Winding for flat wire motor and flat wire motor
By designing a winding structure with a specific span connection in a flat wire motor, the problems of winding lead dispersion and phase difference between branches are solved, achieving low loss and high efficiency in processing.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- SHANGHAI EVK E-MOTOR TECH CO LTD
- Filing Date
- 2025-04-21
- Publication Date
- 2026-05-19
AI Technical Summary
Existing flat wire motor windings suffer from problems such as high processing costs and low efficiency due to dispersed output wires, as well as severe AC losses caused by phase differences and uneven inductance between branches.
By setting stator slots circumferentially at both ends of the iron core, flat wire conductors are wound in each stator slot, and specific spans are connected at the hairpin end and the welding end to form a lapped structure. The outlet of each branch is located in the adjacent stator slot, avoiding conductor crossing or misalignment, realizing centralized outlet and reducing busbar welding.
It effectively reduces AC losses, lowers process costs, and improves processing efficiency.
Smart Images
Figure CN224264728U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of flat wire motor technology, specifically to a winding for a flat wire motor and a flat wire motor. Background Technology
[0002] Flat wire motors, with their advantages of high power density and low electromagnetic noise, are gradually gaining an important place in various driving scenarios. The flat copper wire winding is the core component of a flat wire motor, used to generate a magnetic field and produce torque through its interaction with the rotor, thereby driving the rotor to rotate.
[0003] However, the inventors discovered that, due to defects in the flat copper wire windings, current flat wire motors still have the following drawbacks in practical applications:
[0004] First, the windings in existing flat-wire motors typically consist of multiple parallel branches. The rectangular conductors in each branch winding often exhibit positional differences in layer or phase, leading to significant phase differences or inductance unevenness between the branch windings, resulting in circulating currents. These circulating currents cause significant AC losses during motor operation, particularly at higher speeds, where AC losses at high frequencies become more pronounced. Furthermore, the dispersed distribution of winding leads necessitates the use of busbars during wiring, resulting in high costs and low efficiency in the overall winding manufacturing process. Utility Model Content
[0005] The purpose of this utility model is to provide a winding for a flat wire motor and a flat wire motor to solve the technical problems of high processing cost and low efficiency caused by the dispersed output wires of existing motor windings, and severe AC loss caused by phase and layer difference between winding branches.
[0006] To achieve the above objectives, the present invention proposes the following technical solution:
[0007] In the first aspect, this technical solution provides a winding for a flat wire motor, comprising: an iron core and a flat wire conductor;
[0008] At both ends of the iron core, the same number of stator slots are spaced apart circumferentially; the flat wire conductors are wound in each stator slot, and the same number of layers of flat wire conductors are wound in any stator slot, and each layer of flat wire conductors forms a hairpin end in the stator slot at one end of the iron core and a welding end in the stator slot at the other end of the iron core.
[0009] The whole pitch number is defined as the ratio of the number of stator slots at any end of the iron core to the number of winding poles; the first long pitch number is the whole pitch number plus 1; the first short pitch number is the whole pitch number minus 2; the layer closest to the iron core shaft is defined as the outermost layer;
[0010] At the card-issuing end, the innermost flat wire conductor in any stator slot is connected to the innermost flat wire conductor in a stator slot spaced by a first long distance, or connected to the innermost flat wire conductor in a stator slot spaced by a first short distance; the outermost flat wire conductor in any stator slot is connected to the outermost flat wire conductor in a stator slot spaced by a first long distance, or connected to the outermost flat wire conductor in a stator slot spaced by a first short distance; the flat wire conductor in any middle layer of any stator slot is connected to the adjacent outermost flat wire conductor in a stator slot spaced by a whole distance.
[0011] At the welding end, a flat wire conductor in any layer of any stator slot is connected to a flat wire conductor in an adjacent outer layer of stator slots spaced a full distance apart from it.
[0012] In any phase, the outgoing terminals of each branch are located in adjacent stator slots.
[0013] Furthermore, the card issuing end is the cable output end.
[0014] Furthermore, in any phase, each branch line outlet occupies the innermost and outermost layers of the adjacent stator slots.
[0015] Furthermore, the output terminals of each phase are evenly spaced.
[0016] Furthermore, each winding unit includes at least one of the following small units: small unit E, small unit F, small unit G1, and small unit G2.
[0017] Among them, the number of spans within small unit E is the number of integer spans;
[0018] Within a small unit F, the span count of the innermost and outermost layers is the first long span count, and the span count of any intermediate layer is the integer span count.
[0019] Within a small unit G1, the span of the innermost layer is the first long span, the span of the outermost layer is the first short span, and the span of any intermediate layer is the whole span.
[0020] Within a small unit G2, the span of the innermost layer is the first shortest span, the span of the outermost layer is the first long span, and the span of any intermediate layer is the whole span.
[0021] Furthermore, when there are 6 branch windings,
[0022] Each winding unit in the first and fourth branches consists of two small units E and one small unit F, respectively.
[0023] Each winding unit in the second and fifth branches consists of two small units E and one small unit G2, respectively.
[0024] Each winding unit in the third and sixth branches consists of two small units E and one small unit G1, respectively.
[0025] Furthermore, the number of stator slots at any end is 54, and the number of flat wire conductors in any stator slot is 8 layers.
[0026] Furthermore, the number of phases is 3, and the number of branches within any phase is 6.
[0027] Secondly, this technical solution provides a flat wire motor, including the aforementioned winding.
[0028] Beneficial effects:
[0029] This technical solution provides a winding for a flat wire motor to solve the technical defects of existing motor windings, such as high processing cost, low efficiency, and severe AC loss caused by dispersed lead wires.
[0030] Specifically, this includes: iron core and flat wire conductor;
[0031] At both ends of the iron core, the same number of stator slots are spaced apart circumferentially; the flat wire conductors are wound in each stator slot, and the same number of layers of flat wire conductors are wound in any stator slot, and each layer of flat wire conductors forms a hairpin end in the stator slot at one end of the iron core and a welding end in the stator slot at the other end of the iron core.
[0032] At the issuing end, the innermost flat wire conductor in any stator slot is connected to the innermost flat wire conductor in several stator slots spaced a first long distance apart, or connected to the innermost flat wire conductor in several stator slots spaced a first short distance apart; the outermost flat wire conductor in any stator slot is connected to the outermost flat wire conductor in several stator slots spaced a first long distance apart, or connected to the outermost flat wire conductor in several stator slots spaced a first short distance apart; and any flat wire conductor in any middle layer of any stator slot is connected to the adjacent outer flat wire conductor in several stator slots spaced a whole distance apart. At the welding end, any flat wire conductor in any stator slot is connected to the adjacent outer flat wire conductor in several stator slots spaced a whole distance apart. In this case, the flat wire conductors of each branch directly form a lapped structure, thereby avoiding phase difference or inductance unevenness caused by conductor crossing or misalignment, effectively reducing AC loss. Simultaneously, through the above winding arrangement, the output ends of each branch in any phase are located in adjacent stator slots. This allows for centralized output of each branch line, eliminating the need for welding using a busbar, thus effectively reducing process costs and improving process efficiency.
[0033] It should be understood that all combinations of the foregoing concepts and the additional concepts described in more detail below can be considered as part of the utility model subject matter of this disclosure, provided that such concepts do not contradict each other.
[0034] The foregoing and other aspects, embodiments, and features of the present invention will be more fully understood from the following description in conjunction with the accompanying drawings. Other additional aspects of the present invention, such as features and / or beneficial effects of exemplary embodiments, will become apparent from the following description or may be learned through practice of specific embodiments according to the teachings of the present invention. Attached Figure Description
[0035] The accompanying drawings are not intended to be drawn to scale. In the drawings, each identical or nearly identical component shown in the various figures may be denoted by the same reference numeral. For clarity, not every component is labeled in each figure. Embodiments of various aspects of the present invention will now be described by way of example and with reference to the accompanying drawings, wherein:
[0036] Figure 1 This is a schematic diagram of the winding structure described in this embodiment;
[0037] Figure 2 This is a schematic diagram of the winding path of small unit E in the embodiment;
[0038] Figure 3 This is a schematic diagram of the winding path of the small unit F in the embodiment;
[0039] Figure 4 This is a schematic diagram of the winding path of the small unit G1 in the embodiment;
[0040] Figure 5 This is a schematic diagram of the winding path of the small unit G2 in the embodiment;
[0041] Figure 6 This is a two-dimensional winding diagram of the first branch, the second branch, and the third branch in the embodiment. Detailed Implementation
[0042] 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, not all, of the embodiments of this utility model. All other embodiments obtained by those skilled in the art based on the described embodiments of this utility model without creative effort are within the scope of protection of this utility model. Unless otherwise defined, the technical or scientific terms used herein should have the ordinary meaning understood by those skilled in the art to which this utility model pertains.
[0043] The terms "first," "second," and similar words used in this utility model patent application specification and claims do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Similarly, unless the context clearly indicates otherwise, the singular forms of "an," "a," or "the," etc., do not indicate a quantity limitation, but rather indicate the presence of at least one. Terms such as "comprising" or "including" indicate that the element or object preceding "comprising" encompasses the features, integrals, steps, operations, elements, and / or components listed following "comprising" or "including," and do not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components, and / or collections thereof. Terms such as "upper," "lower," "left," and "right" are used only to indicate relative positional relationships; when the absolute position of the described object changes, the relative positional relationship may also change accordingly.
[0044] Existing flat-wire motors still suffer from the following manufacturing and application defects. Firstly, regarding manufacturing defects, existing flat-wire motors often have scattered wires, requiring busbar welding, resulting in high manufacturing costs and low efficiency. Secondly, regarding application defects, phase differences and uneven inductance between branches in the winding lead to significant AC losses. Therefore, this embodiment aims to provide a winding for flat-wire motors that simultaneously solves the aforementioned technical problems.
[0045] The winding for a flat wire motor disclosed in this utility model will be further described in detail below with reference to the embodiments shown in the accompanying drawings.
[0046] Combination Figures 1-6 As shown, the winding in this embodiment includes an iron core 1 and flat wire conductors 2. At both ends of the iron core 1, the same number of stator slots 11 are spaced circumferentially. The flat wire conductors 2 are wound within each stator slot 11, and each stator slot 11 contains the same number of layers of flat wire conductors 2. Each layer of flat wire conductors 2 forms a hairpin end 22 in the stator slot 11 at one end of the iron core and a weld end 21 in the stator slot 11 at the other end of the iron core.
[0047] For ease of description, the following definitions are made: the whole pitch number is defined as the ratio of the number of stator slots at any end of the iron core to the number of winding poles; the first long pitch number is the whole pitch number plus 1; the first short pitch number is the whole pitch number minus 2.
[0048] At this time, at the card issuing end 22, the innermost flat wire conductor 2 in any stator slot 11 is connected to the innermost flat wire conductor 2 in stator slots 11 spaced apart by a first long distance, or connected to the innermost flat wire conductor 2 in stator slots 11 spaced apart by a first short distance. The outermost flat wire conductor 2 in any stator slot 11 is connected to the outermost flat wire conductor 2 in stator slots 11 spaced apart by a first long distance, or connected to the outermost flat wire conductor 2 in stator slots 11 spaced apart by a first short distance. The flat wire conductor 2 in any middle layer of any stator slot 11 is connected to the adjacent outermost flat wire conductor 2 in stator slots 11 spaced apart by a whole distance.
[0049] At the welding end 21, any layer of flat wire conductor 2 in any stator slot 11 is connected to the adjacent outer layer of flat wire conductor 2 in several stator slots 11 spaced apart.
[0050] In practical implementation, the flat conductors of each branch will directly form a lapped structure, thereby avoiding phase difference or inductance unevenness caused by crossover or misalignment between conductors, and effectively reducing AC loss.
[0051] Meanwhile, the outgoing terminals 23 of each branch in any phase are located within adjacent stator slots 11. This achieves centralized outgoing of each branch, eliminating the need for welding using a busbar, thus effectively reducing process costs and improving process efficiency. In this embodiment, the outgoing terminals 23 are located at the carding end, and the outgoing terminals of each branch in any phase occupy the innermost and outermost layers of adjacent stator slots. Furthermore, the outgoing terminals of each phase are evenly spaced.
[0052] In order to achieve the above-mentioned winding structure when viewed from the self-sponging end 22 and the welding end 21, the winding is carried out in winding units. At the same time, each winding unit includes at least one of the following small units: small unit E, small unit F, small unit G1 and small unit G2.
[0053] Specifically, the span count within small unit E is an integer; within small unit F, the span counts of the innermost and outermost layers are the first long span counts, and the span count of any intermediate layer is an integer; within small unit G1, the span count of the innermost layer is the first long span count, the span count of the outermost layer is the first short span count, and the span count of any intermediate layer is an integer; within small unit G2, the span count of the innermost layer is the first short span count, the span count of the outermost layer is the first long span count, and the span count of any intermediate layer is an integer.
[0054] As a specific implementation method, the winding in this embodiment is: 54 slots, 3 phases, 6 poles, 6 branches, and a total of 8 layers of flat wire conductors.
[0055] At this time, the specific winding path of a certain small unit E is: Z1(1)→Z2(10)→Z3(1)→Z4(10)→Z5(1)→Z6(10)→Z7(1)→Z8(10).
[0056] The specific winding path of a certain small unit F is: Z8(10)→Z8(20)→Z7(11)→Z6(20)→Z5(11)→Z4(20)→Z3(11)→Z2(20)→Z1(11)→Z1(21).
[0057] The specific winding path of a certain small unit G1 is: Z8(12)→Z8(19)→Z7(10)→Z6(19)→Z5(10)→Z4(19)→Z3(10)→Z2(19)→Z1(10)→Z1(20).
[0058] The specific winding path of a certain small unit G2 is: Z8(11)→Z8(21)→Z7(12)→Z6(21)→Z5(12)→Z4(21)→Z3(12)→Z2(21)→Z1(12)→Z1(19).
[0059] In this diagram, the number after Z indicates the number of layers of flat wire conductors, and the number in parentheses indicates the stator slot number. During actual winding, all stator slots are fully wired with 8 flat wire conductors using the above winding method.
[0060] Specifically, in the six branches, each winding unit in the first and fourth branches consists of two small units E and one small unit F. Each winding unit in the second and fifth branches consists of two small units E and one small unit G2. Each winding unit in the third and sixth branches consists of two small units E and one small unit G1.
[0061] Taking the first branch as an example, the specific detour path is: Z1(1)→Z2(10)→Z3(1)→Z4(10)→Z5(1)→Z6(10)→Z7(1)→Z8(10)→Z8(20)→Z7(11)→Z6(20)→Z5(11)→Z4(20)→Z3(11)→Z2(20)→Z1(11)→Z1(21)→Z2(30)→Z3(21)→Z4(30)→Z5(21)→Z6(30)→Z7(21)→Z8(30).
[0062] The specific detour route of the second branch is: Z1(2)→Z2(11)→Z3(2)→Z4(11)→Z5(2)→Z6(11)→Z7(2)→Z8(11)→Z8(21)→Z7(12)→Z6(21)→Z5(12)→Z4(21)→Z3(12)→Z2(21)→Z1(12)→Z1(19)→Z2(28)→Z3(19)→Z4(28)→Z5(19)→Z6(28)→Z7(19)→Z8(28).
[0063] The specific detour route of the third branch is: Z1(3)→Z2(12)→Z3(3)→Z4(12)→Z5(3)→Z6(12)→Z7(3)→Z8(12)→Z8(19)→Z7(10)→Z6(19)→Z5(10)→Z4(19)→Z3(10)→Z2(19)→Z1(10)→Z1(20)→Z2(29)→Z3(20)→Z4(29)→Z5(20)→Z6(29)→Z7(20)→Z8(29).
[0064] The bypass paths of the fourth, fifth, and sixth branches can be obtained by transforming the corresponding arrays of the first, second, and sixth branches.
[0065] This embodiment also provides a flat wire motor, including the aforementioned winding. Therefore, the motor also possesses technical advantages such as low AC loss, low processing cost, and high efficiency.
[0066] Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Those skilled in the art to which this invention pertains can make various modifications and refinements without departing from the spirit and scope of the present invention. Therefore, the scope of protection of this invention shall be determined by the claims.
Claims
1. A winding for a flat wire motor, characterized in that, include: Iron core and flat wire conductor; At both ends of the iron core, the same number of stator slots are spaced apart circumferentially; the flat wire conductors are wound in each stator slot, and the same number of layers of flat wire conductors are wound in any stator slot, and each layer of flat wire conductors forms a hairpin end in the stator slot at one end of the iron core and a welding end in the stator slot at the other end of the iron core. The whole pitch number is defined as the ratio of the number of stator slots at any end of the iron core to the number of winding poles; the first long pitch number is the whole pitch number plus 1; the first short pitch number is the whole pitch number minus 2; the layer closest to the iron core shaft is defined as the outermost layer; At the card-issuing end, the innermost flat wire conductor in any stator slot is connected to the innermost flat wire conductor in a stator slot spaced by a first long distance, or connected to the innermost flat wire conductor in a stator slot spaced by a first short distance; the outermost flat wire conductor in any stator slot is connected to the outermost flat wire conductor in a stator slot spaced by a first long distance, or connected to the outermost flat wire conductor in a stator slot spaced by a first short distance; the flat wire conductor in any middle layer of any stator slot is connected to the adjacent outermost flat wire conductor in a stator slot spaced by a whole distance. At the welding end, a flat wire conductor in any layer of any stator slot is connected to a flat wire conductor in an adjacent outer layer of stator slots spaced a full distance apart from it. In any phase, the outgoing terminals of each branch are located in adjacent stator slots.
2. The winding for a flat wire motor according to claim 1, characterized in that, The card issuing end is the outgoing end.
3. The winding for a flat wire motor according to claim 1, characterized in that, Each branch line in any phase occupies the innermost and outermost layers of the adjacent stator slots.
4. The winding for a flat wire motor according to claim 1, characterized in that, The output terminals of each phase are evenly spaced.
5. The winding for a flat wire motor according to claim 1, characterized in that, Each winding unit includes at least one of the following small units: small unit E, small unit F, small unit G1, and small unit G2; Among them, the number of spans within small unit E is the number of integer spans; Within a small unit F, the span count of the innermost and outermost layers is the first long span count, and the span count of any intermediate layer is the integer span count. Within a small unit G1, the span of the innermost layer is the first long span, the span of the outermost layer is the first short span, and the span of any intermediate layer is the whole span. Within a small unit G2, the span of the innermost layer is the first shortest span, the span of the outermost layer is the first long span, and the span of any intermediate layer is the whole span.
6. The winding for a flat wire motor according to claim 5, characterized in that, When there are 6 branch windings, Each winding unit in the first and fourth branches consists of two small units E and one small unit F, respectively. Each winding unit in the second and fifth branches consists of two small units E and one small unit G2, respectively. Each winding unit in the third and sixth branches consists of two small units E and one small unit G1, respectively.
7. The winding for a flat wire motor according to claim 1, characterized in that, The number of stator slots at any end is 54, and the number of flat wire conductors in any stator slot is 8 layers.
8. The winding for a flat wire motor according to claim 1, characterized in that, The number of phases is 3, and the number of branches within any phase is 6.
9. A flat wire motor, characterized in that, Includes the winding as described in any one of claims 1 to 8.