A flat wire winding assembly motor stator assembly
By using a three-phase winding design and an I-type flat wire gathering structure, the problems of high production cost and difficult processing of flat wire motor stator assemblies have been solved, enabling miniaturization and efficient production of motor stator assemblies.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- NEW UNITED RAIL TRANSIT TECH
- Filing Date
- 2025-05-26
- Publication Date
- 2026-07-21
AI Technical Summary
Existing flat wire motor stator assemblies suffer from problems such as high production costs, difficulty in processing the copper busbars for the outgoing wires, and large size during the manufacturing process.
It adopts a three-phase winding design, with each phase winding including 3 branches connected in parallel. Both the starting and ending ends are set as type I flat wires, and a convergence structure is adopted. The gap between the phases of the winding is increased, reducing the types of type I flat wires and simplifying the welding process.
It reduced production costs, simplified the processing of the copper busbars, reduced the size of the motor stator assembly, and improved production efficiency.
Smart Images
Figure CN224537887U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to a flat wire winding assembly for a motor stator assembly, belonging to the field of motor technology. Background Technology
[0002] Currently, as the requirements for torque density and power density of drive motors in new energy vehicles become increasingly stringent, traditional round-wire motors are gradually failing to meet these demands. Compared to motors using round wires, flat-wire motors, at the same power output, are smaller, require less material, and are less expensive. For the same volume, flat-wire motors have higher slot fill factor and power density, better temperature performance, lower electromagnetic noise, shorter ends, and save copper. Flat-wire motor windings typically employ wave windings, allowing for the use of different pitches to meet requirements for winding layout and insulation.
[0003] For example, the patent application number 202111174785.0, entitled "A Multi-Layer Flat Wire Winding Assembly Stator Assembly and Motor," describes a multi-layer flat wire winding assembly stator assembly that includes a stator core. The starting end of the winding is positioned as the starting layer and the starting slot. The winding is wound along the circumference of the stator core at a pitch y. After one turn along the circumference of the stator core, the flat wire in the slot of the other pole group in the same layer is connected by a cross-wire method with a span k. Then, it is wound again along the circumference of the stator core at the same pitch y. Finally, the output end of the winding is located in the same layer as the starting end. However, in this scheme, the flat wires connected to the busbar or copper busbar have various wire types, requiring multiple wire types, which increases production costs and difficulty. The spacing between the flat wires connected to the busbar or copper busbar in the same layer is large, increasing the amount of copper used in the busbar and the difficulty of the processing technology. Summary of the Invention
[0004] The technical problem to be solved by this utility model is to overcome the shortcomings of the prior art and provide a flat wire winding assembly motor stator assembly, which can improve production efficiency, reduce the processing difficulty of the copper busbar, reduce the volume, and reduce the amount of copper used.
[0005] To solve the above-mentioned technical problems, the technical solution of this utility model is as follows:
[0006] A flat wire winding assembly motor stator assembly, comprising a stator core and a flat wire winding assembly;
[0007] The inner wall of the stator core has several uniformly distributed core slots along the circumferential direction, and slot insulation paper is provided inside the core slots.
[0008] The flat wire winding assembly includes a three-phase winding, each phase winding includes three branches, the three branches of any phase winding are connected in parallel, and each branch is composed of a coil, which is inserted into slotted insulating paper.
[0009] Three I-shaped flat wires are provided at the beginning and end of any phase winding, and the three I-shaped flat wires at the beginning and end of any phase winding adopt a converged structure.
[0010] Furthermore, the tail end connection of the three-phase winding is either a star connection or a delta connection.
[0011] Furthermore, one axial side of the stator core is the insertion side, and the other axial side of the stator core is the twisting side. The starting and ending ends of the three-phase windings are both located on the insertion side.
[0012] Furthermore, each of the coils has six layers, which are arranged sequentially from the outer circle of the stator core towards the center as the first layer, second layer, third layer, fourth layer, fifth layer, and sixth layer.
[0013] Furthermore, the number of slots in the iron core is 72.
[0014] Furthermore, the three-phase winding includes a U-phase winding, a V-phase winding, and a W-phase winding, and the winding structures of the U-phase winding, V-phase winding, and W-phase winding are identical.
[0015] Furthermore, the starting end of any phase winding is designated as the starting slot, containing a type I flat wire. The winding is then wound on the twisting side with a pitch of y = τ + 1, and on the insertion side with a pitch of y = τ - 1, where τ is the motor pole pitch. After the winding completes two layers of coil winding along the circumference of the stator core, it is then wound across layers with a pitch of y = k (k = 6 or k = 9). The winding is then wound on the twisting side with a pitch of... The winding is y = τ + 1, and then wound on the insertion side according to the pitch y = τ - 1; and so on, until all layers have completed one turn of winding along the circumference of the stator core. Then, the flat wire in the slot of the other pole of the same layer is connected to the same layer in the same layer by the same layer cross wire according to the pitch y = τ. Then, it is wound on the twist side according to the pitch y = τ + 1, and on the insertion side according to the pitch y = τ - 1. The position of the tail end of any phase winding is the ending slot, and the ending slot contains type I flat wire.
[0016] By adopting the above technical solution, the type I flat wires at the starting and ending ends of the winding of this utility model are evenly and continuously distributed in the same layer. Only three types of type I flat wires are needed to connect with the outgoing copper busbar, thus reducing the types of type I flat wires and lowering production costs. The three type I flat wires are clustered together, increasing the gap between phases of the winding to meet the discharge spacing requirements, eliminating the need for additional insulation treatment and further reducing costs. At the same time, the continuous and even distribution of the welding points between the outgoing copper busbar and the type I flat wires reduces the welding difficulty of the outgoing copper busbar, reduces its size, and lowers production costs. In addition, the twisting form and size are consistent in the same layer on the twisting head side, so the welding form and insulation treatment processes are the same when welding every two layers, which facilitates improved production efficiency. Attached Figure Description
[0017] Figure 1 This is a front view of the flat wire winding assembly motor stator assembly of this utility model;
[0018] Figure 2 This is a schematic diagram of the stator core structure of this utility model;
[0019] Figure 3 This is a schematic diagram of the unfolded structure of the flat wire winding assembly of this utility model;
[0020] Figure 4 This is a schematic diagram of the structure of a U-shaped flat wire according to the present invention;
[0021] Figure 5 This is a schematic diagram of another U-shaped flat wire according to the present invention;
[0022] Figure 6 This is a schematic diagram of the structure of the Type I flat wire of this utility model;
[0023] Figure 7 This is a schematic diagram of the prior art structure of the present invention, showing the evenly distributed flat wires. Detailed Implementation
[0024] To make the contents of this utility model easier to understand, the present utility model will be further described in detail below with reference to specific embodiments and accompanying drawings.
[0025] like Figure 1 , 2 As shown in Figures 1 and 3, this embodiment provides a flat wire winding assembly for a motor stator, which includes a stator core 1 and a flat wire winding assembly 2.
[0026] The inner wall of the stator core 1 has 72 uniformly distributed core slots 11 along the circumferential direction, and each core slot 11 is provided with slot insulation paper.
[0027] The flat wire winding assembly 2 includes three-phase windings, with the ends of the three-phase windings connected in a star or delta configuration; in this embodiment, a star connection is preferred. If a delta connection is used, the three-phase windings can be connected at the ends via a busbar. Each phase winding includes three branches, which are connected in parallel. Compared to two branches in parallel, three branches in parallel can provide higher current and voltage, thus providing stronger driving capability and higher output power. The three-branch parallel connection further disperses current and voltage, improving system stability and reliability.
[0028] Each branch circuit consists of a coil, which is inserted into the slotted insulating paper. Each coil has 6 layers.
[0029] One axial side of the stator core 1 is the insertion side 12, and the other axial side of the stator core 1 is the torsion side 13. The starting and ending ends of the three-phase windings are both located on the insertion side 12. The three-phase windings are inserted into the core slots 11 of the stator core 1 from the insertion side 12, and then bent and welded on the torsion side 13 to achieve circuit connection.
[0030] like Figures 1-6 As shown, the three-phase windings in this embodiment are the U-phase winding, the V-phase winding, and the W-phase winding, and the winding structures of the U-phase winding, the V-phase winding, and the W-phase winding are the same.
[0031] The starting position of any phase winding is set as the starting slot, which contains type I flat wire 3. The winding is then wound on the toggle side 13 with a pitch of y = τ + 1 and on the insertion side 12 with a pitch of y = τ - 1, where τ is the motor pole pitch (based on the number of slots). After the winding completes two layers of coil winding along the circumference of the stator core 1, it is then moved to the next layer in a cross-layer manner with a pitch of y = k (k = 6 or k = 9). The winding is then wound on the toggle side 13 with a pitch of y = τ + 1 and on the insertion side 12 with a pitch of y = τ - 1. This process continues until all layers have completed one turn of winding along the circumference of the stator core 1. Then, the flat wire in the slot of the other pole of the same layer is connected in a cross-layer manner with a pitch of y = τ. The winding is then wound on the toggle side 13 with a pitch of y = τ + 1 and on the insertion side 12 with a pitch of y = τ - 1. The position of the tail end of any phase winding is set as the ending slot, and the ending slot contains type I flat wire 3.
[0032] Taking the U-phase winding as an example, the U-phase winding includes three branches: U1, U2, and U3, which are connected in parallel. The core slots 11 of the stator core 1 are numbered from 1 to 72 clockwise. Six layers of flat wire can be placed inside the slot insulation paper. The core slots 11, from the outer circle of the stator core to the center, are arranged in the following order: first layer, second layer, third layer, fourth layer, fifth layer, and sixth layer.
[0033] The winding structure of the U-phase winding is as follows:
[0034] The coil of branch U1 enters from the sixth layer of core slot 1, and then sequentially passes through the fifth layer of core slots 11, 19, 29, 37, 47, 55, and 65, the fourth layer of core slot 2, the third layer of core slot 12, 20, 30, 38, 48, 56, and 66, the second layer of core slot 3, the first layer of core slot 13, the second layer of core slot 21, the first layer of core slot 31, the second layer of core slot 39, the first layer of core slot 49, the second layer of core slot 57, and core slot 67. The first layer of core slot 4, the second layer of core slot 66, the first layer of core slot 58, the second layer of core slot 48, the first layer of core slot 40, the second layer of core slot 30, the first layer of core slot 22, the second layer of core slot 12, the third layer of core slot 3, the fourth layer of core slot 65, the third layer of core slot 57, the fourth layer of core slot 47, the third layer of core slot 39, the fourth layer of core slot 29, the third layer of core slot 21, the fourth layer of core slot 11, the fifth layer of core slot 2, the sixth layer of core slot 64, the fifth layer of core slot 56, the sixth layer of core slot 46, the fifth layer of core slot 38, the sixth layer of core slot 28, the fifth layer of core slot 20, and the sixth layer of core slot 10. Among them, the sixth layer of core slot 1 and the sixth layer of core slot 10 both contain type I flat wire 3, while the remaining wire types are type U flat wire 4, such as... Figure 4 , 5 As shown, the U-shaped flat wire 4 has two shapes. The shape of the lower end of the U-shaped flat wire 4 is uniformly twisted out on the twisting side 13 according to the needs of the wiring direction.
[0035] The coil of branch U2 enters from the sixth layer of core slot 2, and then passes sequentially through the fifth layer of core slots 12, 20, 30, 38, 48, 56, and 66, the fourth layer of core slot 3, the third layer of core slot 13, the fourth layer of core slot 21, the third layer of core slot 31, the fourth layer of core slot 39, the third layer of core slot 49, the fourth layer of core slot 57, the third layer of core slot 67, the second layer of core slot 1, the first layer of core slot 11, the second layer of core slot 19, the first layer of core slot 29, the second layer of core slot 37, the first layer of core slot 47, the second layer of core slot 55, and core slot 65. The first layer of core slot 2, the second layer of core slot 64, the first layer of core slot 56, the second layer of core slot 46, the first layer of core slot 38, the second layer of core slot 28, the first layer of core slot 20, the second layer of core slot 10, the third layer of core slot 4, the fourth layer of core slot 66, the third layer of core slot 58, the fourth layer of core slot 48, the third layer of core slot 40, the fourth layer of core slot 30, the third layer of core slot 22, the fourth layer of core slot 12, the fifth layer of core slot 3, the sixth layer of core slot 65, the fifth layer of core slot 57, the sixth layer of core slot 47, the fifth layer of core slot 39, the sixth layer of core slot 29, the fifth layer of core slot 21, and the sixth layer of core slot 11. Among them, the sixth layer of core slot 2 and the sixth layer of core slot 11 both contain type I flat wire 3, while the remaining wire types are type U flat wire 4, such as... Figure 4 , 5 As shown, the U-shaped flat wire 4 has two shapes. The shape of the lower end of the U-shaped flat wire 4 is uniformly twisted out on the twisting side 13 according to the needs of the wiring direction.
[0036] The coil of branch U3 enters from the sixth layer of core slot 3, and then sequentially passes through the fifth layer of core slot 13, the sixth layer of core slot 21, the fifth layer of core slot 31, the sixth layer of core slot 39, the fifth layer of core slot 49, the sixth layer of core slot 57, the first layer of core slot 6, the first layer of core slot 3, the second layer of core slot 65, the first layer of core slot 57, the second layer of core slot 47, the first layer of core slot 39, the second layer of core slot 29, the first layer of core slot 21, and core slot 11. The second layer, the third layer of core slot 2, the fourth layer of core slot 64, the third layer of core slot 56, the fourth layer of core slot 46, the third layer of core slot 38, the fourth layer of core slot 28, the third layer of core slot 20, the fourth layer of core slot 10, the fifth layer of core slot 4, the sixth layer of core slot 66, the fifth layer of core slot 58, the sixth layer of core slot 48, the fifth layer of core slot 40, the sixth layer of core slot 30, the fifth layer of core slot 22, and the sixth layer of core slot 12. Among these, the sixth layers of core slot 3 and core slot 12 both contain type I flat wire 3, the middle wire is type U flat wire 4, and the remaining wires are type U flat wire 4, such as... Figure 4 , 5 As shown, the U-shaped flat wire 4 has two shapes. The shape of the lower end of the U-shaped flat wire 4 is uniformly twisted out on the twisting side 13 according to the needs of the wiring direction.
[0037] like Figure 1 As shown, in this embodiment, three I-shaped flat wires 3 are respectively provided at the starting and ending ends of any phase winding. The three I-shaped flat wires 3 at the starting and ending ends all adopt a converged structure. Figure 1 In the attached diagram, reference numeral 211 indicates the starting end of the U-phase winding, and reference numeral 212 indicates the ending end of the U-phase winding; reference numeral 221 indicates the starting end of the V-phase winding, and reference numeral 222 indicates the ending end of the V-phase winding; reference numeral 231 indicates the starting end of the W-phase winding, and reference numeral 232 indicates the ending end of the W-phase winding. For example... Figure 7 As shown, the existing technology designs the I-type flat wires of the three branches of each phase winding to be of the same specification, resulting in a structure 5 with a total of 18 I-type flat wires evenly distributed. The existing technology has the following disadvantages: the electrical gap between phases is relatively short, making it prone to discharge breakdown, requiring additional insulation treatment, and increasing manufacturing costs. However, in this embodiment, the three I-type flat wires 3 at the beginning and end of each phase winding are designed to be clustered together, increasing the gap between phases and meeting the discharge distance requirements. This eliminates the need for additional insulation treatment, thereby reducing costs.
[0038] The specific embodiments described above further illustrate the technical problems, technical solutions, and beneficial effects of this utility model. It should be understood that the above descriptions are merely specific embodiments of this utility model and are not intended to limit this utility model. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this utility model should be included within the protection scope of this utility model.
Claims
1. A flat wire winding assembly for a motor stator, characterized in that: It includes a stator core (1) and a flat wire winding assembly (2); The inner wall of the stator core (1) has several uniformly distributed core slots (11) along the circumferential direction, and the core slots (11) are provided with slot insulation paper. The flat wire winding assembly (2) includes a three-phase winding, each phase winding includes 3 branches, the 3 branches of any phase winding are connected in parallel, each branch is composed of a coil, and the coil is inserted into the slot insulation paper. Three type I flat wires (3) are provided at the beginning and end of any phase winding, and the three type I flat wires (3) at the beginning and end of any phase winding adopt a clustering structure.
2. The flat wire winding assembly motor stator assembly according to claim 1, characterized in that: The tail end of the three-phase winding is connected in a star or delta configuration.
3. The flat wire winding assembly motor stator assembly according to claim 1, characterized in that: One axial side of the stator core (1) is the insertion side (12), and the other axial side of the stator core (1) is the twisting side (13). The starting end and the ending end of the three-phase winding are both located on the insertion side (12).
4. The flat wire winding assembly motor stator assembly according to claim 1, characterized in that: Each of the coils has six layers, which are arranged sequentially from the outer circle of the stator core (1) towards the center as the first, second, third, fourth, fifth, and sixth layers.
5. The flat wire winding assembly motor stator assembly according to claim 3, characterized in that: The number of slots in the iron core groove (11) is 72.
6. The flat wire winding assembly motor stator assembly according to claim 5, characterized in that: The three-phase winding includes a U-phase winding, a V-phase winding, and a W-phase winding, and the winding structures of the U-phase winding, V-phase winding, and W-phase winding are the same.
7. The flat wire winding assembly motor stator assembly according to claim 6, characterized in that: The starting end of any phase winding is designated as the starting slot, which contains a type I flat wire (3). The winding is then rotated on the twisting side (13) according to the pitch. Winding, on the plug side (12) according to the pitch Winding, among which The motor pole pitch; after the winding completes the winding of two layers of coils along the circumferential direction of the stator core (1), it then crosses to the next layer in a cross-layer manner according to the pitch y=k, where k=6 or k=9, and then the winding is turned on the twisting side (13) according to the pitch Winding, on the plug side (12) according to the pitch Winding; and so on, until all layers have been wound around the circumference of the stator core (1), and then the same layer is crossed over according to the pitch. Connect the flat wire in the slot to the other pole of the same layer, and then, similarly, on the twist side (13), according to the pitch. Winding, on the insertion side (12) according to the pitch Winding; the end of any phase of the winding is the end slot, and the end slot contains a type I flat wire (3).