)-26(1)-20(2)-14(1)-8(2)-2(1)-43(2)-37(3)-31(4)-25(3)-19(4)-13(3)-7(4)-1(3)-44(4)- 38(3)-32(4)-26(3)-20(4)-14(3)-8(4)-2(3)-43(4)-37(5)-31(6)-25(5)-20(6)-14(5)-8(6)-2(5)-44(6)-38(5)-32(6)-26(5)-19(6)-13(5)-7(6)-1(6)-43(6).
[0061] Similarly, as indicated by the above labels, the second branch also has six layers from the opening to the bottom of the stator slot 101. In layers 1-2, the second branch starts from the opening of the stator slot 101 and inserts U-shaped hairpins 3 sequentially with spans of 6, 6, 5, 6, 6, 6, 7, and 6. In layers 3-4, the second branch starts from the U-shaped hairpins 3 in layer 2 and inserts U-shaped hairpins 3 sequentially with spans of 6, 6, 5, 6, 6, 6, 7, and 6. In layers 5-6, the second branch starts from the U-shaped hairpins 3 in layer 4 and inserts U-shaped hairpins 3 sequentially with spans of 6, 6, 5, 6, 6, 6, 7, and 6.
[0062] A flat wire motor, equipped with the aforementioned flat wire stator structure.
[0063] Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.
Claims
1. A flat wire stator structure, characterized in that, It includes a stator core (1) and a three-phase coil (2), wherein a plurality of stator slots (101) are uniformly provided on the end face of the stator core (1) along the circumference of the stator core (1); The three-phase coil (2) is inserted in the stator slot (101) with spans n, n-1 and n+1 in a clockwise or counterclockwise direction, where n≥6; The lead wires of the three-phase coil (2) are located at the bottom and opening of the stator slot (101); The number of stator slots (101) located between adjacent lead wires at the slot opening is 1 or 3.
2. The flat wire stator structure according to claim 1, characterized in that, The number of stator slots (101) is 48, and the span n = 6.
3. The flat wire stator structure according to claim 1, characterized in that, The three-phase coil (2) includes a U-phase coil, a V-phase coil, and a W-phase coil; The U-phase coil, V-phase coil, and W-phase coil are each provided with two parallel first branches and second branches; Along the clockwise or counterclockwise direction, the first branch and the second branch each include a number of U-shaped hairpins (3) connected in sequence, and the U-shaped hairpins (3) are inserted into the stator slots (101) with spans n, n-1 and n+1.
4. A flat wire stator structure according to claim 3, characterized in that, The first branch has 6 layers from the opening of the stator slot (101) to the bottom of the slot; In the first and second layers, the first branch starts from the slot opening of the stator slot (101) and inserts the U-shaped hairpins (3) in sequence according to the spans n, n, n, n-1, n, n, n and n+1; In the 3rd and 4th layers, the first branch starts from the U-shaped hairpin (3) in the 2nd layer and inserts the U-shaped hairpin (3) in sequence according to the spans n, n, n, n-1, n, n, n and n+1; In the 5th and 6th layers, the first branch starts from the U-shaped hairpin (3) in the 4th layer and inserts the U-shaped hairpin (3) in sequence according to the spans n, n, n, n-1, n, n, and n+1.
5. A flat wire stator structure according to claim 4, characterized in that, The second branch has 6 layers from the opening of the stator slot (101) to the bottom of the slot; In the first and second layers, the second branch starts from the slot opening of the stator slot (101) and inserts the U-shaped hairpin (3) in sequence according to the spans n, n, n-1, n, n, n+1 and n; In the 3rd and 4th layers, the second branch starts from the U-shaped hairpin (3) of the 2nd layer and inserts the U-shaped hairpin (3) in sequence according to the spans n, n, n-1, n, n, n+1 and n; In the 5th and 6th layers, the second branch starts from the U-shaped hairpin (3) in the 4th layer and inserts the U-shaped hairpin (3) in sequence according to the spans n, n, n-1, n, n, n+1 and n.
6. A flat wire stator structure according to claim 5, characterized in that, In the first branch, the lead wires are located at the beginning and end of the first branch, respectively; In the second branch, the lead wires are located at the beginning and end of the two branches, respectively.
7. A flat wire stator structure according to claim 5, characterized in that, The number of stator slots (101) between the starting ends of the first branch and the second branch is n-1.
8. A flat wire stator structure according to claim 5, characterized in that, The U-shaped hairpin (3) is a flat copper hairpin, and the open ends of the U-shaped hairpin (3) are welded sequentially in the first branch and the second branch.
9. A flat wire stator structure according to any one of claims 1-8, characterized in that, The number of stator slots (101) located at the slot opening between adjacent lead wires is 3.
10. A flat wire motor, characterized in that, The stator structure is equipped with a flat wire stator structure as described in any one of claims 1-9.