CN118826342A - Flat wire wave winding, stator and motor - Google Patents

Abstract

The application relates to a flat wire wave winding, a stator and a motor. The flat wire wave winding comprises a first molded wire and a second molded wire, and the first coil can be formed by connecting a first wire outlet end of the first molded wire and a second wire outlet end of the second molded wire in series. Only two molding leads are provided, so that the connection is convenient and the error is not easy to occur. The number of the branches formed by the serial connection or parallel connection of the first coils is flexible, and the circulation problem among the branches can be effectively solved. The flat wire wave winding can also greatly reduce the risk operations of cutting, bending, welding and the like of the lead of the traditional flat wire wave winding.

Description

Flat wire wave winding, stator and motor

Technical Field

The application relates to the technical field of motors, in particular to a flat wire wave winding, a stator and a motor.

Background

The new energy automobile takes a motor as a main power source. The motor comprises a stator and a rotor, and power is generated through electromagnetic effect between the stator and the rotor. The flat wire winding of the traditional stator is mainly divided into a Hairpin type (hair pin) or a straight wire type (i-pin), and the two types of flat wire winding need to be bent and welded in a large amount, so that the conductivity of the winding and the overall efficiency of the motor can be influenced if the flat wire winding is damaged in the manufacturing process.

Disclosure of Invention

In view of the above, it is necessary to provide a flat wire wave winding, a stator, and a motor that are simple and reliable to manufacture.

The flat wire wave winding comprises a first molding lead and a second molding lead, wherein the first molding lead comprises a plurality of first straight lead parts and a plurality of first bridging parts, two adjacent first straight lead parts are connected through one first bridging part, and the end parts of two first straight lead parts positioned at the outermost side are first wire outlet ends; the second molding lead comprises a plurality of second straight lead parts and a plurality of second bridging parts, wherein two adjacent second straight lead parts are connected through one second bridging part, and the end parts of two second straight lead parts positioned at the outermost side are second wire outlet ends; wherein; the lengths of the first forming wire and the second forming wire are inconsistent, and a first wire outlet end of the first forming wire and a second wire outlet end of the second forming wire are connected in series to form a first coil.

In one embodiment, the first molding wires are routed from the outermost layer to the innermost layer of the wire layers, and the number of the first straight wire portions of the first molding wires distributed in each wire layer is equal;

The second molding wires are routed from the innermost layer to the outermost layer of the wire layers, and the second straight wire parts of the second molding wires distributed in each wire layer are equal in number.

In one embodiment, two adjacent first straight conducting wires of one first molding conducting wire are positioned in the same conducting wire layer; two adjacent second straight wire parts of one second molding wire are positioned in the same wire layer.

In one embodiment, the first straight wire portions of the first shaped wire are alternately changed in order of a first span and a second span; the second straight wire parts of the second molded wires are alternately changed in sequence according to the sequence of the second span and the first span;

Or alternatively

The spans of the first straight wire part on the non-extraction side are alternately changed according to the sequence of the first span and the second span, and the span of the first straight wire part when crossing layers is a third span; the spans of the second straight wire part on the non-extraction side are alternately changed in the order of the second span and the first span, and the span of the second straight wire part when crossing layers is a third span.

In one embodiment, the first wire outlet end of the first straight wire portion of the wire layer at the innermost layer is connected in series with the second wire outlet end of the second straight wire portion of the wire layer at the outermost layer.

In one embodiment, the first span is equal to span D+1, the second span is equal to span D-1, and the third span is equal to span D; wherein the span is D, d=2n/2 p; p is the pole pair number of the motor and 2n is the number of stator slots.

In one embodiment, each wire layer is distributed with one first straight wire part, and the first straight wire parts of the first forming wires are sequentially changed in turn according to the sequence of a first span and a second span;

Each wire layer is distributed with one second straight wire part, and the second straight wire parts of the second forming wires are changed in turn according to the sequence of the second span and the first span.

In one embodiment, a first wire outlet end of the first straight wire portion of the first molded wire located at the innermost layer of the wire layers is connected in series with a second wire outlet end of the second straight wire portion of the second molded wire located at the innermost layer of the wire layers, and the first wire outlet end and the second wire outlet end connected in series are located under different magnetic poles.

A stator comprising a stator core and the flat wire wave winding, wherein a plurality of stator slots are arranged on the stator core around the axis direction; the flat wire wave winding is arranged in the stator slot.

An electric machine comprising a stator as described above, one phase winding of the flat wire wave winding comprising a plurality of said first coils, the plurality of said first coils being mutually deflected to occupy all of one phase of said stator slots.

The flat wire wave winding, the stator and the motor only need to manufacture two types of molded wires, namely, a first molded wire and a second molded wire, and the first coil can be formed by connecting a first wire outlet end of the first molded wire and a second wire outlet end of the second molded wire in series. Only two molding leads are provided, so that the connection is convenient and the error is not easy to occur. The number of the branches formed by the serial connection or parallel connection of the first coils is flexible, and the circulation problem among the branches can be effectively solved. The flat wire wave winding can also greatly reduce the risk operations of cutting, bending, welding and the like of the lead of the traditional flat wire wave winding.

Drawings

Fig. 1 is a schematic structural diagram of a stator in an embodiment.

Fig. 2 is an expanded schematic view of the flat wire wave winding of fig. 1.

Fig. 3 is a schematic structural diagram of the first molding wire in fig. 1.

Fig. 4 is a layout of the first molding wire shown in fig. 3 within the stator core.

Fig. 5 is a schematic structural view of the second molded conductive wire of fig. 1.

Fig. 6 is a layout of the second molded wire shown in fig. 5 within a stator core.

Fig. 7 is a schematic structural view of a stator in another embodiment.

Fig. 8 is an expanded schematic view of the flat wire wave winding of fig. 7.

Fig. 9 is a schematic structural view of the first molding wire in fig. 7.

Fig. 10 is a layout of the first molding wire shown in fig. 9 within the stator core.

Fig. 11 is a schematic diagram of the structure of the second molded wire of fig. 7.

Fig. 12 is a layout of the second molded wire shown in fig. 11 within a stator core.

Fig. 13 is a schematic structural view of a stator in still another embodiment.

Fig. 14 is an expanded schematic view of the flat wire wave winding of fig. 13.

Fig. 15 is a schematic structural view of the first molding wire in fig. 13.

Fig. 16 is a layout of the first molding wire shown in fig. 15 within the stator core.

Fig. 17 is a schematic view of the structure of the second molded wire of fig. 13.

Fig. 18 is a layout of the second molded wire shown in fig. 17 within the stator core.

10. A stator; 100. a stator core; 110. a stator groove; 210. a first molded wire; 211. a first straight wire portion; 212. a first bridge portion; 213. a first wire outlet end; 220. a second molded wire; 221. a second straight wire portion; 222. a second bridge portion; 223. and a second wire outlet end.

Detailed Description

In order that the above objects, features and advantages of the application will be readily understood, a more particular description of the application will be rendered by reference to the appended drawings. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present application. The present application may be embodied in many other forms than described herein and similarly modified by those skilled in the art without departing from the spirit of the application, whereby the application is not limited to the specific embodiments disclosed below.

In the description of the present application, it should be understood that, if any, these terms "center", "longitudinal", "transverse", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc., are used herein with respect to the orientation or positional relationship shown in the drawings, these terms refer to the orientation or positional relationship for convenience of description and simplicity of description only, and do not indicate or imply that the apparatus or element referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore should not be construed as limiting the application.

Furthermore, the terms "first," "second," and the like, if any, are used for descriptive purposes only and are not to be construed as indicating or implying a relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defining "a first" or "a second" may explicitly or implicitly include at least one such feature. In the description of the present application, the terms "plurality" and "a plurality" if any, mean at least two, such as two, three, etc., unless specifically defined otherwise.

In the present application, unless explicitly stated and limited otherwise, the terms "mounted," "connected," "secured," and the like are to be construed broadly. For example, the two parts can be fixedly connected, detachably connected or integrated; can be mechanically or electrically connected; either directly or indirectly, through intermediaries, or both, may be in communication with each other or in interaction with each other, unless expressly defined otherwise. The specific meaning of the above terms in the present application can be understood by those of ordinary skill in the art according to the specific circumstances.

In the present application, unless expressly stated or limited otherwise, the meaning of a first feature being "on" or "off" a second feature, and the like, is that the first and second features are either in direct contact or in indirect contact through an intervening medium. Moreover, a first feature being "above," "over" and "on" a second feature may be a first feature being directly above or obliquely above the second feature, or simply indicating that the first feature is level higher than the second feature. The first feature being "under", "below" and "beneath" the second feature may be the first feature being directly under or obliquely below the second feature, or simply indicating that the first feature is less level than the second feature.

It will be understood that if an element is referred to as being "fixed" or "disposed" on another element, it can be directly on the other element or intervening elements may also be present. If an element is referred to as being "connected" to another element, it can be directly connected to the other element or intervening elements may also be present. The terms "vertical," "horizontal," "upper," "lower," "left," "right," and the like as used herein, if any, are for descriptive purposes only and do not represent a unique embodiment.

Referring to fig. 1, an electric machine according to an embodiment of the present application includes a stator 10 and a rotor disposed in the stator 10. The stator 10 includes a stator core 100 and a stator winding, and the stator core 100 is provided with a plurality of stator slots 110 arranged in an axial direction. The stator windings are wound in stator slots 110. In this embodiment, the stator winding is a flat wire wave winding.

Referring to fig. 1 and 2, in one embodiment, a stator core 100 includes a plurality of stator slots 110, and an opening of the stator slots 110 faces a rotor. Each stator slot 110 defines a plurality of conductor layers in which the flat wire wave winding of the present application may be placed. In one embodiment, 6 conductive layers L1-L6 are exemplified, but the present application is applicable to any even number of conductive layers, and is not limited to 6 layers.

In one embodiment, the flat wire wave winding may be applied to a multi-phase motor. The number of stator slots 110 of the multiphase motor is (2*n), each stator slot 110 defines (2*k) conductor layer positions, and the pole number pair of the rotor is p, wherein (2*k) is an even number not less than 4. According to the above assumption, the span D of the multiphase motor of the embodiment of the present application can be expressed as: d= (2*n)/(2*p); further, the number of phases per pole can be expressed as: (D/number of phases). For example, assume a three-phase motor includes 48 stator slots 110 (n=24), each stator slot 110 defines 6 wire layer positions (k=3), and the rotor includes 4 pole pairs (p=4). According to this embodiment, the three-phase motor has a span D of 6 and a number of phases per pole of 2. For clarity of illustration of the spirit of the application, the following description of the flat wire wave winding is illustrative of the 48 stator slot 110 three-phase motor embodiment, unless otherwise indicated.

The flat wire wave winding is composed of a plurality of integrally formed forming wires, each forming wire comprises a plurality of straight wire parts and a plurality of bridging parts, two adjacent straight wire parts are connected through one bridging part, and the end part of the straight wire part positioned at the outermost side is a wire outlet end. The flat wire wave winding of the present application may be bent into a desired shape and then pushed into the corresponding stator slot 110 and wire layer position from the open end of the stator slot 110 on a tooling. In one embodiment, the outgoing lines of the flat wire wave winding are concentrated on one outgoing side of the stator 10. In addition, the flat wire wave winding of the application does not limit the parallel count of each phase of current; the designer can design the coil of the flat wire wave winding into a stator winding with 1, 2 or 4 coils connected in parallel according to actual needs.

In an embodiment, the wire outlet ends of two straight wire portions of a molded wire are located on the same side of the stator 10, and the side is the lead-out side of the stator 10, and the opposite side is the non-lead-out side. The bridge portion may be divided into a lead-out side bridge portion on the lead-out side of the stator 10 and a non-lead-out side bridge portion not on the lead-out side of the stator 10.

In the process, a plurality of forming wires are stacked together according to the sequence and offset by a fixed slot pitch according to the winding rule, then the wire is wound into a coil with a set number of slots in the tooling, and the opening end of the stator slot 110 is pushed into the stator 10 to form a winding coil.

Referring to fig. 1 and 2 together, in one embodiment, the flat wire wave winding includes a first shaped wire 210 (shown in fig. 3 and 4) and a second shaped wire 220 (shown in fig. 5 and 6); the first and second shaped wires 210 and 220 are not uniform in length, and the first and second shaped wires 210 and 220 are connected in series to form a first coil. Wherein, a phase winding of the flat wire wave winding sequentially occupies a phase stator slot 110 and a corresponding wire layer position of the phase stator slot 110.

In the present embodiment, the number of the straight wire portions and the bridge portions of a molded wire can be determined by the number of the stator slots 110 and the number of motor phases.

For example, the flat wire wave winding of the present application is suitable for use in a multiphase motor that includes multiphase current. Taking a three-phase motor as an example, the flat wire wave winding of the application is formed by a plurality of forming wires to form a U-phase winding, a V-phase winding and a W-phase winding respectively, so that U-phase current, V-phase current and W-phase current can flow into the windings respectively. The three-phase motor comprises 48 stator slots 110, each phase comprising 16 stator slots 110. In this embodiment, 8 shaped wires are provided for each phase, each of which is designed as a shaped wire including 12 straight wire portions and 11 bridge portions, and a coil winding arrangement of the flat wire wave winding of the present application will be described below taking a U-phase winding as an example.

As shown in fig. 3 and 4, in an embodiment, the first molding conductive wire 210 includes a plurality of first straight conductive wire portions 211 and a plurality of first bridging portions 212, two adjacent first straight conductive wire portions 211 are connected by a first bridging portion 212, and the end portions of two first straight conductive wire portions 211 located at the outermost side are both first wire outlet ends 213. In the present embodiment, the first straight wire portion 211 of the first molded wire 210 occupies a specific stator slot 110 and a specific wire layer position according to a winding rule of the present application. As shown in fig. 2, the first molded conductive lines 210 are conductive lines corresponding to 1-12.

Specifically, the first wire ends 213 of the two first straight wire portions 211 located on the outside are both located on the lead-out side of the stator 10.

As shown in fig. 5 and 6, in an embodiment, the second molding wire 220 includes a plurality of second straight wire portions 221 and a plurality of second bridging portions 222, two adjacent second straight wire portions 221 are connected by a second bridging portion 222, and the end portions of two second straight wire portions 221 located at the outermost side are both second wire outlet ends 223. In the present embodiment, the second straight wire portion 221 of the second molded wire 220 occupies a specific stator slot 110 and a specific wire layer position according to a winding rule of the present application. As shown in FIG. 2, the second molded conductive lines 220 are conductive lines corresponding to a1-a 12.

Specifically, the second wire outlet ends 223 of the two second straight wire portions 221 located on the outer side are both located on the outgoing side of the stator 10.

Referring to fig. 1 and 2, in the present embodiment, a first wire outlet 213 and a second wire outlet 223 under different magnetic poles are connected in series, so that the first molding wire 210 and the second molding wire 220 are connected in series to form a first coil. Specifically, the first coil may be formed by welding a first wire outlet 213 with a second wire outlet 223. In this embodiment, the first coil occupies a total of 24 specific wire layer positions of the specific stator slots 110, forming part of the flat wire wave winding structure of the present application.

Referring to fig. 1 and 2, in the present embodiment, the U-phase winding includes four first coils. The four first coils can be connected in parallel or in series to form a U-phase winding of one, two or four branches according to design requirements. The method of arranging each coil in the stator 10 will be specifically described below.

Referring to fig. 3 and 5 together, in one embodiment, the first coil may be composed of a first molding wire 210 and a second molding wire 220. The first molding conductive line 210 is a conductive line from the outermost layer to the inner layer of the conductive line layer, and the second molding conductive line 220 is a conductive line from the innermost layer to the outer layer of the conductive line layer. Specifically, the first wire outlet end 213 of the first straight wire portion 211 of the innermost wire layer of the first molded wire 210 is connected in series with the second wire outlet end 223 of the second straight wire portion 221 of the outermost wire layer of the second molded wire 220.

Referring to fig. 2, the span rules of the first forming wire 210 (shown in fig. 3 and 4) and the second forming wire 220 (shown in fig. 5 and 6) of the flat wire wave winding in this embodiment are changed according to the following rules:

(1) The first molding wires 210 run from the outermost layer to the innermost layer of the wire layers, and the number of the first straight wire portions 211 of the first molding wires 210 distributed in each wire layer is equal. Specifically, two adjacent first straight wire portions 211 of a first molding wire 210 are located in the same wire layer. As shown in fig. 2 at 1-12 and b1-b12, are first shaped conductors 210.

In the present embodiment, the spans of the first straight line portion 211 on the non-extraction side alternate in the order of the first span and the second span, and the span when the first straight line portion 211 spans the layer is the third span.

(2) The second molding wires 220 are routed from the innermost layer to the outermost layer of the wire layers, and the number of second straight wire portions 221 of the second molding wires 220 distributed in each wire layer is equal. Specifically, two adjacent second straight wire portions 221 of a second molding wire 220 are located in the same wire layer. As shown in fig. 2, a1-a12 and c1-c12, are second shaped conductors 220.

In the present embodiment, the spans of the second straight wire portion 221 on the non-extraction side alternate in the order of the second span and the first span, and the span when the second straight wire portion 221 spans the layer is the third span.

In this embodiment, the first span is equal to span D+1, the second span is equal to span D-1, and the third span is equal to span D. Specifically, taking 48 stator slots 110 as an example, the span is D, d=2n/2 p; p is the pole pair number of the motor and 2n is the number of stator slots 110, then the span D can be found to be equal to 6.

In one embodiment, the stator core 100 may include 48 stator slots 110, the 48 stator slots 110 are numbered 1# to 48# in sequence, and each stator slot 110 defines 6 wire layers, and the 6 wire layer positions are numbered L1 to L6 in sequence. Where L1 is the wire layer position of the outermost ring and L6 is the wire layer position of the innermost ring near the open end of the stator slot 110.

In order to clearly illustrate the positions of the flat wire wave windings in the stator slots 110 and the wire layers, a U-phase winding example of the above-described three-phase motor of 48 stator slots 110 is described next.

As shown in fig. 2 to 4, in an embodiment, taking the wires corresponding to 1-12 in fig. 2 as an example, a first straight wire portion 211 at the outermost side of the first molding wire 210 occupies the wire layer position (1#l1) at the outermost ring of the 1 st stator slot 110, another first straight wire portion 211 at the outermost side of the first molding wire 210 occupies the wire layer position (19#l6) at the innermost layer of the 19 th stator slot 110 near the opening of the stator slot 110, and the first straight wire portion 211 in the middle sequentially occupies the specific stator slot 110 and the wire layer position. Specifically, the structure of the first molding wire 210 in the stator 10 may be configured as follows (as shown in fig. 2 at 1-12):

1#L1-8#L1-14#L2-19#L2-25#L3-32#L3-38#L4-43#L4-1#L5-8#L5-14#L6-19#L6。

As shown in fig. 2, 5 and 6, in an embodiment, taking the wires corresponding to a1-a12 in fig. 2 as an example, a second straight wire portion 221 on the outermost side of the second molding wire 220 occupies the wire layer position (2#l1) on the outermost layer of the 2 nd stator slot 110, another second straight wire portion 221 on the outermost side of the second molding wire 220 occupies the wire layer position (20#l6) on the innermost layer of the 20 th stator slot 110 near the opening of the stator slot 110, and the second straight wire portion 221 in the middle sequentially occupies the specific stator slot 110 and the wire layer position. Specifically, the structure of the second molding wire 220 in the stator 10 may be configured as follows (as shown by a1-a12 in fig. 2):

2#L1-7#L1-13#L2-20#L2-26#L3-31#L3-37#L4-44#L4-2#L5-7#L5-13#L6-20#L6。

In this embodiment, the first wire outlet end 213 of the first straight wire portion 211 of the first molding wire 210 occupying the wire layer position (19#l6) of the 19 th stator slot 110, which is the innermost layer near the opening of the stator slot 110, may be connected to the second wire outlet end 223 of the second straight wire portion 221 of the second molding wire 220 occupying the wire layer position (2#l1) of the 2 nd stator slot 110. I.e., 12 of the first molding wire 210 is connected with a1 of the second molding wire 220 as shown in fig. 2.

Of course, in another embodiment, as shown in fig. 2, b1-b12 also represent the first molding wires 210, and the first molding wires 210 corresponding to b1-b12 are obtained by translating the first molding wires 210 corresponding to 1-12 by 2D stator slots 110. Correspondingly, in the present embodiment, the number of the stator slots 110 is 48, and the first molding wires 210 corresponding to b1-b12 are obtained by translating the first molding wires 210 corresponding to 1-12 by 12 stator slots 110.

Similarly, as shown in fig. 2, c1-c12 also represent second shaped conductive wires 220, and the second shaped conductive wires 220 corresponding to c1-c12 are obtained by translating the second shaped conductive wires 220 corresponding to a1-a12 by 2D stator slots 110. Correspondingly, in the present embodiment, the number of the stator slots 110 is 48, and the second molding wires 220 corresponding to c1-c12 are obtained by translating 12 stator slots 110 by the second molding wires 220 corresponding to a1-a 12.

In another embodiment, the first coil may be further connected by a first wire outlet end 213 of the first straight wire portion 211 of the first molded wire 210 occupying the wire layer position (19#l6) of the 19 th stator slot 110 closest to the opening of the stator slot 110, and a second wire outlet end 223 of the second straight wire portion 221 of the second molded wire 220 corresponding to c1-c12 occupying the wire layer position (14#l1) of the 14 th stator slot 110. I.e., 12 of the first molding wire 210 is connected to c1 of the second molding wire 220 as shown in fig. 2. Or in other embodiments, the first wire outlet end 213 of the first molding wire 210 located at the L6 th layer may be connected to the second wire outlet end 223 of the other second molding wire 220 located at the L1 th layer.

In this embodiment, since the U-phase winding includes four first coils, the four first coils are offset from each other to occupy all of the stator slots 110. The structure of the flat wire wave winding of the present application can be completed by simply manufacturing the plurality of first molding wires 210 and the plurality of second molding wires 220 in a process.

In another embodiment, as shown in fig. 7 and 8, the difference from the above solution is that:

The span rules of the first shaped wire 210 (shown in fig. 9 and 10) and the second shaped wire 220 (shown in fig. 11 and 12) of the flat wire wave winding in this embodiment vary according to the following rules:

(1) The first molding wires 210 are routed from the outermost layer to the innermost layer of the wire layers, and the number of the first straight wire portions 211 of the first molding wires 210 distributed in each wire layer is equal. Specifically, two adjacent first straight wire portions 211 of a first molding wire 210 are located in the same wire layer. As shown in fig. 2 at 1-12 and b1-b12, are first shaped conductors 210.

In the present embodiment, the first straight wire portions 211 of the first molding wire 210 are alternately changed in order of the first span and the second span in order.

(2) The second molding wires 220 are routed from the innermost layer to the outermost layer of the wire layers, and the number of the second straight wire portions 221 of the second molding wires 220 distributed in each of the wire layers is equal. Specifically, two adjacent second straight wire portions 221 of a second molding wire 220 are located in the same wire layer. As shown in fig. 2, a1-a12 and c1-c12, are second shaped conductors 220.

In the present embodiment, the second straight wire parts 221 of the second molding wire 220 are alternately changed in order of the second span and the first span in turn.

In this embodiment, the first span is equal to span D+1 and the second span is equal to span D-1. Taking 48 stator slots 110 as an example, the span D is equal to 6.

In order to clearly illustrate the positions of the flat wire wave windings in the stator slots 110 and the wire layers, a U-phase winding example of the above-described three-phase motor of 48 stator slots 110 is described next.

As shown in fig. 8 to 10, in an embodiment, taking the wires corresponding to 1-12 in fig. 8 as an example, a first straight wire portion 211 at the outermost side of the first molding wire 210 occupies the wire layer position (1#l1) at the outermost ring of the 1 st stator slot 110, another first straight wire portion 211 at the outermost side of the first molding wire 210 occupies the wire layer position (20#l6) at the innermost layer of the 20 th stator slot 110 near the opening of the stator slot 110, and the first straight wire portion 211 in the middle sequentially occupies the specific stator slot 110 and the wire layer position. Specifically, the structure of the first molding wire 210 in the stator 10 may be configured as follows (as shown in 1-12 in fig. 8):

1#L1-8#L1-13#L2-20#L2-25#L3-32#L3-37#L4-44#L4-1#L5-8#L5-13#L6-20#L6。

As shown in fig. 8, 11 and 12, in an embodiment, taking the wires corresponding to a1-a12 in fig. 8 as an example, a second straight wire portion 221 on the outermost side of the second molding wire 220 occupies the wire layer position (2#l1) on the outermost side of the 2 nd stator slot 110, another second straight wire portion 221 on the outermost side of the second molding wire 220 occupies the wire layer position (19#l6) on the innermost layer of the 19 th stator slot 110 near the opening of the stator slot 110, and the second straight wire portion 221 in the middle sequentially occupies the specific stator slot 110 and the wire layer position. Specifically, the structure of the second molding wire 220 in the stator 10 may be configured as follows (as shown by a1-a12 in fig. 8):

2#L1-7#L1-14#L2-19#L2-26#L3-31#L3-38#L4-43#L4-2#L5-7#L5-14#L6-19#L6。

In this embodiment, the first wire outlet end 213 of the first straight wire portion 211 of the first molded wire 210 occupying the wire layer position (20#l6) of the innermost layer of the 20 th stator slot 110 near the opening of the stator slot 110 may be connected with the second wire outlet end 223 of the second straight wire portion 221 of the second molded wire 220 occupying the wire layer position (2#l1) of the outermost layer of the 2 nd stator slot 110. I.e., 12 of the first molding wire 210 is connected with a1 of the second molding wire 220 as shown in fig. 8.

Of course, in another embodiment, as shown in fig. 8, b1-b12 also represents the first molding wire 210, the first molding wire 210 corresponding to b1-b12 is obtained by translating the first molding wire 210 corresponding to 1-12 by 2D stator slots 110, and D1-D2 also represents the first molding wire 210 is obtained by translating the first molding wire 210 corresponding to b1-b12 by 2D stator slots 110. f1-f2 also represent the first shaped wire 210, resulting from the translation of the first shaped wire 210 by 2D stator slots 110 corresponding to D1-D12. Correspondingly, in the present embodiment, the number of stator slots 110 is 48, and D is 6.

Similarly, as shown in fig. 8, c1-c12 also represent second shaped conductive wires 220, and the second shaped conductive wires 220 corresponding to c1-c12 are obtained by translating the second shaped conductive wires 220 corresponding to a1-a12 by 2D stator slots 110. The second shaped wire 220 corresponding to e1-e12 is obtained by translating the second shaped wire 220 corresponding to c1-c12 by 2D stator slots 110. The second shaped wire 220 corresponding to g1-g12 is obtained by translating the second shaped wire 220 corresponding to e1-e12 by 2D stator slots 110. For the corresponding 48 stator slots 110 in this embodiment, D is 6.

In other embodiments, the first coil may be further connected by a first wire outlet end 213 of the first straight wire portion 211 of the innermost layer of the 20 th stator slot 110 occupying the wire layer position (20#l6) close to the opening of the stator slot 110, and a second wire outlet end 223 of the second straight wire portion 221 of the second wire layer position (14#l1) of the outermost layer of the 14 th stator slot 110 occupied by the second molded wire 220 corresponding to c1-c 12. I.e., 12 of the first molding wire 210 is connected to c1 of the second molding wire 220 as shown in fig. 8. Or in other embodiments, the first wire outlet end 213 of the first molding wire 210 located at the L6 th layer may be connected to the second wire outlet end 223 of the other second molding wire 220 located at the L1 th layer.

As shown in fig. 13 and 14, in another embodiment, the point of difference from the above-described scheme is that:

In this embodiment, taking a three-phase motor as an example, the flat wire wave winding of the present application is formed by a plurality of forming wires to form a U-phase winding, a V-phase winding and a W-phase winding, so that the U-phase current, the V-phase current and the W-phase current can flow into the windings respectively. The three-phase motor comprises 48 stator slots 110, each phase comprising 16 stator slots 110. In this embodiment, 16 forming wires are provided for each phase, each forming wire is designed to include 6 straight wire portions and 5 bridging portions, and a U-phase winding will be taken as an example to describe the coil winding configuration of the flat wire wave winding of the present application.

The span rules of the first shaped wire 210 (shown in fig. 15 and 16) and the second shaped wire 220 (shown in fig. 17 and 18) of the flat wire wave winding in this embodiment vary according to the following rules:

(1) The first molding wires 210 run from the outermost layer to the innermost layer of the wire layers, and each wire layer is distributed with a first straight wire portion 211. The first straight wire portions 211 of the first molding wire 210 are alternately changed in order of the first span and the second span in turn.

(2) The second molding wires 220 are routed from the innermost layer to the outermost layer of wire layers, each wire layer being distributed with a second straight wire portion 221. The second straight wire parts 221 of the second molding wire 220 are alternately changed in order of the second span and the first span in turn.

As shown in fig. 14 to 16, in an embodiment, taking the wires corresponding to 1-6 in fig. 14 as an example, a first straight wire portion 211 at the outermost side of the first molding wire 210 occupies the wire layer position (1#l1) at the outermost ring of the 1 st stator slot 110, another first straight wire portion 211 at the outermost side of the first molding wire 210 occupies the wire layer position (32#l6) at the innermost layer of the 32 nd stator slot 110 near the opening of the stator slot 110, and the first straight wire portion 211 in the middle sequentially occupies the specific stator slot 110 and the wire layer position. Specifically, the structure of the first molding wire 210 in the stator 10 may be configured as follows (as shown in 1-6 of fig. 14):

1#L1-8#L2-13#L3-20#L4-25#L5-32#L6。

As shown in fig. 14, 17 and 18, in an embodiment, taking the wires corresponding to a1-a6 in fig. 14 as an example, a second straight wire portion 221 on the outermost side of the second molding wire 220 occupies the wire layer position (2#l1) on the outermost side of the 2 nd stator slot 110, another second straight wire portion 221 on the outermost side of the second molding wire 220 occupies the wire layer position (31#l6) on the innermost layer of the 31 st stator slot 110 near the opening of the stator slot 110, and the second straight wire portion 221 in the middle sequentially occupies the specific stator slot 110 and the wire layer position. Specifically, the structure of the second molding wire 220 in the stator 10 may be configured as follows (as shown as a1-a6 in fig. 14):

2#L1-7#L2-14#L3-19#L4-26#L5-31#L6。

As shown in fig. 14, b1-b6 also represent the first shaped conductive lines 210, and the first shaped conductive lines 210 corresponding to b1-b6 are obtained by translating the D stator slots 110 by the first shaped conductive lines 210 corresponding to 1-6. Correspondingly, in the present embodiment, the number of stator slots 110 is 48, and D is 6.

Similarly, as shown in fig. 14, c1-c6 also represent second shaped wires 220, and the second shaped wires 220 corresponding to c1-c6 are obtained by translating D stator slots 110 from the second shaped wires 220 corresponding to a1-a 6. Correspondingly, in the present embodiment, the number of stator slots 110 is 48, and D is 6.

In one embodiment, the first wire outlet 213 of the first straight wire portion 211 of the innermost wire layer of the first molded wire 210 is connected in series with the second wire outlet 223 of the second wire portion 221 of the innermost wire layer of the second molded wire 220, and the first wire outlet 213 and the second wire outlet 223 connected in series are at different magnetic poles.

In this embodiment, the first wire outlet end 213 of the first straight wire portion 211 of the first molded wire 210 occupying the wire layer position (32#l6) of the innermost layer of the 32 nd stator slot 110 near the opening of the stator slot 110 may be connected to the second wire outlet end 223 of the second straight wire portion 221 of the second molded wire 220 occupying the wire layer position (37#l6) of the 37 th stator slot 110. I.e., 6 of the first molding wire 210 is connected with c6 of the second molding wire 220 as shown in fig. 14.

Further, b6 of the first molding wire 210 may be connected with a6 of the second molding wire 220 as shown in fig. 14.

As shown in fig. 13 and 14, in the present embodiment, since the U-phase winding includes eight first coils, the eight first coils are offset from each other to occupy all of the stator slots 110. The structure of the flat wire wave winding of the present application can be completed by simply manufacturing the plurality of first molding wires 210 and the plurality of second molding wires 220 in a process.

The flat wire wave winding just needs to make two types of molded wires, namely, a first molded wire 210 and a second molded wire 220, and a first coil can be formed by connecting the first molded wire 210 and the second molded wire 220 in series. Only two molding leads are provided, so that the connection is convenient and the error is not easy to occur. The number of the branches formed by the serial connection or parallel connection of the first coils is flexible, and the circulation problem among the branches can be effectively solved. The flat wire wave winding can also greatly reduce the risk operations of cutting, bending, welding and the like of the lead of the traditional flat wire wave winding.

The technical features of the above-described embodiments may be arbitrarily combined, and all possible combinations of the technical features in the above-described embodiments are not described for brevity of description, however, as long as there is no contradiction between the combinations of the technical features, they should be considered as the scope of the description.

The above examples illustrate only a few embodiments of the application, which are described in detail and are not to be construed as limiting the scope of the claims. It should be noted that it will be apparent to those skilled in the art that several variations and modifications can be made without departing from the spirit of the application, which are all within the scope of the application. Accordingly, the scope of protection of the present application is to be determined by the appended claims.

Claims (10)

1. A flat wire wave winding, the flat wire wave winding comprising:

The first molding lead comprises a plurality of first straight lead parts and a plurality of first bridging parts, wherein two adjacent first straight lead parts are connected through one first bridging part, and the end parts of the two outermost first straight lead parts are first wire outlet ends; and

The second molding lead comprises a plurality of second straight lead parts and a plurality of second bridging parts, wherein two adjacent second straight lead parts are connected through one second bridging part, and the end parts of the two second straight lead parts positioned at the outermost side are second wire outlet ends;

Wherein; the lengths of the first forming wire and the second forming wire are inconsistent, and a first wire outlet end of the first forming wire and a second wire outlet end of the second forming wire are connected in series to form a first coil.

2. The flat wire wave winding of claim 1 wherein,

The first forming wires are routed from the outermost layer to the innermost layer of the wire layers, and the number of the first straight wire parts of the first forming wires distributed in each wire layer is equal;

The second molding wires are routed from the innermost layer to the outermost layer of the wire layers, and the second straight wire parts of the second molding wires distributed in each wire layer are equal in number.

3. The flat wire wave winding of claim 2 wherein two adjacent ones of said first straight wire portions of one of said first shaped wires are located in the same said wire layer; two adjacent second straight wire parts of one second molding wire are positioned in the same wire layer.

4. The flat wire wave winding of claim 3 wherein,

The first straight wire parts of the first forming wires are alternately changed in sequence according to the sequence of a first span and a second span; the second straight wire parts of the second molded wires are alternately changed in sequence according to the sequence of the second span and the first span;

Or alternatively

The spans of the first straight wire part on the non-extraction side are alternately changed according to the sequence of the first span and the second span, and the span of the first straight wire part when crossing layers is a third span; the spans of the second straight wire part on the non-extraction side are alternately changed in the order of the second span and the first span, and the span of the second straight wire part when crossing layers is a third span.

5. The flat wire wave winding of claim 4 wherein a first wire outlet end of said first straight wire portion of said first molded wire located at an innermost layer of said wire layers is in series with a second wire outlet end of said second straight wire portion of said second molded wire located at an outermost layer of said wire layers.

6. The flat wire wave winding of claim 4 or 5, wherein the first span is equal to span d+1, the second span is equal to span D-1, and the third span is equal to span D; wherein the span is D, d=2n/2 p; p is the pole pair number of the motor and 2n is the number of stator slots.

7. The flat wire wave winding of claim 2 wherein,

Each wire layer is distributed with one first straight wire part, and the first straight wire parts of the first forming wires are changed in turn according to the sequence of a first span and a second span;

Each wire layer is distributed with one second straight wire part, and the second straight wire parts of the second forming wires are changed in turn according to the sequence of the second span and the first span.

8. The flat wire wave winding of claim 7, wherein a first wire outlet end of the first straight wire portion of the first molded wire at an innermost layer of the wire layers is in series with a second wire outlet end of the second straight wire portion of the second molded wire at an innermost layer of the wire layers, and the first wire outlet end and the second wire outlet end of the series connection are at different poles.

9. A stator, the stator comprising:

The stator core is provided with a plurality of stator grooves which are arranged around the axis direction; and

The flat wire wave winding of any of claims 1-8, disposed within the stator slot.

10. An electric machine comprising a stator as claimed in claim 9, wherein a phase winding of said flat wire wave winding comprises a plurality of said first coils, said plurality of first coils being mutually deflected to occupy all of one phase of said stator slots.