Hairpin motor winding
By optimizing the winding structure of the flat wire motor, adopting multi-layer flat wire winding parallel branches and reverse twist welding, the problems of high harmonic content and torque fluctuation caused by full-pitch windings were solved, achieving stable operation of the motor and reducing costs.
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- SUZHOU DOCTOR MINI TECHNOLOGY CO LTD
- Filing Date
- 2025-11-25
- Publication Date
- 2026-06-04
AI Technical Summary
The full-pitch windings of existing flat wire motors result in high harmonic content, leading to large torque fluctuations, unstable output power, and affecting the normal operating efficiency and performance of the equipment.
The multi-layer flat wire winding structure is adopted, and the U-phase, V-phase and W-phase windings are formed by connecting them with bridging wires and parallel branches. Combined with the reverse twist welding method, the use of bridging wires is reduced, thereby reducing the weight and cost of the motor.
By optimizing the winding structure, the use of bridging wires was reduced, thereby lowering the weight and cost of the motor while improving its operational stability and efficiency.
Smart Images
Figure CN2025137595_04062026_PF_FP_ABST
Abstract
Description
flat wire motor winding
[0001] This application claims priority to Chinese patent application No. 202411729862.8, filed on November 29, 2024, the entire contents of which are incorporated herein by reference. Technical Field
[0002] This application belongs to the field of motor technology, specifically relating to a flat wire motor winding. Background Technology
[0003] Flat-wire motors are a new type of motor that uses flat copper wire windings. The windings are one of the core components of a flat-wire motor. Flat-wire windings typically employ a hairpin structure, where the flat wire is bent into a hairpin-like shape and then inserted into the stator slots. To further improve motor performance, flat-wire motor windings often use a multi-layer structure. Multi-layer windings increase the number of conductors, thereby increasing the motor's output power and efficiency. Currently, in the new energy field, most flat-wire motors use full-pitch windings. However, this winding method has certain drawbacks. Due to the characteristics of full-pitch windings, the motor has a higher harmonic content, leading to large torque fluctuations. This, in turn, results in unstable power output during operation, affecting the normal operating efficiency and performance of the equipment. Summary of the Invention
[0004] This application provides a flat wire motor winding, including a stator assembly. The stator assembly has 8 pole pairs and 3 phases. The stator assembly includes a stator core with 48 slots, numbered 1 to 48 in counterclockwise order. Each pole and phase has 2 slots. The stator core has multiple flat wire windings with insulation layers. The number of flat wire layers on the stator core is 6, and the number of flat wire layers is numbered 1 to 6 from the inner to the outer ring of the stator core (corresponding to layers a, b, c, d, e, and f, respectively). The multiple flat wire windings are interconnected by bridging wires to form a winding structure. The winding structure includes a U-phase winding, a V-phase winding, and a W-phase winding. The U-phase winding, V-phase winding, and W-phase winding all adopt one parallel branch or two parallel branches. The one parallel branch is composed of two two-parallel branches.
[0005] The two parallel branches include: a first branch and a second branch;
[0006] The connection sequence of the first branch and the second branch both satisfy the following: the flat wire winding copper wire enters from the 6th layer and exits from the 5th layer, alternating 4 times in sequence. The initial entry point of the flat wire winding copper wire is 5 points smaller than the initial exit point. The entry point in the 6th layer increases by 12 points in sequence, and the exit point in the 5th layer increases by 12 points in sequence. The flat wire winding copper wire then enters from the 4th layer and exits from the 3rd layer, alternating 4 times in sequence. The initial entry point of the flat wire winding copper wire is 5 points smaller than the initial exit point. The initial entry point is 5 points smaller than the initial exit point. The number of entry points in the 4th layer increases by 12 points sequentially, and the number of exit points in the 3rd layer increases by 12 points sequentially. The flat wire winding copper wire then enters from the 2nd layer and exits from the 1st layer, alternating 4 times. The initial entry point of the flat wire winding copper wire is 5 points smaller than the initial exit point. The number of entry points in the 2nd layer increases by 12 points sequentially, and the number of exit points in the 1st layer increases by 12 points sequentially. The initial entry and exit points of the 6th, 4th, and 2nd layers are all the same. The flat wire winding copper wire enters from the first layer and exits from the second layer, alternating 4 times. The initial entry point of the flat wire winding copper wire is 5 points higher than the initial exit point. The entry point of the first layer decreases by 12 points clockwise, and the exit point of the second layer decreases by 12 points clockwise. The flat wire winding copper wire then enters from the third layer and exits from the fourth layer, alternating 4 times. The initial entry point of the flat wire winding copper wire is 5 points lower than the initial exit point. The entry point of the third layer decreases by 12 points clockwise. Decrease the number of points clockwise by 12, and then decrease the number of exit points in the 4th layer clockwise by 12 points. The flat wire winding copper wire then enters from the 5th layer and exits from the 6th layer, alternating 4 times. The initial entry point of the flat wire winding copper wire is 5 points smaller than the initial exit point. The entry point in the 5th layer decreases by 12 points clockwise, and the exit point in the 6th layer decreases by 12 points clockwise. The initial entry point and initial exit point of the 1st, 3rd, and 5th layers are all the same.
[0007] The second branch is obtained by subtracting one bit from each point in the first branch;
[0008] A parallel branch is obtained by connecting the first branch and the second branch;
[0009] The V-phase winding can be obtained by adding 4 slots sequentially along the direction of increasing slot number, following the same pattern as the U-phase winding.
[0010] The W-phase winding can be obtained by adding 4 slots in sequence along the direction of increasing slot number, following the same pattern as the V-phase winding. Attached Figure Description
[0011] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.
[0012] Figure 1 is a three-dimensional structural schematic diagram of a flat wire motor winding provided in an embodiment of this application;
[0013] Figure 2 is a front view of a flat wire motor winding provided in an embodiment of this application;
[0014] Figure 3 is a diagram of a parallel branch winding of the U-phase winding of a flat wire motor winding provided in an embodiment of this application.
[0015] Figure 4 is a diagram of a parallel branch winding of the V-phase winding of a flat wire motor winding provided in an embodiment of this application.
[0016] Figure 5 is a diagram of the parallel branch winding of the W phase winding of a flat wire motor winding provided in an embodiment of this application.
[0017] Figure label:
[0018] 1. Stator core; 2. Flat wire winding copper wire. Embodiments of the present invention
[0019] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application 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 application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application.
[0020] The present application will be further described below with reference to embodiments.
[0021] The terms "left," "right," "front," "back," "up," and "down" used in the following description refer to the orientation from the perspective of the front view.
[0022] In related technologies, due to the characteristics of full-pitch windings, the motor has a large harmonic content, resulting in large torque fluctuations. This leads to unstable power output during motor operation, affecting the normal operating efficiency and performance of the equipment.
[0023] Chinese patent CN118214190A proposes a winding structure, stator assembly, and motor. The winding structure includes three-phase winding lines, phase copper busbars, and star copper busbars. The starting positions of the 2m parallel winding branches of each phase winding line correspond to the winding in m conductor slots. The m winding branches starting at the outermost position of the m conductor slots cycle sequentially in the first winding direction or in the first and second winding directions, and the winding end position is the innermost or outermost position of the m conductor slots. The m winding branches starting at the innermost position of the m conductor slots cycle sequentially in the second winding direction or in the second and first winding directions, and the winding end position is the innermost or outermost position of the m conductor slots. The winding structure avoids the problems of difficult manufacturing and high cost caused by the relatively large size and complex structure of the phase copper busbars and star copper busbars in the three-phase winding structure.
[0024] However, the technical solution of this patent has the following problems:
[0025] This patent allows for a relatively simple structure for the three-phase copper busbars by dividing the 2m parallel winding branches of each phase into two groups and setting the winding start positions at the outermost and innermost sides of a series of m conductor slots. However, the winding structure requires connection through the copper busbars, which increases the weight and cost of the motor.
[0026] Based on this, this application designs a flat wire motor winding to solve the above problems.
[0027] Example 1: In some embodiments, please refer to Figures 1 to 5. A flat wire motor winding includes a stator assembly. The stator assembly has 8 pole pairs and 3 phases. The stator assembly includes a stator core 1 with 48 slots, numbered 1-48 in counterclockwise order. Each pole and phase has 2 slots. The stator core 1 has multiple flat wire winding copper wires 2 with insulating layers. The number of flat wire layers of the flat wire winding copper wires 2 on the stator core 1 is... The stator core 1 has 6 layers. The number of flat wire layers is marked from the inner ring to the outer ring as 1-6 (corresponding to layers a, b, c, d, e, and f respectively). Multiple flat wire winding copper wires 2 are interconnected by bridging wires to form a winding structure. The winding structure includes a U-phase winding, a V-phase winding, and a W-phase winding. The U-phase winding, V-phase winding, and W-phase winding all adopt one parallel branch or two parallel branches. The one parallel branch is composed of two two parallel branches.
[0028] The two parallel branches include: a first branch and a second branch.
[0029] The connection sequence of the first branch and the second branch both satisfy the following: the flat wire winding copper wire 2 enters from the 6th layer and exits from the 5th layer, alternating 4 times in sequence. The initial entry point of the flat wire winding copper wire 2 is 5 points smaller than the initial exit point. The entry point in the 6th layer increases by 12 points in sequence, and the exit point in the 5th layer increases by 12 points in sequence. The flat wire winding copper wire 2 then enters from the 4th layer and exits from the 3rd layer, alternating 4 times in sequence. The initial entry point of the flat wire winding copper wire 2 is 5 points smaller than the initial exit point. The number of incoming points in the fourth layer increases by 12 points, and the number of outgoing points in the third layer increases by 12 points. The flat wire winding copper wire 2 then enters from the second layer and exits from the first layer, alternating 4 times. The initial incoming point of the flat wire winding copper wire 2 is 5 points smaller than the initial outgoing point. The number of incoming points in the second layer increases by 12 points, and the number of outgoing points in the first layer increases by 12 points. The initial incoming and outgoing points of the sixth, fourth, and second layers are all the same. The flat wire winding copper wire 2 enters from the fourth layer... The process alternates four times: first layer incoming wire, second layer outgoing wire. The initial incoming point of the flat wire winding copper wire 2 is 5 points higher than the initial outgoing point. The incoming point of the first layer decreases by 12 points clockwise, and the outgoing point of the second layer decreases by 12 points clockwise. Then, the flat wire winding copper wire 2 enters from the third layer and exits from the fourth layer, alternating four times. The initial incoming point of the flat wire winding copper wire 2 is 5 points lower than the initial outgoing point. The incoming point of the third layer decreases by 12 points clockwise, and the outgoing point of the fourth layer... The wire entry point decreases by 12 points clockwise in sequence; the flat wire winding copper wire 2 then enters from the 5th layer and exits from the 6th layer, alternating 4 times in sequence. The initial entry point of the flat wire winding copper wire 2 is 5 points smaller than the initial exit point. The entry point of the 5th layer decreases by 12 points clockwise in sequence, and the exit point of the 6th layer decreases by 12 points clockwise in sequence. The initial entry point and initial exit point of the 1st, 3rd, and 5th layers are the same, and the final exit point of the 6th layer is 5 points larger than the initial entry point of the 6th layer.
[0030] The second branch is obtained by subtracting one from the number of points in the first branch.
[0031] A parallel branch is obtained by connecting the first branch and the second branch.
[0032] The V-phase winding can be obtained by adding 4 slots in sequence along the direction of increasing slot number, following the same pattern as the U-phase winding.
[0033] The W-phase winding can be obtained by adding 4 slots in sequence along the direction of increasing slot number, following the same pattern as the V-phase winding.
[0034] Example 2: In some embodiments, as shown in Figures 1-5, as a preferred embodiment of this application, if a parallel branch is used in the U-phase winding, its connection sequence is as follows:
[0035] f7-->e12-->f19-->e24-->f31-->e36-->f43-->e48-->d7-->c12-->d19-->c24-- >d31-->c36-->d43-->c48-->b7-->a12-->b19-->a24-->b31-->a36-->b43-->a48- ->a6-->b1-->a42-->b37-->a30-->b25-->a18-->b13-->c6-->d1-->c42-->d37--> c30-->d25-->c18-->d13-->e6-->f1-->e42-->f37-->e30-->f25-->e18-->f13--> f6-->e11-->f18-->e23-->f30-->e35-->f42-->e47-->d6-->c11-->d18-->c23--> d30-->c35-->d42-->c47-->b6-->a11-->b18-->a23-->b30-->a35-->b42-->a47-- >a5-->b48-->a41-->b36-->a29-->b24-->a17-->b12-->c5-->d48-->c41-->d36-- >c29-->d24-->c17-->d12-->e5-->f48-->e41-->f36-->e29-->f24-->e17-->f12.
[0036] In the U-phase winding, if two parallel branches are used, the connection sequence of the first branch is as follows:
[0037] f7-->e12-->f19-->e24-->f31-->e36-->f43-->e48-->d7-->c12-->d19-->c24-- >d31-->c36-->d43-->c48-->b7-->a12-->b19-->a24-->b31-->a36-->b43-->a48 -->a6-->b1-->a42-->b37-->a30-->b25-->a18-->b13-->c6-->d1-->c42-->d37- ->c30-->d25-->c18-->d13-->e6-->f1-->e42-->f37-->e30-->f25-->e18-->f13.
[0038] The connection sequence of the second branch is as follows:
[0039] f6-->e11-->f18-->e23-->f30-->e35-->f42-->e47-->d6-->c11-->d18-->c23--> d30-->c35-->d42-->c47-->b6-->a11-->b18-->a23-->b30-->a35-->b42-->a47-- ->b6-->a11-->b18-->a23-->b30-->a35-->b42-->a47-->c5-->d48-->c41-->d36- ->c29-->d24-->c17-->d12-->e5-->f48-->e41-->f36-->e29-->f24-->e17-->f12.
[0040] When the winding is a parallel branch, the copper wires 2 of the flat wire winding are reversed so that the copper wires 2 of the flat wire winding that need to be connected in the same phase are brought close to each other and welded together, thereby reducing the number of bridging wires. By reducing the amount of material used, the weight and cost of the motor are reduced.
[0041] The stator core 1 is made of stacked silicon steel sheets, and the thickness of the silicon steel sheets is between 0.2mm and 0.27mm.
[0042] Each of the flat wire winding copper wires 2 is provided with insulating paper on the outside.
[0043] The stator assembly includes any of the winding structures provided in this application.
[0044] Beneficial effects: The flat wire motor winding provided in this application embodiment uses the reverse twisting of the flat wire winding copper wires to bring the flat wire winding copper wires that need to be connected in the same phase closer to each other and weld them together, thereby reducing bridging wires. By reducing the amount of materials used, the weight and cost of the motor are reduced.
[0045] The above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions will not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application.
Claims
1. A flat wire motor winding, comprising a stator assembly having 8 pole pairs and 3 phases, the stator assembly comprising: The stator core has 48 slots, numbered 1 to 48 in a counter-clockwise direction. Each pole and phase has 2 slots. The stator core has multiple flat wire windings with insulation layers. The flat wire windings on the stator core have 6 layers, numbered 1 to 6 from the inner to the outer ring of the stator core. The multiple flat wire windings are interconnected by bridging wires to form a winding structure. The winding structure includes a U-phase winding, a V-phase winding, and a W-phase winding. The U-phase winding, V-phase winding, and W-phase winding all adopt one parallel branch or two parallel branches. The one parallel branch is composed of two two parallel branches. The two parallel branches include: a first branch and a second branch; The connection sequence of the first branch and the second branch both satisfy the following: the flat wire winding copper wire enters from the 6th layer and exits from the 5th layer, alternating 4 times in sequence. The initial entry point of the flat wire winding copper wire is 5 points smaller than the initial exit point. The entry point in the 6th layer increases by 12 points in sequence, and the exit point in the 5th layer increases by 12 points in sequence. The flat wire winding copper wire then enters from the 4th layer and exits from the 3rd layer, alternating 4 times in sequence. The initial entry point of the flat wire winding copper wire is 5 points smaller than the initial exit point. The initial entry point is 5 points smaller than the initial exit point. The number of entry points in the 4th layer increases by 12 points sequentially, and the number of exit points in the 3rd layer increases by 12 points sequentially. The flat wire winding copper wire then enters from the 2nd layer and exits from the 1st layer, alternating 4 times. The initial entry point of the flat wire winding copper wire is 5 points smaller than the initial exit point. The number of entry points in the 2nd layer increases by 12 points sequentially, and the number of exit points in the 1st layer increases by 12 points sequentially. The initial entry and exit points of the 6th, 4th, and 2nd layers are all the same. The flat wire winding copper wire enters from the first layer and exits from the second layer, alternating 4 times. The initial entry point of the flat wire winding copper wire is 5 points higher than the initial exit point. The entry point of the first layer decreases by 12 points clockwise, and the exit point of the second layer decreases by 12 points clockwise. The flat wire winding copper wire then enters from the third layer and exits from the fourth layer, alternating 4 times. The initial entry point of the flat wire winding copper wire is 5 points lower than the initial exit point. The entry point of the third layer decreases by 12 points clockwise. Decrease the number of points clockwise by 12, and then decrease the number of exit points in the 4th layer clockwise by 12 points. The flat wire winding copper wire then enters from the 5th layer and exits from the 6th layer, alternating 4 times. The initial entry point of the flat wire winding copper wire is 5 points smaller than the initial exit point. The entry point in the 5th layer decreases by 12 points clockwise, and the exit point in the 6th layer decreases by 12 points clockwise. The initial entry point and initial exit point of the 1st, 3rd, and 5th layers are all the same. The second branch is obtained by subtracting one bit from each point in the first branch; A parallel branch is obtained by connecting the first branch and the second branch; The V-phase winding can be obtained by adding 4 slots sequentially along the direction of increasing slot number, following the same pattern as the U-phase winding. The W-phase winding can be obtained by adding 4 slots in sequence along the direction of increasing slot number, following the same pattern as the V-phase winding.
2. The flat wire motor winding according to claim 1, wherein layers 1-6 correspond to layers a, b, c, d, e, and f, respectively.
3. In the flat wire motor winding according to claim 2, if a parallel branch is used in the U-phase winding, its connection sequence is as follows: 。 4. In the flat wire motor winding according to claim 2, if two parallel branches are used in the U-phase winding, the connection sequence of the first branch is as follows: 。 5. The flat wire motor winding according to claim 4, wherein the connection sequence of the second branch is as follows: 。 6. The flat wire motor winding according to claim 1, wherein the stator core is formed by stacking silicon steel sheets, and the thickness of the silicon steel sheets is 0.2 mm to 0.27 mm.
7. The flat wire motor winding according to claim 1, wherein insulating paper is provided on the outer side of the copper wire of each flat wire winding.
8. In the flat wire motor winding according to claim 1, the last exit point of the 6th layer is 5 points larger than the initial entry point of the 6th layer.