A 96-slot 16-pole dual independent winding structure

Abstract

This utility model relates to a 96-slot, 16-pole dual independent winding structure, comprising a stator and a rotor. The stator has N stator slots. Each stator slot is divided into two parts along its centerline. A first set of windings and a second set of windings are respectively provided on each part of the stator slot. The first and second sets of windings are insulated from each other and are dual three-phase independent windings. The rotor simultaneously drives both sets of windings. The first set of windings forms the first three-phase outputs U1, V1, and W1, and the second set of windings forms the second three-phase outputs U2, V2, and W2. This 96-slot, 16-pole dual independent winding structure breaks through the traditional six-phase design by using physically isolated dual independent three-phase windings combined with optimized pole and slot distribution, achieving true current / heat distribution optimization. The 16-pole rotor simultaneously drives two sets of 8-pole windings, maximizing magnetic circuit utilization.

Description

Technical Field

[0001] This utility model relates to the field of electrical engineering technology, and in particular to a 96-slot 16-pole double independent winding structure. Background Technology

[0002] The motor windings in an electric motor serve as the input of electrical energy and play a crucial role in the overall operation of the motor. The motor windings are the copper wire groups embedded inside the motor. Currently, most axial motor windings use flat copper wires with a fixed cross-section and an insulating layer. These wires are then wound vertically to create several single copper wire winding units before being inserted into the motor's iron core.

[0003] The current state of motor winding technology is as follows: High-power motors (such as those for industrial drives, electric vehicles, and ship propulsion) primarily employ the following solutions:

[0004] (1) Traditional three-phase motor (mainstream solution)

[0005] Structure: A single set of three-phase windings (e.g., 96 slots, 16 poles) is driven by a single high-capacity inverter.

[0006] Pain point: Current concentration: The winding current is extremely high at high power, resulting in high copper loss and severe temperature rise.

[0007] Heat dissipation challenge: Heat is concentrated in a single winding, requiring a complex cooling system (such as oil cooling).

[0008] Inverter under high pressure: requires high-current IGBT modules, resulting in high cost and significant switching losses.

[0009] (2) Multiphase motors (such as six-phase or nine-phase motors)

[0010] Structure: Single set of multi-phase windings (such as six-phase double Y-shift 30°), which reduces harmonics and improves fault tolerance by increasing the number of phases.

[0011] Pain points: Complex control: requires multi-phase modulation algorithms (such as six-phase SVPWM), which is difficult to develop; Limited power density: the current is still concentrated in the same magnetic circuit, and the heat dissipation problem has not been fundamentally solved.

[0012] High cost: Requires multi-channel inverters, increasing the number of components.

[0013] (3) Parallel winding design

[0014] Structure: A single winding shunts the current through parallel branches (such as a two-way parallel three-phase circuit).

[0015] Pain point: Circulating current risk: Uneven current due to impedance imbalance leads to decreased efficiency. Utility Model Content

[0016] Therefore, the technical problem to be solved by this utility model is to overcome the three major problems of current concentration, heat dissipation difficulty, and control complexity in the existing technology of high-power motors.

[0017] To address the aforementioned technical problems, this utility model provides a 96-slot, 16-pole dual independent winding structure, comprising a stator and a rotor. The stator has N stator slots. Each stator slot is divided into two parts along its centerline, and a first set of windings and a second set of windings are respectively provided on each part. The first and second sets of windings are insulated from each other and are dual three-phase independent windings. The rotor simultaneously drives both sets of windings. The first set of windings forms a first three-phase output U1, V1, and W1, and the second set of windings forms a second three-phase output U2, V2, and W2. This utility model's 96-slot, 16-pole dual independent winding structure, through its innovative design of dual independent three-phase windings and pole / slot decomposition, provides a high-power-density, low-complexity, and high-reliability solution, filling a gap in existing technology.

[0018] In one embodiment of this utility model, the stator has 96 slots and 16 poles, the first winding and the second winding each have 8 poles, the rotor has 16 poles, and the 16-pole rotor simultaneously drives the two 8-pole first winding and the second winding.

[0019] In one embodiment of this utility model, the first group of windings occupies 1-48 slots, the second group of windings occupies 49-96 slots, both the first group of windings and the second group of windings adopt 8-pole 48-slot three-phase short-pitch windings, and the pitch of both the first group of windings and the second group of windings is 5 slots, and the neutral points of the first group of windings and the second group of windings are set independently.

[0020] In one embodiment of this utility model, an epoxy resin isolation layer is provided between the windings of the first group of windings and the second group of windings.

[0021] In one embodiment of this utility model, the stator slot is provided with double-layer polyimide insulating paper.

[0022] In one embodiment of this utility model, the first set of windings and the second set of windings adopt double-layer concentric winding.

[0023] In one embodiment of this utility model, both the first group of windings and the second group of windings have 12 coils.

[0024] In one embodiment of this utility model, the coil distribution of the first group of windings is as follows: the input and output ends of the first coil have 1 and 7 slots respectively; the input and output ends of the second coil have 5 and 11 slots respectively; the input and output ends of the third coil have 9 and 15 slots respectively; the input and output ends of the fourth coil have 13 and 19 slots respectively; the input and output ends of the fifth coil have 17 and 23 slots respectively; the input and output ends of the sixth coil have 21 and 27 slots respectively; the input and output ends of the seventh coil have 25 and 31 slots respectively; the input and output ends of the eighth coil have 29 and 35 slots respectively; the input and output ends of the ninth coil have 33 and 39 slots respectively; the input and output ends of the tenth coil have 37 and 43 slots respectively; the input and output ends of the eleventh coil have 41 and 47 slots respectively; and the input and output ends of the twelfth coil have 45 and 51 slots respectively.

[0025] In one embodiment of this utility model, the coil distribution of the second group of windings is as follows: the input and output ends of the first coil have 49 and 55 slots respectively; the input and output ends of the second coil have 53 and 59 slots respectively; the input and output ends of the third coil have 57 and 63 slots respectively; the input and output ends of the fourth coil have 61 and 67 slots respectively; the input and output ends of the fifth coil have 65 and 71 slots respectively; the input and output ends of the sixth coil have 69 and 75 slots respectively; the input and output ends of the seventh coil have 73 and 79 slots respectively; the input and output ends of the eighth coil have 77 and 83 slots respectively; the input and output ends of the ninth coil have 81 and 87 slots respectively; the input and output ends of the tenth coil have 85 and 91 slots respectively; the input and output ends of the eleventh coil have 89 and 95 slots respectively; and the input and output ends of the twelfth coil have 93 and 3 slots respectively.

[0026] In one embodiment of this utility model, the rotor is arranged in an array of embedded magnets.

[0027] Compared with the prior art, the above-mentioned technical solution of this utility model has the following beneficial effects:

[0028] The 96-slot, 16-pole dual independent winding structure of this invention breaks through the traditional six-phase design by combining physically isolated dual independent three-phase windings with optimized pole and slot distribution, achieving true current / heat distribution optimization. The 16-pole rotor simultaneously drives two sets of 8-pole windings, maximizing magnetic circuit utilization. It achieves the following performance:

[0029] (1) Increased power density: The total current capacity is doubled in the same volume (compared to a single three-phase winding).

[0030] (2) Reduced losses: Copper losses are reduced by about 30% (due to the shortened current path and weakened skin effect).

[0031] (3) Heat dissipation optimization: heat source is dispersed, and peak temperature rise is reduced by 15%~20%;

[0032] (4) Reliability: When a single group fails, the other group can operate under short-term overload (derating mode). The number of slots per pole per phase is 2, which can be expanded for use. Attached Figure Description

[0033] To make the content 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, wherein:

[0034] Figure 1 This is a winding development diagram of the 96-slot 16-pole double independent winding structure in a preferred embodiment of this utility model;

[0035] Figure 2 An analysis of the 96-slot, 16-pole double independent winding structure in the preferred embodiment of this utility model. Figure 1 ;

[0036] Figure 3 An analysis of the 96-slot, 16-pole double independent winding structure in the preferred embodiment of this utility model. Figure 2 ;

[0037] Figure 4 An analysis of the 96-slot, 16-pole double independent winding structure in the preferred embodiment of this utility model. Figure 3 ;

[0038] Figure 5 This is a circuit connection diagram of the 96-slot 16-pole double independent winding structure in a preferred embodiment of this utility model;

[0039] Figure 6 This is a schematic diagram of the stator structure in a preferred embodiment of the present invention;

[0040] Figure 7 This is a schematic diagram of the stator and winding structure in a preferred embodiment of the present invention;

[0041] Figure 8 This table compares the performance of the 96-slot 16-pole double independent winding structure with that of a single-phase or three-phase structure in the preferred embodiment of this utility model. Detailed Implementation

[0042] The present invention will be further described below with reference to the accompanying drawings and specific embodiments, so that those skilled in the art can better understand and implement the present invention. However, the embodiments are not intended to limit the present invention.

[0043] Reference Figure 1-7As shown, the 96-slot, 16-pole dual independent winding structure of this utility model includes: a stator and a rotor. The stator has stator slots, and the number of stator slots is N. The stator slots are divided into two parts along the center line of the stator. A first set of windings and a second set of windings are respectively provided on the two parts of the stator slots. The first set of windings and the second set of windings are insulated from each other. The first set of windings and the second set of windings are dual three-phase independent windings. The rotor drives the first set of windings and the second set of windings simultaneously. The first set of windings forms a first three-phase output U1, V1 and W1, and the second set of windings forms a second three-phase output U2, V2 and W2.

[0044] The stator is grouped as follows: the stator has 96 slots and 16 poles. The first and second winding groups each have 8 poles. The rotor has 16 poles, simultaneously driving two sets of 8-pole first and second winding groups. That is, the 96 slots are divided into two groups, with each group occupying 48 slots. Specifically, the first winding group occupies 1-48 slots, and the second winding group occupies 49-96 slots. Both the first and second winding groups use 8-pole, 48-slot three-phase short-pitch windings, and the pitch of both groups is 5 slots. The neutral points of the first and second winding groups are independently set, meaning there is no shared neutral point, which completely avoids circulating current.

[0045] In terms of insulation design, an epoxy resin insulating layer with a withstand voltage of ≥3kV is provided between the first and second windings. The stator slots are lined with double-layer polyimide insulating paper.

[0046] In this invention, the first and second windings employ double-layer concentric winding. Furthermore, both the first and second windings consist of 12 coils. The coil distribution of the first group of windings is as follows: the input and output ends of the first coil are 1 and 7 slots respectively; the input and output ends of the second coil are 5 and 11 slots respectively; the input and output ends of the third coil are 9 and 15 slots respectively; the input and output ends of the fourth coil are 13 and 19 slots respectively; the input and output ends of the fifth coil are 17 and 23 slots respectively; the input and output ends of the sixth coil are 21 and 27 slots respectively; the input and output ends of the seventh coil are 25 and 31 slots respectively; the input and output ends of the eighth coil are 29 and 35 slots respectively; the input and output ends of the ninth coil are 33 and 39 slots respectively; the input and output ends of the tenth coil are 37 and 43 slots respectively; the input and output ends of the eleventh coil are 41 and 47 slots respectively; and the input and output ends of the twelfth coil are 45 and 51 slots respectively. The coil distribution of the second winding group is as follows: the input and output ends of the first coil are 49 and 55 respectively; the input and output ends of the second coil are 53 and 59 respectively; the input and output ends of the third coil are 57 and 63 respectively; the input and output ends of the fourth coil are 61 and 67 respectively; the input and output ends of the fifth coil are 65 and 71 respectively; the input and output ends of the sixth coil are 69 and 75 respectively; the input and output ends of the seventh coil are 73 and 79 respectively; the input and output ends of the eighth coil are 77 and 83 respectively; the input and output ends of the ninth coil are 81 and 87 respectively; the input and output ends of the tenth coil are 85 and 91 respectively; the input and output ends of the eleventh coil are 89 and 95 respectively; and the input and output ends of the twelfth coil are 93 and 3 respectively.

[0047] The rotor's adaptation design is as follows:

[0048] 16-pole permanent magnet arrangement: The magnetic field is optimized by using an embedded magnet array; the pole arc coefficient is 0.82 (to balance torque and cogging effect).

[0049] Magnetic circuit decoupling: The stator core uses segmented silicon steel sheets (each winding corresponds to an independent magnetic circuit region). The rotor is equipped with magnetic barrier slots (to reduce magnetic coupling between the two windings).

[0050] Magnetic circuit optimization: The dual magnetic circuits are designed in parallel, and the two sets of winding magnetic circuits are physically separated by the stator magnetic isolation bridge (width ≥ 2mm); the rotor magnetic pole center line is offset from the winding center line by a mechanical angle of 5° (to reduce mutual interference).

[0051] Leakage magnetic field control: The thickness of the stator yoke is increased by 15% (to reduce magnetic saturation), and an asymmetric air gap is adopted (0.8mm on Group A side and 1.0mm on Group B side).

[0052] I. Theoretical Comparison and Formula Derivation of Dual Three-Phase Winding Systems vs. Single Three-Phase Systems:

[0053] 1. Derivation of the electromagnetic torque formula

[0054] Basic torque formula: for permanent magnet synchronous motors (PMSM).

[0055] The electromagnetic torque Te can be expressed as:

[0056] Simplified analysis (assuming Id=0 control):

[0057] Key parameter comparison:

[0058]

[0059] Magnetic flux linkage:

[0060] Because the number of turns is reduced (20→16), the flux linkage of a single winding decreases to 16 / 20 = 0.8 times the original value. However, the total ampere-turns after the two windings are connected in parallel are: 1040A * 16 = 16640A.

[0061] Original system: 850A * 20 = 17000

[0062] The total ampere-turns remain basically the same: 16640 / 17000 ≈ 0.979 times.

[0063] Torque verification:

[0064] Single-phase and three-phase systems: Te1 ∝ 850 * 20 = 17000

[0065] Dual three-phase system: Te2 ∝ 1040 * 16 = 16640

[0066] Te2 / Te1≈0.979 times

[0067] Actual peak torque: 2950Nm / 3010Nm≈0.98, which meets the design requirements.

[0068] 2. Theoretical basis for power enhancement

[0069] Rated power formula: P=T*n / 9550

[0070] II. Sources of power enhancement:

[0071] 1. Enhanced current carrying capacity:

[0072] Dual-winding current distribution allows for higher total current (520A*2 vs 850A).

[0073] Reduced copper loss: lower current density and better temperature rise.

[0074] 2. Relationship between voltage and rotational speed:

[0075] The reduction in the number of turns (20→16) leads to a decrease in the back electromotive force constant ke: ke2 = ke1*16 / 20=0.8ke1

[0076] At the same speed, the required voltage is reduced, allowing for higher speed operation (extending the constant power range).

[0077] Calculation example:

[0078] Original system rated capacity: n1=1700rpm, T1=2000Nm, P1=356kW

[0079] New system rated capacity: n2 = 1700 rpm / 0.8 = 2125 rpm, T2 = 2000 Nm, P2 = 440 kW

[0080] 3. Matching Analysis of Electronic Control System

[0081] Current distribution:

[0082] Single electric control: 800A module drives 850Arms (insufficient margin, derating is required).

[0083] Dual electronic control: Each module independently drives 1040 Arms (actually distributed among 520 Arms modules).

[0084] Module utilization:

[0085] The original system utilization rate = 850 / 800*2 = 53% (low utilization rate, parallel losses).

[0086] New system utilization rate = 520 / 800 = 65% (high utilization rate)

[0087] 4. Comparison of Losses and Efficiency

[0088] Copper loss formula: Pcu=I²*R*3; R ∝ N² / Acu1 (Acu1 conductor cross-sectional area)

[0089] Although the number of series turns per phase in the dual-winding system is reduced by 20%, the current of the dual-winding system with the same torque is also increased by about 20%. The reduction in copper loss is mainly due to the increase in the half-turn length of the dual winding and the increase in copper fill factor, which together contribute about 3%. Therefore, even if the speed is increased, the rated torque of 2000 Nm can be maintained, and the overall efficiency is also improved to a certain extent.

[0090] 5. Summary

[0091] 1. Torque balance:

[0092] The dual-winding system compensates for the reduced number of turns (-20%) by increasing the total current (+18%), thus maintaining a basically constant torque.

[0093] 2. Power Boost:

[0094] The combined effects of increased speed (+19%), reduced half-turn length, and reduced torque copper loss (-3%) contribute to this improvement.

[0095] 3. Advantages of electronic control:

[0096] The dual-module current sharing allows it to operate within a safety margin while outputting higher current.

[0097] 4. Efficiency optimization:

[0098] Copper losses remained stable and the power increase rate was higher than the iron loss increase rate, resulting in improved system efficiency.

[0099] Final verification: 356kW / 440kW≈0.81 (actual measurement matching theory).

[0100] Obviously, the above embodiments are merely illustrative examples for clear explanation and are not intended to limit the implementation. Those skilled in the art will recognize that other variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations here. However, obvious variations or modifications derived therefrom are still within the protection scope of this invention.

Claims

1. A 96-slot, 16-pole double independent winding structure, characterized in that, include: The stator and rotor are provided. The stator has stator slots, and the number of stator slots is N. The stator slots are divided into two parts along the center line of the stator. The two parts of the stator slots are respectively provided with a first set of windings and a second set of windings. The first set of windings and the second set of windings are insulated from each other. The first set of windings and the second set of windings are independent three-phase windings. The rotor drives the first set of windings and the second set of windings simultaneously. The first set of windings forms a first three-phase output U1, V1 and W1, and the second set of windings forms a second three-phase output U2, V2 and W2.

2. The 96-slot 16-pole double independent winding structure according to claim 1, characterized in that: The stator has 96 slots and 16 poles. The first and second windings each have 8 poles. The rotor has 16 poles and simultaneously drives the two 8-pole first and second windings.

3. The 96-slot 16-pole double independent winding structure according to claim 2, characterized in that: The first group of windings occupies 1-48 slots, and the second group of windings occupies 49-96 slots. Both the first group of windings and the second group of windings adopt 8-pole 48-slot three-phase short-pitch windings, and the pitch of both the first group of windings and the second group of windings is 5 slots. The neutral points of the first group of windings and the second group of windings are set independently.

4. The 96-slot 16-pole double independent winding structure according to claim 1 or 3, characterized in that: An epoxy resin insulating layer is provided between the windings of the first group of windings and the second group of windings.

5. The 96-slot 16-pole double independent winding structure according to claim 4, characterized in that: The stator slot is provided with double-layer polyimide insulating paper.

6. The 96-slot 16-pole double independent winding structure according to claim 5, characterized in that: The first and second windings use double-layer concentric windings.

7. The 96-slot 16-pole double independent winding structure according to claim 2, characterized in that: Both the first and second windings have 12 coils.

8. The 96-slot 16-pole double independent winding structure according to claim 7, characterized in that: The coil distribution of the first group of windings is as follows: the input and output ends of the first coil are 1 and 7 slots respectively; the input and output ends of the second coil are 5 and 11 slots respectively; the input and output ends of the third coil are 9 and 15 slots respectively; the input and output ends of the fourth coil are 13 and 19 slots respectively; the input and output ends of the fifth coil are 17 and 23 slots respectively; the input and output ends of the sixth coil are 21 and 27 slots respectively; the input and output ends of the seventh coil are 25 and 31 slots respectively; the input and output ends of the eighth coil are 29 and 35 slots respectively; the input and output ends of the ninth coil are 33 and 39 slots respectively; the input and output ends of the tenth coil are 37 and 43 slots respectively; the input and output ends of the eleventh coil are 41 and 47 slots respectively; and the input and output ends of the twelfth coil are 45 and 51 slots respectively.

9. The 96-slot 16-pole double independent winding structure according to claim 8, characterized in that: The coil distribution of the second winding group is as follows: the input and output ends of the first coil are 49 and 55 respectively; the input and output ends of the second coil are 53 and 59 respectively; the input and output ends of the third coil are 57 and 63 respectively; the input and output ends of the fourth coil are 61 and 67 respectively; the input and output ends of the fifth coil are 65 and 71 respectively; the input and output ends of the sixth coil are 69 and 75 respectively; the input and output ends of the seventh coil are 73 and 79 respectively; the input and output ends of the eighth coil are 77 and 83 respectively; the input and output ends of the ninth coil are 81 and 87 respectively; the input and output ends of the tenth coil are 85 and 91 respectively; the input and output ends of the eleventh coil are 89 and 95 respectively; and the input and output ends of the twelfth coil are 93 and 3 respectively.

10. The 96-slot 16-pole double independent winding structure according to claim 1, characterized in that: The rotor is configured with an array of embedded magnets.

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