Hybrid winding structure and stator assembly

Abstract

The utility model discloses a hybrid winding structure and a stator assembly, the hybrid winding structure comprises two groups of three-phase windings, each phase winding comprises two coil rings arranged at adjacent magnetic pole positions, each coil ring comprises P coil groups uniformly distributed along the circumferential direction, and P is the number of pole pairs; each coil assembly comprises two supporting legs which are bent in opposite directions in the circumferential direction, the supporting legs of the P coil assemblies are sequentially connected in series in the circumferential direction to form the coil ring, and the end supporting leg of at least one coil ring is a power source supporting leg used for being connected with a power source; and in the two groups of three-phase windings, the power supply supporting feet of the two phase windings positioned on the adjacent slot positions in the circumferential direction are arranged at an interval of 180 degrees in the circumferential direction. The utility model has the advantages of reasonable structural design, few hairpin types and low cost, is favorable for reducing the assembly difficulty, improving the assembly efficiency and the assembly quality, and the like.

Description

Technical Field

[0001] This utility model relates to the field of flat wire motor technology, and in particular to a hybrid winding structure and stator assembly. Background Technology

[0002] In recent years, miniaturization and high speed have become the main development trends of motors for new energy electric vehicles. Compared with traditional permanent magnet motors, flat wire motors have the characteristic of high copper fill factor in their windings, which can significantly improve the torque density and power density of the motor. The winding end length of flat wire motors is relatively short, which can further improve the utilization rate of vehicle space. The larger contact area between the wires effectively enhances the heat dissipation capacity of the motor. Therefore, flat wire motors have good application prospects in new energy electric vehicles.

[0003] Compared to three-phase motors, six-phase motors can cancel specific order harmonics, reduce torque ripple, and improve NVH performance. As the number of phases increases, the motor's fault tolerance is enhanced, resulting in higher operational reliability. Existing winding structures require various special shapes and conductors with different long or short spans to bridge the hairpin conductor layers, leading to a wide variety of hairpin conductor types, increased assembly difficulty, and higher costs. Utility Model Content

[0004] In view of the shortcomings of the prior art, the technical problem to be solved by this utility model is: how to provide a hybrid winding structure and stator assembly with reasonable structural design, fewer types of hairpins, low cost, and the ability to reduce assembly difficulty, improve assembly efficiency and assembly quality.

[0005] To solve the above-mentioned technical problems, the present invention adopts the following technical solution:

[0006] A hybrid winding structure includes two sets of three-phase windings. Each phase winding includes two coil loops located at adjacent magnetic pole positions. Each coil loop includes P coil groups evenly distributed circumferentially, where P is the number of pole pairs. Each coil group includes two legs that deflect in opposite directions circumferentially. The legs of the P coil groups are connected in series circumferentially to form the coil loop. At least one end leg of each coil loop is a power supply leg for connecting to a power source. In the two sets of three-phase windings, the power supply legs of the two phase windings located in adjacent circumferential slots are spaced 180° apart circumferentially.

[0007] The two sets of phase windings constructed as described above result in a 60-degree electrical angle difference between each phase, allowing for both single-winding and dual-winding operation. This widens the motor's high-efficiency range, significantly reduces overall heat generation, lowers harmonic components, and reduces noise. Furthermore, each coil ring consists of evenly distributed coil groups. The type of hairpins in these coil groups directly determines the type of hairpins used in the entire winding, thus avoiding irregularly shaped hairpins, reducing the variety of hairpins, lowering production costs, and helping to reduce assembly difficulty, improve assembly efficiency, and enhance assembly quality.

[0008] Furthermore, the coil assembly includes a first hairpin and a second hairpin with the same pitch at the same magnetic pole position. Both the first and second hairpins include a hairpin body that is bent in a U-shape. The hairpin body includes two parallel legs and a head connected to one end of the two legs. The other end of the two legs is a connecting segment. The two connecting segments of the first hairpin deflect clockwise or counterclockwise in the phase winding, and the two connecting segments of the second hairpin deflect counterclockwise or clockwise in the phase winding. The connecting segments of the first and second hairpins that deflect in opposite directions form the legs, and the other two connecting segments are connected in series to form the coil assembly.

[0009] Furthermore, the two legs of the first hairpin are located in the second and third layers radially above the phase winding, respectively, and the two legs of the second hairpin are located in the first and fourth layers radially above the phase winding, respectively.

[0010] Furthermore, the coil assembly also includes a third hairpin arranged side by side with the first hairpin, and the first, second, and third hairpins have the same pitch; the third hairpin includes a hairpin body with a U-shaped bend, the hairpin body including two parallel legs and a head connected to one end of the two legs, the other end of the two legs being bent toward the center in the width direction of the hairpin body to form a connecting section, and the two connecting sections of the third hairpin being welded to two adjacent connecting sections on the two hairpin conductors respectively.

[0011] Furthermore, the two legs of the first and third hairpins are located in the Nth and N+1th layers radially on the phase winding, respectively, where N is an even number, and the two legs of the second hairpin are located in the innermost and outermost layers radially on the phase winding, respectively.

[0012] Furthermore, the pitch of the card-issuing body is Y or Y-1, where Y is the pole pitch.

[0013] A stator assembly includes a stator core and a hybrid winding structure as described above, the hybrid winding structure being mounted on the stator core.

[0014] In summary, this utility model has the advantages of reasonable structural design, fewer types of hair clips, low cost, and is conducive to reducing assembly difficulty, improving assembly efficiency and assembly quality. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the overall structure of this embodiment.

[0016] Figure 2 This is a schematic diagram of the overall structure of the hidden part of the second hairpin in this embodiment.

[0017] Figure 3 for Figure 2 A partial top-view structural diagram.

[0018] Figure 4 This is a schematic diagram of the phase windings on two adjacent slots.

[0019] Figure 5 and Figure 6 This is a schematic diagram of the overall structure of the coil loop. Detailed Implementation

[0020] The present invention will be further described in detail below with reference to the embodiments.

[0021] In practical implementation: such as Figures 1-6 As shown, a hybrid winding motor includes a stator assembly, which includes a stator core 1 and two sets of three-phase windings. The stator core 1 includes a cylindrical body. Multiple stator core slots with radially inward openings are arranged circumferentially on the inner ring of the stator core 1. The lower end of the stator core slot is the insertion side (or crown side), and the upper end is the connection side.

[0022] In this embodiment, each phase winding 2 includes two coil rings 3 positioned at adjacent magnetic poles. Each coil ring 3 includes P coil groups 4 evenly distributed circumferentially, where P is the number of pole pairs. In this embodiment, the number of pole pairs P = 8. Each coil group 4 includes two legs that deflect in opposite directions circumferentially. The legs of the P coil groups 4 are connected in series circumferentially to form the coil ring 3. At least one end leg of each coil ring 3 is a power supply leg for connecting to a power source. In the two sets of three-phase windings, the power supply legs of two phase windings 2 located in adjacent circumferential slots are spaced 180° apart circumferentially. Figure 4 As shown.

[0023] In this embodiment, as Figure 5 and Figure 6As shown, the coil group 4 includes a first hairpin 5, a second hairpin 6, and a third hairpin 7 with the same pitch at the same magnetic pole position. The first hairpin 5, the second hairpin 6, and the third hairpin 7 all include a hairpin body that is bent in a U-shape. The hairpin body includes two parallel legs and a head connected to one end of the two legs. The other end of the two legs is a connecting section.

[0024] From the connection side, the two connecting segments of the first hairpin 5 deflect counterclockwise in the phase winding 2, and the two connecting segments of the second hairpin 6 deflect clockwise in the phase winding 2; the two connecting segments of the third hairpin 7 deflect towards the center in the width direction of the hairpin body, and are respectively welded to the connecting segments of the first hairpin 5 and the second hairpin 6 that deflect towards the center of the hairpin, forming the coil group 4.

[0025] In this embodiment, the pitch and pole pitch of the first hairpin 5, the second hairpin 6, and the third hairpin 7 are all 6. The two support legs of the first hairpin 5 and the third hairpin 7 are located in the Nth and N+1th layers radially in the phase winding 2, respectively, where N is an even number. The two support legs of the second hairpin 6 are located in the innermost and outermost layers radially in the phase winding 2, respectively. In this embodiment, the two support legs of the first hairpin 5 are located in the 2nd and 3rd layers of the phase winding 2, the two support legs of the third hairpin 7 are located in the 4th and 5th layers of the phase winding 2, and the two support legs of the second hairpin 6 are located in the 1st and 6th layers of the phase winding 2.

[0026] In the above structure, the first hairpin 5 and the third hairpin 7 have the same pitch, and the two support legs are located on two adjacent layers (layers 2 and 3 or layers 4 and 5) of the phase winding 2. This allows the first hairpin 5 and the third hairpin 7 to be formed using the same mold. After assembly, the first hairpin 5 and the third hairpin 7 form a concentric ring shape in the stator core, such as... Figure 2 and Figure 3 As shown, the second hairpin 6 is externally disposed on the first hairpin 5 and the second hairpin 6.

[0027] Specifically, in the same phase winding 2, the two end supports on the coil ring 3 are respectively a power supply support for connecting to the power source and a star support for connecting to the star point. The power supply support and star support on the two coil rings 3 are located in the same radial direction, and the two power supply support are located on two adjacent layers and are connected to power terminals (not shown in the figure); the two star supports are located on the inner and outer sides of the two power supply support. The star supports located on the same three-phase winding are welded together through star terminals 8.

[0028] In this embodiment, the two sets of three-phase windings result in a 60-degree electrical angle difference between each phase, allowing for both single-winding and dual-winding operation. This widens the motor's high-efficiency range, significantly reduces overall heat generation, lowers harmonic components, and reduces noise. Furthermore, each coil ring 3 consists of evenly distributed coil groups 4. The type of hairpins in the coil groups 4 directly determines the type of hairpins used in the entire winding, thus avoiding irregularly shaped hairpins, reducing the variety of hairpins, lowering production costs, and helping to reduce assembly difficulty, improve assembly efficiency, and enhance assembly quality.

[0029] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A hybrid winding structure, characterized by, Each phase winding comprises two coil rings arranged at adjacent magnetic pole positions, each coil ring comprising P coil groups circumferentially distributed, P being the number of pole pairs; each coil group comprises two legs bent in circumferential opposite directions, the legs of the P coil groups are sequentially connected in series along the circumferential direction to form the coil ring, and the end legs of at least one coil ring are power supply legs for connecting power supply; in the two groups of three-phase windings, the power supply legs of two phase windings located in circumferentially adjacent slot positions are arranged at an interval of 180° in the circumferential direction.

2. The hybrid winding structure of claim 1, wherein, The coil group comprises a first hairpin and a second hairpin arranged at the same magnetic pole position with the same pitch, each of the first hairpin and the second hairpin comprises a hairpin body bent as a whole in a U shape, the hairpin body comprises two leg portions arranged in parallel and a head portion connected to one end of the two leg portions, and the other end of the two leg portions is a connecting segment; the two connecting segments of the first hairpin are bent in the clockwise or counterclockwise direction of the phase winding, the two connecting segments of the second hairpin are bent in the counterclockwise or clockwise direction of the phase winding, the connecting segments bent in opposite directions of the first hairpin and the second hairpin form the legs, and the other two connecting segments are connected in series.

3. The hybrid winding structure of claim 2, wherein, The two leg portions of the first hairpin are located at the 2nd layer and the 3rd layer in the radial direction of the phase winding respectively, and the two leg portions of the second hairpin are located at the 1st layer and the 4th layer in the radial direction of the phase winding respectively.

4. The hybrid winding structure of claim 2, wherein, The coil group further comprises a third hairpin arranged side by side with the first hairpin, and the first hairpin, the second hairpin and the third hairpin have the same pitch; the third hairpin comprises a hairpin body bent in a U shape, the hairpin body comprises two leg portions arranged in parallel and a head portion connected to one end of the two leg portions, and the other end of the two leg portions is bent in the width direction of the hairpin body to form a connecting segment toward the middle part, and the two connecting segments of the third hairpin are respectively welded to the two connecting segments close to each other on the two hairpin conductors.

5. The hybrid winding structure of claim 4, wherein, The third hairpin is arranged side by side in the radial direction of the phase winding at least twice, and the first hairpin and the third hairpin are connected in series.

6. The hybrid winding structure of claim 4, wherein, The two leg portions of the first hairpin and the third hairpin are located at the Nth layer and the N+1th layer in the radial direction of the phase winding respectively, N is an even number, and the two leg portions of the second hairpin are located at the innermost layer and the outermost layer in the radial direction of the phase winding respectively.

7. The hybrid winding structure according to any one of claims 2 to 6, wherein The pitch of the hairpin body is Y or Y-1, Y is the pole pitch.

8. A stator assembly characterized by, The motor comprises a stator core and a hybrid winding structure as claimed in any one of claims 1 to 7, and the hybrid winding structure is mounted on the stator core.

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