Wave lap winding structure and stator assembly
By employing an alternating series structure of two sets of three-phase windings in a six-phase motor, the problems of high assembly difficulty and cost caused by multiple conductors and jumpers are solved, achieving efficient assembly and high power density of the motor, and improving the reliability and heat dissipation performance of the motor.
Patent Information
- Application Number
- CN202520170441.X
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-01-25
- Publication Date
- 2026-01-09
- Estimated Expiration
- 2035-01-25
AI Technical Summary
In the existing technology, the winding structure of a six-phase motor requires a variety of conductors and jumpers with special shapes, which makes assembly difficult and costly, and makes it difficult to meet the needs of miniaturized and high-speed new energy electric vehicle motors.
Two sets of three-phase windings are used. Each phase winding includes coil loops at adjacent magnetic pole positions. By adjusting the support direction of the coil conductors, they are alternately set and connected in series in the circumferential direction, reducing the types of hairpins and jumpers. The same set of control programs is used to realize single-winding and double-winding operation.
It simplifies the assembly process, reduces costs and debugging difficulty, improves the power density and heat dissipation capacity of the motor, and enhances the reliability of the motor.
Smart Images
Figure CN223785833U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of flat wire motor technology, and in particular to a wave-lapped 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 specially shaped conductors or jumpers to bridge the hairpin conductor layers in order to achieve six-phase winding connections. This results in a wide variety of hairpin conductor types, increasing assembly difficulty and cost. 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 wave-layer winding structure and stator assembly with reasonable structural design, which can reduce the types of hairpins and jumpers and facilitate assembly.
[0005] To solve the above-mentioned technical problems, the present invention adopts the following technical solution:
[0006] A wave-stacked winding structure includes two sets of three-phase windings. Each phase winding includes two coil loops arranged at adjacent magnetic pole positions. Each coil loop includes P first coil conductors and P second coil conductors evenly distributed circumferentially, where P is the number of pole pairs. Both the first and second coil conductors have a hairpin body with a pitch of Y. The hairpin body of the first coil conductor has two legs that deflect in opposite directions circumferentially, and the hairpin body of the second coil conductor has two legs that deflect in opposite directions. The first and second coil conductors are alternately arranged circumferentially and connected in series through the legs. At a magnetic pole position in any phase winding, among the two legs of the first and second coil conductors belonging to different coil loops, the leg of the first coil conductor is recessed by one slot and deflected inward in the opposite direction to be connected in series with the other coil loop, and the corresponding leg of the second coil conductor is extended by one slot and deflected outward in the opposite direction to be connected in series with the other coil loop.
[0007] In the above structure, since each phase winding has only two coil loops at adjacent magnetic pole positions, responsible for the S and N poles respectively, interference between the two coil loops is avoided by adjusting the supports of the first and second coil conductors at a magnetic pole position. The first coil conductor's support is recessed by one slot and deflected inward, while the corresponding support of the second coil conductor is expanded by one slot and deflected outward. Furthermore, the two coil loops can be directly connected in series to form corresponding phase windings, reducing the types of hairpins and jumpers, and simplifying installation. In addition, the two sets of three-phase windings can achieve single-winding and dual-winding operation using the same control program, reducing the cost and debugging difficulty of the six-phase motor drive system, significantly reducing overall heat generation, and increasing power output.
[0008] Furthermore, the hairpin body of the second coil conductor includes a U-shaped hairpin, the U-shaped hairpin including two parallel legs and a head integrally 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 the legs.
[0009] Furthermore, the hairpin body of the second coil conductor includes at least two U-shaped hairpins arranged side by side in the thickness direction. The two legs of each U-shaped hairpin are bent towards the center in the width direction of the hairpin body to form the legs, and are arranged in series.
[0010] Furthermore, the hairpin body of the first coil conductor includes a U-shaped hairpin, wherein the two legs of the U-shaped hairpin are bent in opposite directions in the width direction of the hairpin body to form the legs.
[0011] Furthermore, the hairpin body of the first coil conductor includes two U-shaped hairpins arranged side by side in the thickness direction. The two legs of one U-shaped hairpin deflect in the clockwise or counterclockwise direction of the phase winding, and the two legs of the other U-shaped hairpin deflect in the counterclockwise or clockwise direction of the phase winding. The legs of the two U-shaped hairpins that deflect in opposite directions are connected in series.
[0012] Furthermore, at least one U-shaped hairpin with a leg that bends toward the center in the width direction of the hairpin body is connected in series between the two U-shaped hairpins.
[0013] Furthermore, the two sets of three-phase windings are arranged 90° apart in the circumferential direction.
[0014] Furthermore, on one set of the three-phase windings, the feet for connecting the power supply and the star point are located in the innermost and second innermost layers; on the other set of the three-phase windings, the feet for connecting the power supply and the star point are located in the outermost and second outermost layers.
[0015] A stator assembly includes a stator core and a wave-lapped winding structure as described above, the wave-lapped winding structure being mounted on the stator core.
[0016] In summary, this utility model has the advantages of reasonable structural design, reducing the types of hair clips and jumpers, and facilitating assembly. Attached Figure Description
[0017] Figure 1 This is a schematic diagram of the overall structure of Example 1.
[0018] Figure 2 for Figure 1 A schematic diagram of the two phases in the middle.
[0019] Figure 3 This is a schematic diagram of the structure of the first coil conductor and the second coil conductor.
[0020] Figure 4 and Figure 5 This is a schematic diagram of the structure of two coil loops on the same phase winding.
[0021] Figure 6 for Figure 4 and Figure 5 A schematic diagram showing the connection relationship between conductor 41 and conductor 52.
[0022] Figure 7 This is a schematic diagram showing the connection relationship between conductor 41 and conductor 52 on another set of phase windings.
[0023] Figure 8 for Figure 4 and Figure 5 A schematic diagram of the structure of the phase winding.
[0024] Figure 9 for Figure 8 A partial structural diagram.
[0025] Figure 10 This is a schematic diagram of the structure of the first coil conductor and the second coil conductor in Example 2.
[0026] Figure 11 This is a schematic diagram of the structure of the first coil conductor in Example 3.
[0027] Figure 12 This is a schematic diagram of the structure of the first coil conductor and the second coil conductor in Example 3.
[0028] Figure 13 This is a schematic diagram of the structure of the first coil conductor and the second coil conductor in Example 4. Detailed Implementation
[0029] The present invention will be further described in detail below with reference to the embodiments.
[0030] Example 1: As Figure 1 and Figure 2 As shown, a wave-wound 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 provided 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.
[0031] In this embodiment, each phase winding 2 includes two coil rings 3 arranged at adjacent magnetic pole positions. Each coil ring 3 includes P first coil conductors 4 and P second coil conductors 5 evenly distributed circumferentially, where P is the number of pole pairs. The first coil conductors 4 and the second coil conductors 5 each have a hairpin body with a pitch of Y. The hairpin body of the first coil conductor 4 has two legs that deflect in opposite directions circumferentially, and the hairpin body of the second coil conductor 5 has two legs that deflect in opposite directions. The first coil conductors 4 and the second coil conductors 5 are alternately arranged circumferentially and connected in series through the legs. At any magnetic pole position of any phase winding, among the two legs of the first coil conductor 4 and the second coil conductor 5 belonging to different coil rings, the leg of the first coil conductor 4 is recessed by one slot and deflected inward in the opposite direction to be connected in series with the other coil ring 3. The corresponding leg of the second coil conductor 5 is extended by one slot and deflected outward in the opposite direction to be connected in series with the other coil ring 3.
[0032] In this embodiment, as Figure 3 As shown, the hairpin body of the second coil conductor 5 includes a U-shaped hairpin. The U-shaped hairpin includes two parallel legs and a head integrally connected to one end of the two legs. The other ends of the two legs are bent towards the center in the width direction of the hairpin body to form the legs. The hairpin body of the first coil conductor 4 includes the U-shaped hairpin, and the two legs of the U-shaped hairpin are bent in opposite directions in the width direction of the hairpin body to form the legs.
[0033] like Figure 4 and Figure 5 As shown, the pole pair number P=4, and each coil ring 3 has 4 first coil conductors 4 and 4 second coil conductors 5. Figure 4 At the center position, the rightmost support of the first coil conductor 4 on a coil loop is recessed into a slot and then bends inward in the opposite direction to form conductor 41, with a pitch of Y-1; Figure 5At the center position, the right-hand support leg of the second coil conductor 5 on another coil loop extends outward by one slot and bends outward in the opposite direction to form conductor 51, with a pitch of Y+1. In this way, conductors 41 and 51 form a concentric structure, meaning conductor 41 is located in the middle of conductor 51. Figure 6 As shown, the structure of conductors 41 and 51 on another set of phase windings is as follows: Figure 7 As shown. At this point, the two opposing deflected legs do not interfere with each other. Conductor 41 (coil loop A) is connected to the first coil conductor 4 on the other coil loop (coil loop B); conductor 51 (coil loop B) is connected to the second coil conductor 5 on the other coil loop (coil loop A), as shown. Figures 8-9 As shown.
[0034] like Figure 1 and Figure 2 As shown, the two sets of three-phase windings are arranged 90° apart in the circumferential direction. The feet for connecting the power supply and the star point on one set of three-phase windings are located in the innermost and second innermost layers; the feet for connecting the power supply and the star point on the other set of three-phase windings are located in the outermost and second outermost layers.
[0035] In this embodiment, since each phase winding has only two coil loops at adjacent magnetic pole positions, responsible for the S and N poles respectively, by adjusting the supports of the first and second coil conductors at a magnetic pole position on the two coil loops—making the support of the first coil conductor recessed by one slot and deflected inward, and making the corresponding support of the second coil conductor expanded by one slot and deflected outward—interference between the supports is avoided. Furthermore, by directly connecting the two coil loops in series to form corresponding phase windings, the types of hairpins and jumpers are reduced, facilitating installation. In addition, the two sets of three-phase windings can achieve single-winding and dual-winding operation using the same control program, reducing the cost and debugging difficulty of the six-phase motor drive system, significantly reducing overall heat generation, and increasing power.
[0036] Example 2: As Figure 10 As shown, the main difference from Embodiment 1 is that the hairpin body of the second coil conductor 5 includes two U-shaped hairpins arranged side by side in the thickness direction. The two legs of each U-shaped hairpin are bent towards the center in the width direction of the hairpin body to form the legs, and are arranged in series.
[0037] Example 3: As Figure 11 and Figure 12As shown, the main difference from Embodiment 1 is that the hairpin body of the first coil conductor 4 includes two U-shaped hairpins arranged side by side in the thickness direction. The two legs of one U-shaped hairpin are deflected in the clockwise direction of the phase winding, and the two legs of the other U-shaped hairpin are deflected in the counterclockwise direction of the phase winding. The legs of the two U-shaped hairpins that are deflected in opposite directions are connected in series.
[0038] Example 4: Figure 13 As shown, the main difference from Embodiment 1 is that the hairpin body of the first coil conductor 4 includes three U-shaped hairpins arranged side by side in the thickness direction. The two legs of the outermost U-shaped hairpin 42 are deflected in the clockwise direction of the phase winding, the two legs of the innermost U-shaped hairpin 43 are deflected in the counterclockwise direction of the phase winding, and the two legs of the middle U-shaped hairpin 44 are deflected towards the center in the width direction of the hairpin body, and are connected in series with the legs of the innermost U-shaped hairpin 42 and the outermost U-shaped hairpin 43 respectively.
[0039] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.
Claims
1. A wave-overlapping winding structure, characterized in that, The device includes two sets of three-phase windings. Each phase winding includes two coil loops positioned at adjacent magnetic poles. Each coil loop includes P first coil conductors and P second coil conductors evenly distributed circumferentially, where P is the number of pole pairs. Both the first and second coil conductors have a hairpin body with a pitch of Y. The hairpin body of the first coil conductor has two legs that deflect in opposite directions circumferentially, and the hairpin body of the second coil conductor has two legs that deflect in opposite directions. The first and second coil conductors are alternately arranged circumferentially and connected in series through the legs. At any magnetic pole position in any phase winding, among the two legs of the first and second coil conductors belonging to different coil loops, the leg of the first coil conductor is recessed by one slot and deflected inward in the opposite direction to be connected in series with the other coil loop. The corresponding leg of the second coil conductor is extended by one slot and deflected outward in the opposite direction to be connected in series with the other coil loop.
2. The wave-overlapping winding structure as described in claim 1, characterized in that, The hairpin body of the second coil conductor includes a U-shaped hairpin, which includes two parallel legs and a head integrally connected to one end of the two legs. The other ends of the two legs are bent toward the center in the width direction of the hairpin body to form the legs.
3. The wave-stacking winding structure as described in claim 2, characterized in that, The hairpin body of the second coil conductor includes at least two U-shaped hairpins arranged side by side in the thickness direction. The two legs of each U-shaped hairpin are bent toward the center in the width direction of the hairpin body to form the legs, and are arranged in series.
4. The wave-overlapping winding structure as described in claim 2 or 3, characterized in that, The hairpin body of the first coil conductor includes a U-shaped hairpin, and the two legs of the U-shaped hairpin are bent in opposite directions in the width direction of the hairpin body to form the legs.
5. The wave-stacking winding structure as described in claim 2 or 3, characterized in that, The hairpin body of the first coil conductor includes two U-shaped hairpins arranged side by side in the thickness direction. The two legs of one U-shaped hairpin are deflected in the clockwise or counterclockwise direction of the phase winding, and the two legs of the other U-shaped hairpin are deflected in the counterclockwise or clockwise direction of the phase winding. The legs of the two U-shaped hairpins that are deflected in opposite directions are connected in series.
6. The wave-stacking winding structure as described in claim 5, characterized in that, At least one U-shaped hairpin with a leg that bends toward the center in the width direction of the hairpin body is connected in series between the two U-shaped hairpins.
7. The wave-stacking winding structure as described in claim 1, characterized in that, The two sets of three-phase windings are arranged 90° apart in the circumferential direction.
8. The wave-stacking winding structure as described in claim 1, characterized in that, On one set of the three-phase windings, the feet for connecting the power supply and the star point are located in the innermost and second innermost layers; on the other set of the three-phase windings, the feet for connecting the power supply and the star point are located in the outermost and second outermost layers.
9. A stator assembly, characterized in that, It includes a stator core and a wave-lapped winding structure as described in any one of claims 1 to 8, wherein the wave-lapped winding structure is mounted on the stator core.