Odd-layer flat wire winding stator assembly and motor

Abstract

The utility model relates to an odd number layer flat wire winding stator assembly, the stator assembly comprises a stator iron core and a stator winding, the stator iron core is provided with Z stator slots, each stator slot is internally provided with N wiring layers, N is an odd number and N > = 5; n wiring layers are divided into three adjacent groups, the first group comprises a layers in total, the second group comprises b layers in total, the third group comprises c layers in total, a is an odd number, and b and c are even numbers; the stator winding comprises a plurality of coils, and the coils are inserted in all wiring layers of the stator slots. Compared with the prior art, the winding arrangement of the stator core with an odd number of wiring layers and more than five layers is provided, a rotating magnetic field can be formed by introducing three-phase current, five, seventh, eleventh and thirteenth harmonic waves are weakened while branch symmetry is realized, the NVH vibration noise problem of the motor is improved, and the winding arrangement of the stator core with the odd number of wiring layers and the winding arrangement of the stator core with the odd number of wiring layers and more than five layers are realized on the basis of cost and performance consideration of batch production. And adverse effects caused by using a flat wire technology are reduced to the greatest extent.

Description

TECHNICAL FIELD

[0001] The utility model relates to motor stator assembly design especially to an odd layer flat wire winding stator assembly and motor. BACKGROUND

[0002] The main difference between the flat wire motor and the traditional round wire motor is that the shape of the wire cross section is rectangular, and the flat wire with a rectangular cross section improves the slot fill factor of the motor stator core, and the power density is higher. With the development of new energy vehicles, the flat wire motor is increasingly widely used in new energy vehicles due to its small size, high efficiency and high power density.

[0003] The stator winding arrangement of the flat wire motor is a complex and key design link, which directly affects the performance, efficiency and reliability of the motor. Due to the particularity of the winding structure and the difference of the winding connection mode, the flat wire motor has many types of hairpin coils and complex arrangement modes. The existing arrangement mode has the problem of large NVH (noise, vibration and harshness) of the motor.

[0004] Therefore, how to design a stator assembly and motor with small NVH is a technical problem to be solved. SUMMARY

[0005] The utility model discloses a kind of odd layer flat wire winding stator assembly and motor to overcome the defect of the NVH of the existing technology described above, and the NVH is small.

[0006] The purpose of the utility model can be realized by the following technical solutions:

[0007] According to one aspect of the utility model, an odd layer flat wire winding stator assembly is provided, which includes a stator core and a stator winding. The stator core has Z stator slots, and each stator slot has N layers of wiring layers, where N is an odd number and N≥5. The N layers of wiring layers are divided into three adjacent groups, the first group includes a layers, the second group includes b layers, and the third group includes c layers, where a is an odd number, and b and c are even numbers. The stator winding includes multiple coils, and coils are inserted into all wiring layers of the stator slot.

[0008] As a preferred technical solution, the first group of wiring layers and the second group of wiring layers are adjacent and staggered by one stator slot in the clockwise or counterclockwise direction along the circumference. The second group of wiring layers and the third group of wiring layers are adjacent and staggered by one stator slot in the clockwise or counterclockwise direction along the circumference.

[0009] As a preferred technical scheme, the number of slots per pole per phase q of the stator core is Z / mP, m is the number of phases of the motor, P is the number of poles of the rotor matched with the stator assembly, the pole pitch of the stator core is t stator slots, wherein t=Z / P, and the coil span between the adjacent two groups of wiring layers is t+1 stator slots or t-1 stator slots.

[0010] As a preferred technical scheme, the coil spans one layer or two layers of wiring layers; the coil spans of the same one layer of wiring layers are all the same, and the coil spans of the same two layers of wiring layers are all the same.

[0011] As a preferred technical scheme, when N>5, the pole pitch of the stator core is t stator slots, wherein t=Z / P, P is the number of poles of the rotor matched with the stator assembly, and the coil spans of only two layers of the wiring layers other than the first layer and the Nth layer are t-1 stator slots, the coil spans of only two layers of the wiring layers are t+1 stator slots, and the coil spans of the remaining wiring layers are t stator slots.

[0012] As a preferred technical scheme, the coil of the first layer or the Nth layer of the wiring layer spans one layer of wiring layers; when the pole pitch of the stator core is t stator slots, the coil span of the first layer or the Nth layer is t+1 stator slots or t-1 stator slots.

[0013] As a preferred technical scheme, when the coil of the first layer of the wiring layer spans one layer of wiring layers, the coil of the Nth layer is connected through same-layer twist head welding; when the coil of the Nth layer of the wiring layer spans one layer of wiring layers, the coil of the first layer is connected through same-layer twist head welding; the sum of the stator slot numbers spanned by the same-layer twist head welding and the coil spanning one layer of wiring layers is 2t.

[0014] As a preferred technical scheme, the stator winding includes three phases, each phase includes two branches, and the end of each branch is connected with a connecting wire or the ends of the two branches are connected.

[0015] As a preferred technical scheme, the three phases of the stator winding are arranged in two directions by rotating 120° electrical angle from one phase.

[0016] According to another aspect of the present application, a motor is provided, which comprises an odd number of layers of flat wire winding stator assemblies.

[0017] Compared with the prior art, the present application has the following beneficial effects:

[0018] 1) The utility model provides a winding arrangement of stator core of wiring layer is odd and greater than 5 layers, and three -phase current can form rotating magnetic field into, based on this flat wire winding arrangement mode, can realize branch symmetry while weakening 5, 7, 11, 13 harmonic, to improve the NVH vibration noise problem of motor, under the cost and performance consideration based on batch production, maximum degree reduces the adverse effect brought by using flat wire technology;

[0019] 2) The utility model discloses a hairpin end outgoing line, and the same layer twist head welding and same layer cross connection are used in the innermost or outermost layer of winding respectively, based on this arrangement mode, while realizing branch balance, no circulating current, 5, 7 harmonic of motor can be weakened, to improve the NVH vibration noise problem of motor, reduce harmonic loss, improve efficiency, compared with welding end outgoing line, the number of line type increases limitedly and is more favorable to the realization of new winding technology such as X-Pin of new energy automobile drive motor and end coating technology. DRAWINGS

[0020] Figure 1 It is a flat wire winding stator assembly overall structure schematic diagram of the utility model;

[0021] Figure 2 It is a stator slot inner slot layer arrangement schematic diagram of the utility model. CONCRETE IMPLEMENTING METHOD

[0022] The technical scheme in the embodiments of the utility model will be clearly and completely described below with the drawings in the embodiments of the utility model. Obviously, the described embodiments are a part of the embodiments of the utility model, rather than all the embodiments. Based on the embodiments in the utility model, all other embodiments obtained by those skilled in the art without creative labor should belong to the protection scope of the utility model.

[0023] As Figure 1 The utility model provides an odd layer flat wire winding stator assembly, and 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 uniformly distributed along the circumferential direction of the stator core. Each stator slot is provided with N wiring layers, wherein N is an odd number and N is greater than or equal to 5. The stator winding includes a plurality of coils, and the coils are inserted into all wiring layers of the stator slot. The pole number of the rotor matched with the stator assembly is 8. The stator winding includes three phases, and each phase is arranged by rotating 120° electric angle in two directions, each phase includes two branches, and the end of each branch is connected with a connecting line, and the two branches are arranged as one branch.

[0024] The N wiring layers are divided into three adjacent groups, the first group includes a layers in total, the second group includes b layers in total, and the third group includes c layers in total, and a+b+c=N, wherein a is an odd number, and b and c are even numbers. The first group of wiring layers and the second group of wiring layers are adjacent and staggered by one stator slot in the clockwise or counterclockwise direction along the circumference; the second group of wiring layers and the third group of wiring layers are adjacent and staggered by one stator slot in the clockwise or counterclockwise direction along the circumference; and a short-pitch winding is formed, which can weaken the 5th and 7th harmonics of the motor, improve the NVH vibration noise problem of the motor, reduce harmonic loss, and improve efficiency.

[0025] The coils span one or two wiring layers; the coil spans of the coils spanning the same one wiring layer are all the same, and the coil spans of the coils spanning the same two wiring layers are all the same. The coil span between the two adjacent groups of wiring layers is t+1 stator slots or t-1 stator slots; when N>5, except the first layer and the Nth layer, only two layers of the wiring layers have a coil span of t-1 stator slots, only two layers of the wiring layers have a coil span of t+1 stator slots, and the coil spans of the remaining wiring layers are t stator slots. The coil of the first layer or the Nth layer spans one wiring layer, and the coil span is t+1 stator slots or t-1 stator slots; when the coil of the first layer of the wiring layer spans one wiring layer, the coil of the Nth layer is connected by the same layer twist head welding; when the coil of the Nth layer of the wiring layer spans one wiring layer, the coil of the first layer is connected by the same layer twist head welding; the sum of the stator slots spanned by the same layer twist head welding and the coil spanning one wiring layer is 2t.

[0026] The in-out line positions of the stator winding include two I-Pin hairpin winding types, the first layer or the Nth layer includes one coil type (i.e. only one span coil), and the other layers include one coil type, so the stator winding at most has one coil type.

[0027] Embodiment 1

[0028] The embodiment provides an odd-layer flat wire winding stator assembly. The stator assembly comprises a stator core and a stator winding. The stator core is provided with 48 stator slots, and each stator slot is provided with 5 wiring layers. The number of poles of a rotor matched with the stator assembly is 8. The stator winding comprises a plurality of coils, and the coils are inserted into all the wiring layers of the stator slots. The stator winding comprises three phases of U, V and W, and each phase is arranged in two directions at an electrical angle of 120°. Each phase comprises two branches.

[0029] As shown in Table 1, the solid line is the hairpin end, and the dashed line is the welding end. The arrangement of the two branches of the U-phase winding in the stator slot is described. 3(1) represents the first wiring layer of the No. 3 slot, and 9(2) represents the second wiring layer of the No. 9 slot. Similarly, the specific wiring mode of the first branch U1 of the U-phase is as follows:

[0030] 3(1)-9(2)-2(3)-8(4)-3(5)-8(6)-13(4)-7(3)-14(2)-8(1)-15(1)-21(2)-14(3)-20(4)-15(5)-20(6)-25(4)-19(3)-26(2)-20(1)-27(1)-33(2)-26(3)-32(4)-27(5)-32(6)-37(4)-31(3)-38(2)-32(1)-39(1)-45(2)-38(3)-44(4)-39(5)-44(6)-1(4)-43(3)-2(2)-44(1)

[0031] Similarly, the specific wiring method for the second branch U2 of phase U is as follows:

[0032] 2(1)-8(2)-1(3)-7(4)-2(5)-45(5)-2(4)-44(3)-3(2)-45(1)-38(1)-44(2)-37(3)-43(4)-38(5)-33(5)-38(4)-32(3)-39(2)-33(1)-26(1)-32(2)-25(3)-31(4)-26(5)-21(5)-26(4)-20(3)-27(2)-21(1)-14(1)-20(2)-13(3)-19(4)-14(5)-9(5)-14(4)-8(3)-15(2)-9(1)

[0033] Table 2 shows the layout of the first and second branches. Solid lines represent the card-issuing ends, and dashed lines represent the soldering ends. The wiring patterns of the V and W phases can be derived from the U phase.

[0034] Table 1 Independent Wiring Table for U-Phase 2 Branches in Example 1

[0035]

[0036] Table 2. Example 1: U-phase 2 branch combined wiring table

[0037]

[0038] Example 2

[0039] This embodiment provides an odd-layer flat wire winding stator assembly. The stator assembly includes a stator core and stator windings. The stator core has 48 stator slots, and each stator slot has 5 wiring layers. The rotor that cooperates with the stator assembly has 8 poles. The stator windings include multiple coils, and coils are inserted in all wiring layers of the stator slots. The stator windings include three phases: U, V, and W, arranged by rotating one phase 120° electrical angle in each of two directions. Each phase includes two branches.

[0040] As shown in Table 3, the solid line is the hairpin end, and the dashed line is the welding end. The arrangement of the two branches of the U-phase winding in the stator slot is described, 3(5) represents the 5th wiring layer of the 3rd slot, and 9(4) represents the 4th wiring layer of the 9th slot, and so on. The specific wiring mode of the first branch U1 of the U-phase is as follows:

[0041] 3(5)-9(4)-14(3)-20(2)-27(1)-20(1)-13(2)-7(3)-2(4)-44(5)-39(5)-45(4)-2(3)-8(2)-15(1)-8(1)-1(2)-43(3)-38(4)-32(5)-27(5)-33(4)-38(3)-44(2)-3(1)-44(1)-37(2)-31(3)-26(4)-20(5)-15(5)-21(4)-26(3)-32(2)-39(1)-32(1)-25(2)-19(3)-14(4)-8(5)

[0042] Similarly, the specific wiring mode of the second branch U2 of the U-phase is as follows:

[0043] 2(5)-8(4)-13(3)-19(2)-26(1)-33(1)-26(2)-20(3)-15(4)-9(5)-14(5)-20(4)-25(3)-31(2)-38(1)-45(1)-38(2)-32(3)-27(4)-21(5)-26(5)-32(4)-37(3)-43(2)-2(1)-9(1)-2(2)-44(3)-39(4)-33(5)-38(5)-44(4)-1(3)-7(2)-14(1)-21(1)-14(2)-8(3)-3(4)-45(5)

[0044] The wiring mode of the V-phase and W-phase can be obtained from the U-phase.

[0045] Table 3 Example 2 U-phase 2-branch independent wiring table

[0046]

[0047] Example 3

[0048] The embodiment provides a flat wire winding stator assembly with odd layers, the stator assembly comprises a stator core and a stator winding, the stator core is provided with 48 stator slots, each stator slot is provided with 7 wiring layers, and the pole number of a rotor matched with the stator assembly is 8. The stator winding comprises a plurality of coils, and the coils are arranged in all the wiring layers of the stator slots. The stator winding comprises three phases of U, V and W, one phase is arranged in two directions with an electrical angle of 120°, and each phase comprises two branches.

[0049] As shown in Table 4, the solid line is a card end, the dashed line is a welding end, the arrangement mode of two branches of the U-phase winding in the stator slot is described, 3(7) represents the 7th wiring layer of the 3rd slot, 9(6) represents the 6th wiring layer of the 9th slot, and the like, and the specific wiring mode of the first branch U1 of the U-phase is as follows:

[0050] 3(7)-9(6)-14(5)-20(4)-26(3)-32(2)-39(1)-32(1)-26(2)-19(3)-13(4)-7(5)-2(6)-44(7)-39(7)-45(6)-2(5)-8(4)-14(3)-20(2)-27(1)-20(1)-14(2)-7(3)-1(4)-43(5)-38(6)-32(7)-27(7)-33(6)-38(5)-44(4)-2(3)-8(2)-15(1)-8(1)-2(2)-43(3)-37(4)-31(5)-36(6)-20(7)-15(7)-21(6)-26(5)-32(4)-38(3)-44(2)-3(1)-44(1)-38(2)-31(3)-25(4)-19(5)-24(6)-8(7)

[0051] Similarly, the specific wiring mode of the second branch U2 of the U-phase is as follows:

[0052] 2(7)-8(6)-13(5)-19(4)-25(3)-31(2)-38(1)-45(1)-38(2)-32(3)-26(4)-20(5)-15(6)-9(7)-14(7)-20(6)-25(5)-31(4)-37(3)-43(2)-2(1)-9(1)-2(2)-44(3)-38(4)-32(5)-27(6)-21(7)-26(7)-32(6)-37(5)-43(4)-1(3)-7(2)-14(1)-21(1)-14(2)-8(3)-2(4)-44(5)-39(6)-33(7)-38(7)-44(6)-1(5)-7(4)-13(3)-19(2)-26(1)-33(1)-26(2)-20(3)-14(4)-8(5)-3(6)-45(7)

[0053] The wiring mode by which the V phase and the W phase are obtained from the U phase.

[0054] Table 4 U phase 2 branch independent wiring table of example 3

[0055]

[0056] Example 4

[0057] The embodiment provides an odd-layer flat wire winding stator assembly, the stator assembly comprising a stator core and a stator winding, the stator core being provided with 48 stator slots, and each stator slot being provided with 7 wiring layers, and the pole number of a rotor matched with the stator assembly being 8. The stator winding comprises a plurality of coils, and the coils are arranged in all the wiring layers of the stator slots. The stator winding comprises three phases of U, V and W, and each phase is arranged in two directions with a rotation angle of 120°, and each phase comprises two branches.

[0058] As shown in Table 5, the solid line is the hairpin end, and the dashed line is the welding end. The arrangement mode of the two branches of the U phase winding in the stator slot is described, 3(7) represents the 7th wiring layer of the 3rd slot, and 9(6) represents the 6th wiring layer of the 9th slot, and so on. The specific wiring mode of the first branch U1 of the U phase is as follows:

[0059] 2(7)-8(6)-15(5)-21(4)-26(3)-32(2)-38(1)-31(1)-25(2)-19(3)-14(4)-8(5)-1(6)-43(7)-38(7)-44(6)-3(5)-9(4)-14(3)-20(2)-26(1)-19(1)-13(2)-7(3)-2(4)-44(5)-37(6)-31(7)-26(7)-32(6)-39(5)-45(4)-2(3)-8(2)-14(1)-7(1)-1(2)-43(3)-38(4)-32(5)-25(6)-19(7)-14(7)-20(6)-27(5)-33(4)-38(3)-44(2)-2(1)-43(1)-37(2)-31(3)-26(4)-20(5)-13(6)-7(7)

[0060] Similarly, the specific wiring mode of the U-phase second branch U2 is as follows:

[0061] 1(7)-7(6)-14(5)-20(4)-25(3)-31(2)-37(1)-44(1)-38(2)-32(3)-27(4)-21(5)-14(6)-8(7)-13(7)-19(6)-26(5)-32(4)-37(3)-43(2)-1(1)-8(1)-2(2)-44(3)-39(4)-33(5)-26(6)-20(7)-25(7)-31(6)-38(5)-44(4)-1(3)-7(2)-13(1)-20(1)-14(2)-8(3)-3(4)-45(5)-38(6)-32(7)-37(7)-43(6)-2(5)-8(4)-13(3)-19(2)-5(1)-32(1)-26(2)-20(3)-15(4)-9(5)-2(6)-44(7)

[0062] Table 6 is a schematic arrangement of the first branch and the second branch, the solid line is the card end, and the dashed line is the welding end. The wiring mode of the V-phase and the W-phase can be obtained from the U-phase.

[0063] Table 5 Example 4 U-phase 2-branch independent wiring table

[0064]

[0065] Table 6 Example 4 U-phase 2-branch combined wiring table

[0066]

[0067] Example 5

[0068] The embodiment provides an odd-layer flat wire winding stator assembly, based on any one of the odd-layer flat wire winding stator assemblies in embodiments 1-4, two branches are connected in a series connection mode through end connection copper bars, and terminal performance of a final branch is realized.

[0069] Embodiment 6

[0070] The embodiment provides a motor, including any one of the odd-layer flat wire winding stator assemblies in embodiments 1-5.

[0071] The above merely provides a specific implementation manner of the utility model, but the protection scope of the utility model is not limited to this, any skilled person in the art can easily think of various equivalent modifications or replacements within the technical range disclosed by the utility model, and these modifications or replacements should be covered in the protection scope of the utility model. Therefore, the protection scope of the utility model should be subject to the protection scope of claims.

Claims

1. A stator assembly of an odd number of flat wire windings, characterized in that, The stator assembly comprises a stator core and a stator winding, the stator core is provided with Z stator slots, each of the stator slots has N layers of wiring layers in common, wherein N is an odd number and N≥5; the N layers of wiring layers are divided into three adjacent groups, the first group includes a layers in common, the second group includes b layers in common, and the third group includes c layers in common, wherein a is an odd number, b and c are even numbers; the stator winding comprises a plurality of coils, and the coils are arranged in all the wiring layers of the stator slots.

2. A stator assembly of a flat odd layer winding according to claim 1, characterized in that The first group of wiring layers and the second group of wiring layers are adjacent and staggered by one stator slot in the clockwise or counterclockwise direction along the circumference; the second group of wiring layers and the third group of wiring layers are adjacent and staggered by one stator slot in the clockwise or counterclockwise direction along the circumference.

3. A stator assembly of a flat odd layer winding according to claim 1, characterized in that, The number of slots per pole per phase q of the stator core is Z / mP, m is the number of motor phases, P is the number of poles of a rotor matched with the stator assembly, and the pole pitch of the stator core is t stator slots, wherein t=Z / P, and the coil span between the adjacent two groups of wiring layers is t+1 stator slots or t-1 stator slots.

4. A stator assembly of a flat odd layer winding according to claim 1, characterized in that, The coil spans one layer or two layers of wiring layers; the coil spans the same layer of wiring layers by the same span, and the coil spans the same two layers of wiring layers by the same span.

5. An odd layer flat conductor winding stator assembly according to claim 1, characterized in that When N>5, the pole pitch of the stator core is t stator slots, wherein t=Z / P, P is the number of poles of a rotor matched with the stator assembly, and the coil span of two layers of wiring layers other than the first layer and the Nth layer is t-1 stator slots, the coil span of two layers of wiring layers is t+1 stator slots, and the coil span of the remaining wiring layers is t stator slots.

6. A flat conductor winding stator assembly of odd number of layers as claimed in claim 1 wherein, The coil of the first layer or the Nth layer of the wiring layer spans one layer of wiring layers; when the pole pitch of the stator core is t stator slots, the coil span of the first layer or the Nth layer is t+1 stator slots or t-1 stator slots.

7. A stator assembly of a flat odd layer winding according to claim 6, characterized in that When the coil of the first layer of the wiring layer spans one layer of wiring layers, the coil of the Nth layer is connected by same-layer twist head welding; when the coil of the Nth layer of the wiring layer spans one layer of wiring layers, the coil of the first layer is connected by same-layer twist head welding; the total number of stator slots spanned by the coil spanning one layer of wiring layers and the same-layer twist head welding is 2t.

8. A flat conductor winding stator assembly of odd number of layers as claimed in claim 1 wherein, The stator winding comprises three phases, each phase includes two branches, and the end of each branch is connected by a connecting line or the ends of the two branches are connected.

9. A stator assembly of a flat odd layer winding according to claim 8, characterized in that The three phases of the stator winding are arranged by rotating one of the phases by 120° electrical angle in two directions respectively.

10. An electric machine characterized by The odd number of layers of flat wire winding stator assemblies in claims 1-9 are included.

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