A stator assembly and motor having an even number of full pitch windings

Abstract

The utility model belongs to motor technical field discloses a kind of stator assembly and motor with even layer of whole pitch winding. Including stator core and stator winding;The stator winding includes several stacked coils;Several stator slots are set along the circumferential direction of the stator core;N layers of conductors are provided in each stator slot;The first layer to the layer in any stator slot is occupied by the stacked side of each stacked coil, and the other stacked side occupies the Nth layer to the Nth layer in another stator slot spaced apart from the any stator slot by one stator slot;Wherein, N is even, Z is the total number of stator slots, and P is the number of poles;The end portions of the two stacked coils arranged adjacently located in the same layer are welded and fixed.The utility model has the technical advantages of simple welding, low copper consumption and no interphase circulating current.

Description

Technical Field

[0001] This utility model relates to the field of motor technology, specifically to a stator assembly and motor having an even number of layers of full-pitch windings. Background Technology

[0002] Compared to round wire motors, flat wire motors have the advantages of better heat dissipation and higher power density, making them effective in applications such as new energy vehicles, automation equipment, and aerospace.

[0003] In the stator assembly of a flat-wire motor, rectangular conductors wound around the stator core constitute the winding. Considering the winding structure, the winding can be categorized into I-pin, Hair-pin, X-pin, and S-Winding structures. The I-pin structure requires welding at both ends, resulting in numerous solder joints and high copper loss at the weld points. While the Hair-pin structure only requires single-end welding, it offers no significant advantage over the I-pin in terms of the number of solder joints or copper loss at the weld point. The X-pin structure has low copper loss at the weld points, but the number of solder joints is the same as the I-pin structure. Although the S-Winding structure uses continuous conductors to improve the problems of numerous solder joints and high copper loss, it requires specific tooling for winding, thus introducing a new drawback: increased winding complexity.

[0004] From the perspective of winding performance, in order to eliminate the circulating current problem caused by phase difference or inductance imbalance between branches of each phase, it is necessary to adopt various short-pitch or long-pitch combinations to achieve balanced deployment, which also leads to the problem of complex winding. Utility Model Content

[0005] The purpose of this invention is to provide a stator assembly and motor with an even number of layers of full-pitch windings, so as to solve the technical problems of complex welding, high copper consumption and complex winding of current windings.

[0006] To achieve the above objectives, the present invention proposes the following technical solution:

[0007] In a first aspect, a stator assembly with an even number of layers of full-pitch windings is provided, including a stator core and stator windings; the stator windings include a plurality of lapped coils;

[0008] A plurality of stator slots are provided along the circumference of the stator core; each stator slot contains N layers of conductors; one layer of each lapped coil occupies the first to second layers in any stator slot. The other layer, the overlapping side, occupies the space between the two stator slots. The first stator slot in another stator slot Layer N to layer N; where N is an even number, Z is the total number of stator slots, and P is the number of poles;

[0009] The ends of two adjacent lapped coils located on the same layer are welded and fixed.

[0010] Furthermore, it includes only one minimum winding unit; wherein each minimum winding unit consists of two adjacent stacked coils.

[0011] Furthermore, the winding path of the minimum winding unit is as follows: one layer of the first lap-wound coil occupies the first to second layers within any stator slot. The other layer, the overlapping side, occupies the space between the two stator slots. The first stator slot in another stator slot Layer N; the second lapped coil and the lapped side adjacent to the first lapped coil occupy the interval between any stator slot. The first layer to the second layer in another stator slot of one stator slot The other layer, the overlapping side, occupies the space between the two stator slots. The first stator slot in another stator slot Layer N to the Nth layer.

[0012] Furthermore, the leads of each phase winding are located in the innermost or outermost layer of the stator slot.

[0013] Furthermore, the three-phase leads are connected in a star configuration.

[0014] Furthermore, the three-phase leads are connected in a delta configuration.

[0015] Furthermore, the leads of each phase winding are arranged adjacent to each other.

[0016] Furthermore, the stator winding includes a three-phase single-branch winding.

[0017] Furthermore, the openings of each stator slot are inverted trapezoidal structures.

[0018] In a second aspect, an electric motor is provided, including the aforementioned stator assembly.

[0019] Beneficial effects:

[0020] This technical solution provides a stator assembly, which includes a stator core and a stator winding, to simultaneously solve the defects of high copper loss, complex welding and difficult winding in existing stator windings.

[0021] The stator winding in this technical solution includes several lapped coils. The winding path of each lapped coil is set as follows: N layers of conductors are provided in each stator slot; one lapped side of each lapped coil occupies the first to second layers in any stator slot. The other layer, the overlapping side, occupies the space between the two stator slots. The first stator slot in another stator slot Layer N is formed; where N is an even number, Z is the total number of stator slots, and P is the number of poles. Then, the ends of two adjacent lapped coils located on the same layer are welded and fixed.

[0022] Therefore, this technical solution employs lapped coils. Except for the innermost and outermost layers, there are no solder joints in the middle layers, greatly reducing soldering complexity and copper loss. Furthermore, since each lapped coil corresponds to only two fixed-span stator slots, and occupies a fixed and adjacent number of layers within the same stator slot, the winding method is similar to a hairpin structure, offering the advantage of low winding difficulty. The consistent span of all lapped coils also effectively reduces winding difficulty. Moreover, the identical number of layers occupied by each lapped coil in this technical solution, and consequently, the identical number of layers occupied by each branch in each phase, effectively prevents the generation of circulating currents.

[0023] 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.

[0024] 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

[0025] 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:

[0026] Figure 1 This is a three-dimensional structural diagram of the stator assembly described in this embodiment;

[0027] Figure 2 for Figure 1 The front view of the stator assembly;

[0028] Figure 3 for Figure 1 Top view of the stator assembly;

[0029] Figure 4 for Figure 1 Top view of one phase branch in the stator assembly;

[0030] Figure 5This is a schematic diagram of the lapped coil structure in the stator assembly described in this embodiment;

[0031] Figure 6 This is a schematic diagram of the conductor arrangement in any stator slot of the stator assembly described in this embodiment;

[0032] Figure 7 This is a schematic diagram of the stator winding connection in the stator assembly described in this embodiment;

[0033] Figure 8 This is a schematic diagram of the winding of any smallest winding unit in this embodiment. Detailed Implementation

[0034] 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.

[0035] 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.

[0036] In the stator assembly of a flat-wire motor, the windings are divided into I-pin, Hair-pin, X-pin, and S-Winding structures. The I-pin structure involves directly inserting rectangular conductors, then twisting both ends of each conductor using a twisting fixture according to the winding logic, followed by end welding for fixation. This type of structure suffers from complex welding processes and high tooling costs; it also requires a relatively long end length, resulting in high copper loss. Hair-pin and X-pin structures are improvements on the I-pin structure. The Hair-pin structure involves shaping before insertion; although it only requires single-end welding compared to the I-pin structure, the end length is not improved during single-end welding, and even with single-end welding, there are many welding points. While the X-pin structure has a shorter end length and reduced copper loss, it still requires double-end welding, resulting in many welding points. The S-Winding structure, while using continuous conductors, offers advantages such as fewer welding points and lower copper loss, but it requires specific tooling for winding, introducing the problem of increased winding difficulty.

[0037] Furthermore, in current three-phase flat wire motors, each phase winding is often composed of multiple branches connected in parallel, such as two, three, or even six branches connected in parallel to form any phase winding. However, when the layer or phase of the rectangular conductor in each branch winding of each phase is different, a significant phase difference or inductance unevenness will be generated directly in each branch of each phase, leading to circulating current. Therefore, various short-pitch and long-pitch windings are required to achieve winding balance during the winding setup. This results in complex and difficult winding setup.

[0038] Based on this, this embodiment aims to provide a stator assembly with an even number of layers of full-pitch windings to simultaneously solve the above-mentioned defects.

[0039] The stator assembly with an even number of layers of full-pitch windings disclosed in this utility model will be further described in detail below with reference to the embodiments shown in the accompanying drawings.

[0040] Combination Figures 1 to 7 As shown, the stator assembly includes a stator core 1 and a stator winding 2. A plurality of stator slots 11 are formed along the circumference of the stator core 1 to accommodate the stator winding 2. The stator winding 2 includes a plurality of lapped coils 21.

[0041] The number of conductor layers in each stator slot is defined as N, the total number of stator slots on the stator core 1 is Z, and the number of poles of the target stator winding 2 is P. The number of conductor layers is even, and the conductor closest to the stator slot opening is defined as the Nth conductor layer. The number of poles is an integer multiple of 2. Then, each lapped coil 21 is wound in its corresponding stator slot 11 as follows:

[0042] First, one layer of each stacked coil 21 occupies the first to second layers within any stator slot 11. The other layer, the overlapping side, occupies the space between the two stator slots. The first stator slot in another stator slot The winding process proceeds from layer 1 to layer N. Then, the ends of two adjacent lapped coils 21 located on the same layer are used as welding ends 21c and welded together (i.e., the ends of the two lapped coils 21 located on the first layer are welded together, and the ends located on the Nth layer are welded together). Finally, after winding is completed, the lead-out ends of each phase and branch are reserved according to actual needs to form corresponding lead-out wires 21a. In this embodiment, the lead-out wire 21a of each phase winding can be located in the innermost or outermost layer of the corresponding stator slot, i.e., layer 1 or layer N.

[0043] As a specific implementation method, a star connection can be used when connecting the three-phase leads. This involves connecting the three ends of the three-phase windings together to form a common point (i.e., the neutral point), and then connecting the beginnings of the three-phase windings to the three-phase power supply respectively. To facilitate connection and reduce copper losses, a star-point copper busbar can be used.

[0044] As an alternative implementation, a delta connection can be used when connecting the three-phase leads. This involves connecting the beginning and end of the three-phase windings sequentially to form a closed delta circuit, and then connecting the terminals from the three vertices of the triangle to the three-phase power supply.

[0045] As a further preferred embodiment, the lead wire 21a of each phase winding corresponds to the three adjacent lapped coils 21; that is, the lead wires of each phase winding are arranged adjacently. In this case, it is more convenient to lead out the lead wires 21a in a unified manner and connect them to the high-voltage harness end.

[0046] At this point, the entire stator winding 2 includes only one minimum winding unit. Each minimum winding unit consists of two adjacent lapped coils 21. Specifically, in conjunction with... Figure 8 As shown, the winding path of the minimum winding unit is as follows: the first layer to the second layer of the first lapped coil occupy the first layer in any stator slot. The other layer, the overlapping side, occupies the space between the two stator slots. The first stator slot in another stator slot Layer N; the second lapped coil and the lapped side adjacent to the first lapped coil occupy the interval between any stator slot. The first layer to the second layer in another stator slot of one stator slot The other layer, the overlapping side, occupies the space between the two stator slots. The first stator slot in another stator slot Layer N to the Nth layer.

[0047] Based on the stator assembly described in this embodiment, since lapped coils 21 are used, there are no solder joints in the middle layers except for the innermost and outermost layers, which greatly reduces soldering complexity and copper loss. Furthermore, since each lapped coil 21 corresponds to only two fixed-span stator slots 11, and occupies a fixed and adjacent number of layers within the same stator slot 11, the winding method is similar to the hairpin structure, offering the advantage of low winding difficulty. Moreover, the consistent span of all lapped coils 11 during deployment also effectively reduces winding difficulty. Furthermore, the identical number of layers occupied by each lapped coil 11, and consequently, the identical number of layers occupied by each branch in each phase, effectively prevents the generation of circulating currents.

[0048] To facilitate the insertion or mounting of the lapped coil 21, the opening of the stator slot 21 is also provided as an inverted trapezoidal structure. In this case, when the lapped coil 21 is deployed in the stator slot, the opening of the inverted trapezoidal structure can accommodate the unused coil layers to facilitate the mounting of the coil layers that are installed first.

[0049] As a specific implementation, when the number of poles of stator winding 2 is 12 and the total number of stator slots is 36, the corresponding full pitch is... Specifically, it is 3. Simultaneously, the number of conductor layers in each stator slot 11 is 8. The number of phases is 3, including three phases: U, W, and V. Furthermore, to further avoid circulating currents between branches of the same phase, the number of branches per phase is set to 1.

[0050] In the specific winding process, each stack of winding coils occupies the 1st to 4th layers or the 5th to 8th layers of the corresponding stator slot 11. Correspondingly, the connection path of any minimum winding unit is: Z1(1)→Z4(5)→Z1(2)→Z4(6)→Z1(3)→Z4(7)→Z1(4)→Z4(8)→Z7(8)→Z4(4)→Z7(7)→Z4(3)→Z7(6)→Z4(2)→Z7(5)→Z4(1). At this time, each phase winding will consist of 6 minimum winding units; the three phases U, V and W will consist of a total of 18 minimum winding units. It can be seen that the winding structure of the winding in this embodiment has a significant advantage of simple structure compared with other windings of the same type.

[0051] Specifically, taking phase U as an example, its complete winding path is as follows:

[0052] Z1(1)→Z4(5)→Z1(2)→Z4(6)→Z1(3)→Z4(7)→Z1(4)→Z4(8)→Z7(8)→Z4(4)→Z7(7)→Z4(3)→Z7(6)→Z4( 2)→Z7(5)→Z4(1)→Z7(1)→Z10(5)→Z7(2)→Z10(6)→Z7(3)→Z10(7)→Z7(4)→Z10(8)→Z13(8)→Z10(4)→ Z13(7)→Z10(3)→Z13(6)→Z10(2)→Z13(5)→Z10(1)→Z13(1)→Z16(5)→Z13(2)→Z16(6)→Z13(3)→Z16( 7)→Z13(4)→Z16(8)→Z19(8)→Z16(4)→Z19(7)→Z16(3)→Z19(6)→Z16(2)→Z19(5)→Z16(1)→Z19(1)→Z 22(5)→Z19(2)→Z22(6)→Z19(3)→Z22(7)→Z19(4)→Z22(8)→Z25(8)→Z22(4)→Z25(7)→Z22(3)→Z25(6)→Z22(2)→Z25(5)→Z22(1)→Z25(1)→Z28(5)→Z25(2)→Z28(6)→Z25(3)→Z28(7)→Z25(4)→Z28(8)→Z3 1(8)→Z28(4)→Z31(7)→Z28(3)→Z31(6)→Z28(2)→Z31(5)→Z28(1)→Z31(1)→Z34(5)→Z31(2)→Z34(6)→Z31(3)→Z34(7)→Z31(4)→Z34(8)→Z1(8)→Z34(4)→Z1(7)→Z34(3)→Z1(6)→Z34(2)→Z1(5)→Z34(1).

[0053] A star connection is used during wiring. To keep the three-phase leads within a small angle range, bring the star points close together, and reduce the length of the star point copper busbar, the leads of each phase winding are aligned with the three adjacent lapped coils 21. This ensures that the three-phase leads are as close as possible, thereby reducing copper losses.

[0054] In summary, the stator assembly described in this embodiment has the following technical advantages: (1) The resistance and inductance of the stator winding are balanced, and no circulating current is generated; (2) The stator winding structure is simple, consisting of a single type of lapped coil, with no solder joints in the middle layer, requiring less copper and resulting in low manufacturing cost; (3) The stator winding only needs to be welded to the outer and inner layers of the lead-out terminals, and the three-phase lead-out of each branch can be set at any lead-out position on the outer or inner layer, increasing the diversity of lead-out position selection; at the same time, similar three-phase lead-out positions can be selected to effectively shorten the end length and reduce manufacturing cost; (4) The stator winding structure is regular, and the corresponding types of twisting head fixtures, welding fixtures, etc. are few, saving tooling costs.

[0055] This embodiment also provides a motor, which includes the stator assembly described above. This results in advantages such as low cost and simple manufacturing process during the initial winding of the motor, and stable operation, good heat dissipation, and low maintenance difficulty during subsequent applications.

[0056] 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.

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