WO2025209364A1 - Flat wire winding, motor, electric drive assembly and vehicle - Google Patents

Abstract

The present application provides a flat wire winding, a motor and a vehicle. The flat wire winding is wound in a plurality of motor slots of a motor that are arranged in an array; the flat wire winding comprises multiple turns of winding structure, each turn of winding structure a plurality of coil structures; each coil structure comprises two conductor edges, the two conductor edges threading through different motor slots respectively; the two conductor edges of each coil structure are arranged across two adjacent layers in the motor slots, the spans of the coil structures in the same turn being identical to each other; from the outer turn of winding structure to the inner turn of winding structure, the distances between the two conductor edges of the coil structures of each turn of winding structure are gradually reduced. Among the flat wire winding, the motor, the electric drive assembly and the vehicle of the present application, coils in the flat wire winding have few overall types and models, thus reducing manufacturing costs, simplifying wiring processes, and quickening the takt time.

Description

Flat wire winding, motor, electric drive assembly and vehicle

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is based on the Chinese patent application with application number 202420685312.X and application date April 3, 2024, and claims the priority of the above-mentioned Chinese patent application. The entire content of the above-mentioned Chinese patent application is hereby introduced into this application as a reference.

Technical Field

The present application relates to the field of motor technology, and in particular to a flat wire winding, a motor, an electric drive assembly, and a vehicle.

Background Art

In new energy vehicles, flat wire motors are usually used for driving. The flat wire motors include a plurality of motor slots arranged along their circumference, and each motor slot is provided with a plurality of layers of conductors.

Currently, motor slots typically have an even number of conductor layers. Each layer has different winding configurations, employing various types, such as I- and U-shaped windings. Furthermore, the size and structure of windings within a layer can vary depending on the motor design. For example, a U-shaped winding may include both regular and jumper windings. This variety of winding coil types and sizes increases manufacturing costs and complicates the wire insertion process, impacting production schedules.

Summary of the Invention

The flat wire winding, motor, electric drive assembly and vehicle provided in this application have fewer types and models of coils in the flat wire winding, which can reduce manufacturing costs, simplify the wire insertion process and speed up production time.

The present application provides a flat wire winding, which is wound in multiple array-arranged motor slots of a motor. The flat wire winding includes a multi-turn winding structure, each turn winding structure includes multiple coil structures, and the coil structure includes two conductor sides. The two conductor sides are respectively arranged in different motor slots. The two conductor sides of each coil structure span two adjacent layers in the motor slot. The span of the coil structures in the same turn is the same, and the distance between the two conductor sides of the coil structure of each turn winding structure gradually decreases from the outer turn to the inner turn of the winding structure.

As for the flat wire winding as above, the spans of the coil structures of the multi-turn winding structure are all set to be the same, and the number of coil structures in one turn is equal to the number of motor slots.

As shown above, the flat wire winding includes a four-turn winding structure, each motor slot is arranged with an eight-layer coil structure, and the multiple coil structures of each turn winding structure include multiple first coils and multiple second coils. In the same turn winding structure, the multiple first coils are electrically connected in sequence, and the multiple second coils are electrically connected in sequence.

As for the flat wire winding as above, along the radial direction of the motor, the flat wire winding includes a hairpin end and an outlet end that are relatively arranged. At the hairpin end, different winding structures are independently arranged.

As shown in the flat wire winding above, part of the coil structure includes two welding parts provided at the output end, the two welding parts are respectively passed through two different motor slots and extended out of the motor slots, and the coil structure is electrically connected to the coil structure of the same turn winding structure or the coil structure of the adjacent turn winding structure through the welding parts.

As shown in the flat wire winding above, the partial coil structure of the innermost winding structure includes a welding portion and a wire outlet portion, and the wire outlet portions of multiple coil structures are sequentially arranged in adjacent motor slots. The length of the wire outlet portion is greater than the length of the welding portion, and the wire outlet portion is used to connect to external electrical equipment.

As shown in the flat wire winding above, the two welding parts of the coil structure are respectively arranged in two adjacent layers of the motor slot. In one-turn winding structure, the welding parts of multiple coil structures arranged in the same layer are twisted in the same direction, and the welding parts of multiple coil structures arranged in adjacent layers are twisted in opposite directions.

In the above rectangular wire winding, in the welding parts of the same layer of the outermost winding structure, the welding parts are arranged in groups of two, and the twisting distances of two adjacent welding parts in a group are different.

On the other hand, the present application further provides a motor, wherein the motor includes a plurality of motor slots and the above-mentioned flat wire winding, and the flat wire winding is wound in the plurality of motor slots.

On the other hand, the present application also provides an electric drive assembly, wherein the electric drive assembly includes the above-mentioned motor.

On the other hand, the present application also provides a vehicle, wherein the vehicle includes the above-mentioned electric drive assembly.

The flat wire winding of the present application is wound in multiple array-arranged motor slots of the motor. The flat wire winding includes a multi-turn winding structure, and each turn winding structure includes multiple coil structures. From the outer turn to the inner turn, the spacing between the two conductor sides of the coil structure in each turn gradually decreases, and the span of the coil structure in the same turn is the same. Therefore, it is only necessary to design the coil structure of each turn separately, and the coil structure of the same turn is designed to have the same overall size. The type of coil structure designed in this way is equal to the number of turns, so that the overall types and models of the coil structure are relatively few, so that there is no need to perform multiple types of complex designs on the coil structure during the manufacturing process, and it is also more convenient to install fewer types of coil structures in the motor slot, thereby achieving the needs of reducing manufacturing costs, simplifying the wire insertion process and speeding up the production cycle.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG1 is a connection diagram of a unidirectional winding structure of a flat wire winding provided in an embodiment of the present application;

FIG2 is a schematic diagram of the structure inside the motor slot of the motor provided in an embodiment of the present application;

FIG3 is a schematic diagram of the overall structure of a motor provided in an embodiment of the present application;

FIG4 is a schematic structural diagram of a hairpin end of a flat wire winding provided in an embodiment of the present application.

DETAILED DESCRIPTION

In order to more clearly understand the above-mentioned objectives, features and advantages of the present disclosure, the scheme of the present disclosure will be further described below. It should be noted that the embodiments of the present disclosure and the features therein can be combined with each other in the absence of conflict.

In the following description, many specific details are set forth to facilitate a full understanding of the present disclosure, but the present disclosure may also be implemented in other ways different from those described herein; it is obvious that the embodiments in the specification are only part of the embodiments of the present disclosure, rather than all of the embodiments.

In the embodiment of the present application, the flat wire winding is used in conjunction with a 12-pole 72-slot motor, and the number of pole-slot combinations of the motor is 2, but is not limited to the specific number of poles, number of slots and number of pole-slot combinations in the embodiment of the present application, wherein the pole pitch of the 12-pole 72-slot motor is 6.

As shown in Figures 1 to 4, an embodiment of the present application provides a flat wire winding, which is wound in multiple array-arranged motor slots 30 of the motor. The flat wire winding includes a multi-turn winding structure 10, each turn winding structure 10 includes multiple coil structures 20, and the coil structure 20 includes two conductor edges 25. The two conductor edges 25 are respectively arranged in different motor slots 30. The two conductor edges 25 of each coil structure 20 are arranged across two adjacent layers in the motor slot 30. The span of the coil structures 20 in the same turn is the same, and the distance between the two conductor edges 25 of the coil structure 20 of each turn winding structure 10 gradually decreases from the outer turn to the inner turn of the winding structure 10.

It should be noted that each coil structure 20 includes two conductor edges 25 arranged at intervals. When the coil structure 20 is assembled in the motor slot 30 of the motor, the two conductor edges 25 are arranged across multiple motor slots 30, and the number of motor slots 30 spanned by the two conductor edges 25 is the span of the coil structure 20; in the circumferentially arranged motor slots 30, each motor slot 30 can accommodate multiple conductor edges 25, and multiple conductor edges 25 are stacked in the motor slot 30 along the radial direction of the motor. Therefore, the two conductor edges 25 of each coil structure 20 are respectively arranged in adjacent layers in different motor slots 30, that is, one of the conductor edges 25 is arranged in the first layer of the first motor slot 30, and the other conductor edge 25 is arranged in the second layer of the seventh motor slot 30.

During specific implementation, the flat wire winding of the embodiment of the present application is wound in multiple array-arranged motor slots 30 of the motor. The flat wire winding includes a multi-turn winding structure 10, and each turn winding structure 10 includes multiple coil structures 20. From the outer turn to the inner turn, the spacing between the two conductor edges 25 of the coil structure 20 in each turn gradually decreases, and the span of the coil structure 20 in the same turn is the same. Therefore, it is only necessary to design the coil structure 20 of each turn separately, and the coil structure 20 of the same turn is designed to have the same overall size. The type of coil structure 20 designed in this way is equal to the number of turns, so that the overall types and models of the coil structure 20 are relatively few, so that there is no need to perform multiple types of complex designs on the coil structure 20 during the manufacturing process, and it is also more convenient to install fewer types of coil structures 20 in the motor slot 30, thereby achieving the needs of reducing manufacturing costs, simplifying the wiring process and speeding up the production cycle.

As shown in FIG1 and FIG3 , in the flat wire winding of the embodiment of the present application, the spans of the coil structures 20 of the multi-turn winding structure 10 are all set to be the same, and the number of coil structures 20 in one turn is equal to the number of motor slots 30 .

During specific implementation, the spans of the coil structures 20 of the multi-turn winding structure 10 are all the same. During the design and production process, only the size design of the coil structures 20 of the winding structures 10 with different turns needs to be considered, which simplifies the design and production, thereby achieving the needs of reducing manufacturing costs, simplifying the wire insertion process and speeding up the production cycle; the setting that the number of coil structures 20 in one turn is equal to the number of motor slots 30 satisfies the setting that each coil structure 20 of the one-turn winding structure 10 spans two adjacent layers in the motor slot 30, forming a complete even-layer flat wire winding structure.

As shown in Figures 1 and 2, the flat wire winding of the embodiment of the present application includes a four-turn winding structure 10, and each motor slot 30 is arranged with an eight-layer coil structure 20. The multiple coil structures 20 of each turn winding structure 10 include multiple first coils 23 and multiple second coils 24. In the same turn winding structure 10, the multiple first coils 23 are electrically connected in sequence, and the multiple second coils 24 are electrically connected in sequence.

In specific implementation, the multiple coil structures 20 are divided into multiple first coils 23 and multiple second coils 24 of equal number, which can meet the requirement that the pole slot matching number of the motor in the embodiment of the present application is 2. Among them, in the same circle winding structure 10, the setting of multiple first coils 23 electrically connected in sequence and the setting of multiple second coils 24 electrically connected in sequence can form a complete current path inside the motor, thereby realizing the normal operation of the motor.

As shown in Figures 3 and 4, the flat wire winding of the embodiment of the present application includes a hairpin end 40 and an outlet end 50 that are relatively arranged along the radial direction of the motor. At the hairpin end 40, different turn winding structures 10 are independently arranged.

In specific implementation, at the hairpin end 40, the two conductor sides 25 of each coil structure 20 in different slots are connected by a connecting wire, and when observed from the hairpin end 40, the different circle winding structures 10 are set independently, avoiding radial connection of different circle winding structures 10, thereby avoiding contact and electrical connection between the coil structures 20 of different circle winding structures 10, ensuring that the motor can work normally.

As shown in Figures 1 to 4, the flat wire winding of the embodiment of the present application, wherein a portion of the coil structure 20 includes two welding portions 21 provided at the outlet end 50, the two welding portions 21 are respectively provided in two different motor slots 30 and extend out of the motor slots 30, and the coil structure 20 is electrically connected to the coil structure 20 of the same-turn winding structure 10 or the coil structure 20 of the adjacent-turn winding structure 10 through the welding portions 21.

During specific implementation, the two welding parts 21 of the coil structure 20 are respectively connected to the two conductor edges 25, and the coil structures 20 of the same-turn winding structure 10 are electrically connected through the welding parts 21, forming a complete loop of one-turn winding structure 10, and the coil structures 20 of adjacent-turn winding structures 10 are electrically connected through the welding parts 21, forming a complete loop of the multi-turn winding structure 10 of the entire motor.

Specifically, the welding portions 21 of the two coil structures 20 are stacked and connected by welding. The stacking connection method is suitable for flat wire windings, which makes the connection between the welding portions 21 more stable.

As shown in Figures 1 to 4, the flat wire winding of the embodiment of the present application, wherein the partial coil structure 20 of the innermost circle winding structure 10 includes a welding portion 21 and a wire outlet portion 22, and the wire outlet portions 22 of multiple coil structures 20 are sequentially arranged in adjacent motor slots 30, and the length of the wire outlet portion 22 is greater than the length of the welding portion 21, and the wire outlet portion 22 is used to connect to external electrical equipment.

In specific implementation, the wire outlet 22 is arranged on the innermost winding structure 10 with the smallest diameter, and the wire outlets 22 of multiple coil structures 20 are arranged in adjacent motor slots 30 in sequence, which can minimize the space occupied by the multiple wire outlets 22, and the structure is also the simplest, and will not affect the layout of other parts of the motor.

As shown in Figure 3, the flat wire winding of the embodiment of the present application, wherein the two welding portions 21 of the coil structure 20 are respectively arranged in two adjacent layers of the motor slot 30. In one circle of the winding structure 10, the welding portions 21 of multiple coil structures 20 arranged in the same layer are twisted in the same direction, and the welding portions 21 of multiple coil structures 20 arranged in adjacent layers are twisted in opposite directions.

During specific implementation, in a one-turn winding structure 10, the welding portions 21 of multiple coil structures 20 located on the same layer are twisted in the same direction, which can facilitate the arrangement of the coil structures 20 in the motor slots 30 and avoid position conflicts between the welding portions 21 on the same layer; and the welding portions 21 of multiple coil structures 20 located on adjacent layers are twisted in opposite directions, which can facilitate the welding connection of the welding portions 21 of adjacent layers, thereby forming a complete current loop in the same turn winding structure 10.

As shown in FIG3 , in the flat wire winding of the embodiment of the present application, in the welding portions 21 of the outermost winding structure 10 on the same layer, multiple welding portions 21 are arranged in groups of two, and the twisting distances of two adjacent welding portions 21 in a group are different.

In specific implementation, the twisting distances of two adjacent welding parts 21 in a group of the outermost circle winding structure 10 are different, that is, the welding part 21 of the first coil 23 and the welding part 21 of the second coil 24 of the outermost circle winding structure 10 can form a double-layer reverse twist structure, and the welding part 21 with a longer twisting distance can be radially arranged on the upper layer of the welding part 21 with a shorter twisting distance of the flat wire winding. Such an arrangement can achieve voltage balance in the branches where the first coil 23 and the second coil 24 are located, and reduce the circulating current between the branches.

As shown in FIG. 1 to FIG. 4 , an embodiment of the present application further provides a motor, wherein the motor includes a plurality of motor slots 30 and the above-mentioned flat wire windings, and the flat wire windings are wound in the plurality of motor slots 30 .

An embodiment of the present application further provides an electric drive assembly, wherein the electric drive assembly includes the above-mentioned motor.

An embodiment of the present application also provides a vehicle, wherein the vehicle includes the above-mentioned electric drive assembly.

In specific implementation, the electric drive assembly of the embodiment of the present application includes a motor, and the motor includes a flat wire winding. The flat wire winding is wound in multiple array-arranged motor slots 30 of the motor. The flat wire winding includes a multi-turn winding structure 10, and each turn winding structure 10 includes multiple coil structures 20. The size of the coil structure 20 in each turn gradually decreases from the outer turn to the inner turn, and the span of the coil structure 20 in the same turn is the same. Therefore, it is only necessary to design the coil structure 20 of each turn separately, and the coil structure 20 of the same turn is designed to have the same overall size. The type of coil structure 20 designed in this way is equal to the number of turns, so that the overall type and model of the coil structure 20 are relatively small, so that there is no need to perform multiple types of complex designs on the coil structure 20 during the manufacturing process, and it is also more convenient to install fewer types of coil structures 20 in the motor slot 30, thereby achieving the needs of reducing manufacturing costs, simplifying the wiring process and speeding up the production cycle.

It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the term "comprises" or any other variant thereof is intended to cover non-exclusive inclusion, so that a process, method, article or device that includes a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. In the absence of further restrictions, the elements defined by the sentence "comprise a..." do not exclude the presence of other identical elements in the process, method, article or device that includes the elements.

Claims (11)

A flat wire winding is wound in multiple array-arranged motor slots of a motor, the flat wire winding comprising a multi-turn winding structure, each turn of the winding structure comprising multiple coil structures, the coil structure comprising two conductor sides, the two conductor sides respectively passing through different motor slots, the two conductor sides of each coil structure being arranged across two adjacent layers in the motor slot, the coil structures of the same turn having the same span, and the spacing between the two conductor sides of the coil structure of each turn of the winding structure gradually decreasing from the outer turn to the inner turn. According to the flat wire winding according to claim 1, the spans of the coil structures of multiple turns of the winding structure are all arranged to be the same, and the number of the coil structures in one turn is arranged to be equal to the number of the motor slots. The flat wire winding according to claim 1 or 2, comprises four turns of the winding structure, each of the motor slots is arranged with eight layers of the coil structure, the multiple coil structures of each turn of the winding structure include multiple first coils and multiple second coils, and in the same turn of the winding structure, the multiple first coils are electrically connected in sequence, and the multiple second coils are electrically connected in sequence. According to any one of claims 1 to 3, the flat wire winding comprises a hairpin end and a wire outlet end that are oppositely arranged along the radial direction of the motor, and at the hairpin end, different turns of the winding structure are independently arranged. According to the flat wire winding according to claim 4, part of the coil structure includes two welding parts provided at the outlet end, the two welding parts are respectively penetrated into two different motor slots and extended out of the motor slots, and the coil structure is electrically connected to the coil structure of the same circle of the winding structure or the coil structure of the adjacent circle of the winding structure through the welding parts. According to the flat wire winding according to claim 5, the coil structure of the innermost circle of the winding structure includes a welding portion and a wire outlet portion, and the wire outlet portions of multiple coil structures are sequentially arranged in adjacent motor slots. The length of the wire outlet portion is greater than the length of the welding portion, and the wire outlet portion is used to connect to external electrical equipment. According to the flat wire winding according to claim 5 or 6, the two welding portions of the coil structure are respectively arranged in two adjacent layers of the motor slot. In one circle of the winding structure, the welding portions of multiple coil structures arranged in the same layer are twisted in the same direction, and the welding portions of multiple coil structures arranged in adjacent layers are twisted in opposite directions. According to any one of claims 5 to 7, in the welding portions of the same layer of the outermost winding structure, the welding portions are arranged in groups of two, and the twisting distances of two adjacent welding portions in a group are different. A motor comprises a plurality of motor slots and the flat wire winding according to any one of claims 1 to 8, wherein the flat wire winding is wound in the plurality of motor slots. An electric drive assembly comprises the motor according to claim 9. A vehicle comprising the electric drive assembly according to claim 10.