Flat Wire Motor Winding Layout for Torque Fluctuation Suppression
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Solution Overview
Problem
Existing flat wire motors experience significant torque fluctuation and high back electromotive force harmonics due to their full-pitch winding structure, which reduces motor performance.
Innovation Solution
A short-pitch winding structure is implemented by staggering the layers of the flat wire winding in the stator slots, with each phase divided into two parts, where the quantity of layers in each part is a and b, respectively, and a≠b, to achieve a reduced equivalent pitch, thereby reducing torque fluctuation and back electromotive force harmonics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a full-pitch winding structure is used in a flat wire motor, then the winding can be easily manufactured with high copper slot fill factor, but the motor experiences large torque fluctuation and high back electromotive force harmonics which reduces motor performance
Solution Approach 1:
The patent divides each phase of the flat wire winding structure into a first part and a second part with different layer quantities (a and b respectively, where a≠b). This segmentation creates an asymmetric winding distribution that reduces the equivalent pitch below the pole pitch, thereby suppressing torque fluctuation and reducing back electromotive force harmonics while maintaining the ease of flat wire winding manufacturing
Solution Approach 2:
The patent introduces asymmetry by setting different quantities of layers for the first part (a layers) and second part (b layers) of each phase winding, where a≠b. This asymmetric arrangement creates a short-pitch effect that reduces the equivalent pitch, effectively suppressing torque fluctuation and harmonics while preserving the manufacturing advantages of flat wire windings
2Device complexity
If the flat wire winding structure uses equal layers (a=b) in each stator slot, then the structure is simple and easy to manufacture, but torque fluctuation suppression is insufficient
Solution Approach 1:
The patent deliberately introduces asymmetry by setting a≠b for the layer quantities of the first and second parts of each phase winding. This asymmetric configuration creates the necessary pitch reduction effect to suppress torque fluctuation, while the overall structure remains relatively simple and compatible with existing flat wire winding manufacturing processes
Data Source
AI summary
A motor and a vehicle. The motor includes a stator iron core and a flat wire winding structure. Each stator slot has n layers of the flat wire winding structure. Each phase of the flat wire winding structure includes a first part and a second part, the first part occupies a layers in the stator slot, and the second part occupies b layers in the stator slot, and a≠b. In addition, in each pole of each phase of the flat wire winding structure, a stator slot wound with the first part and a stator slot wound with the second part are staggered by y1 slots. The pitch y is less than a pole pitch y0. In this way, the flat wire winding structure is a short-pitch winding, and further, when the motor runs, good torque fluctuation suppression effect is achieved.