Motor, stator module and coil winding method thereof

Patent metadata

Field	Value
Publication number	US-11323000-B2
Application number	US-201816652342-A
Country	US
Kind code	B2
Filing date	Sep 29, 2018
Priority date	Sep 29, 2017
Publication date	May 3, 2022
Grant date	May 3, 2022

Abstract

A winding method for a stator module applicable to a motor having z slots, 2p poles, and m phases. The stator module includes a stator core and a winding coil. The winding coil is made of a flat wire. The winding method includes: forwardly winding some stator slots by means of the arrangement and connection of multiple U-shaped conductor sections, and then reversely winding the stator slots; afterwards, forwardly winding the remaining stator slots, and then reversely winding the stator slots; and cycling in this way.

First claim

What is claimed is:

1. A winding method for a winding of a stator module for a motor having z slots, 2p poles, and m phases, a number of slots per pole and phase being q=z/m/(2p), a number of parallel branches being a, a≤q, the stator module comprising a stator core having a plurality of stator slots, and each of the stator slots having a plurality of slot layers, the winding method comprising:
S 1 : providing a plurality of U-shaped conductor sections, each of the U-shaped conductor sections comprising a bent portion and a first in-slot portion and a second in-slot portion respectively connected to the bent portion, and pitches between the first in-slot portion and the second in-slot portion being all y stator slots, where y is an integer and y=z/2p;
S 2 : enabling the first in-slot portion of the U-shaped conductor section to pass through one of the slot layers in one of the stator slots and the second in-slot portion to pass through one of the slot layers in another stator slot, end portions of the first in-slot portion and the second in-slot portion extending beyond the stator core to form a welding end after the first in-slot portion and the second in-slot portion pass through the stator slots;
S 3 : welding and connecting the first in-slot portion and the second in-slot portion in different layers of the plurality of U-shaped conductor sections to the welding end, such that a winding direction of the winding is configured in each phase and each way:
S 31 : leading out a lead-out wire to a radially outermost slot layer of an initial slot;
S 32 : spanning y stator slots on the same layer along a first direction;
S 33 : spanning along a second direction by starting from a radially second outermost slot layer that spans the y stator slots, the number of layers of the slot layer changing by one every time the y stator slots are spanned, the number of layers changing radially from outside to inside till a radially second innermost slot layer;
S 34 : spanning y stator slots on the same layer along the first direction by starting from a radially innermost slot layer that spans the y stator slots;
S 35 : spanning along the first direction by starting from the radially second innermost slot layer that spans the y stator slots, the number of layers of the slot layer changing by one every time the y stator slots are spanned, the number of layers changing radially from inside to outside till the radially second outermost slot layer;
S 36 : spanning y stator slots on the same layer along the first direction by starting from the radially outermost slot layer that spans the y stator slots; and
S 37 : repeating S 33 -S 36 until the winding reaches an adjacent layer of the radially outermost slot layer of a termination slot and then a star point wire of this phase and this way is led out, the termination slot being spaced from the initial slot by y stator slots in a forward direction,
wherein the first direction and the second direction are opposite directions along the circumference of the stator core.

2. The winding method for the winding of the stator module according to claim 1 , wherein the number of layers of the slot layer in each of the stator slots is an even number.

3. The winding method for the winding of the stator module according to claim 1 , wherein lead-out wires of the same phase and respective ways differ by one stator slot between two adjacent phases in a circumferential direction.

4. The winding method for the winding of the stator module according to claim 1 , wherein star-point wires of respective phases and each way differ by 2q slots between two adjacent phases in the circumferential direction, and lead-out wires of respective phases and each way differ by 2q slots between two adjacent phases in the circumferential direction.

5. The winding method for the winding of the stator module according to claim 1 , wherein the U-shaped conductor section at least comprises:
a plurality of first U-shaped conductor sections, the first U-shaped conductor sections being used for spanning on the same layer in step S 32 ;
a plurality of second U-shaped conductor sections, the second U-shaped conductor sections being used for spanning inwards radially by one layer from a radial outer layer when spanning in a second winding direction in step S 33 ;
a plurality of third U-shaped conductor sections, the third U-shaped conductor sections being used for spanning outwards radially by one layer from a radial inner layer when spanning in a first winding direction in step S 35 ; and
a plurality of fourth U-shaped conductor sections, the fourth U-shaped conductor sections being used for spanning on the same layer in step S 34 .

6. The winding method for the winding of the stator module according to claim 5 , wherein a connecting leg and a welding leg are connected to an end of any one of the first in-slot portion and the second in-slot portion of the U-shaped conductor section respectively, the connecting leg being bent with respect to the corresponding in-slot portion.

7. The winding method for the winding of the stator module according to claim 6 , wherein the connecting legs of the first in-slot portion and the second in-slot portion in the first U-shaped conductor section are bent in the same direction;
the connecting legs of the first in-slot portion and the second in-slot portion in the fourth U-shaped conductor section are bent in the same direction; and
the connecting legs of the first U-shaped conductor section and the fourth U-shaped conductor section are bent in opposite directions.

8. The winding method for the winding of the stator module according to claim 6 , wherein the connecting legs of the first in-slot portion and the second in-slot portion of the second U-shaped conductor section are bent in opposite directions, and the second U-shaped conductor section and the third U-shaped conductor section are of the same shape.

9. The winding method for the winding of the stator module according to claim 1 , wherein the stator module is applicable to the motor having a slot number z of 48, a pole pair number p of 4, a phase number of 3, and a pitch y of 6.

10. The winding method for the winding of the stator module according to claim 9 , wherein each of the 48 stator slots has six slot layers a, b, c, d, e, and f, three phases comprise a U phase, a V phase and a W phase, and the number a of ways per phase is 2, a winding route of a first way of the U phase of a stator being as follows:
1f→43f→1e→7d→13c→19b→25a→19a→13b→7c→1d→43e→37f→31f→37e→43d→1c→7b→13a→7a→1b→43c→37d→31e→25f→19f→25e→31d→37c→43b→1a→43a→37b→31c→25d→19e→13f→7f→13e→19d→25c→31b→37a→31a→25b→19c→13d→7e
a winding line of a second way of the U phase differs from that of the first way of the U phase by one stator slot in a circumferential direction;
corresponding adjacent star-point wires in the U phase, the V phase and the W phase differ by four stator slots in the circumferential direction; and
corresponding adjacent lead-out wires in the U phase, the V phase and the W phase differ by four stator slots in the circumferential direction.

11. The winding method for the winding of the stator module according to claim 1 , wherein the U-shaped conductor section has a rectangular span section, a short side of the rectangle being perpendicular to a bottom wall of the stator slot.

12. The winding method for the winding of the stator module according to claim 11 , wherein in an extending direction of the U-shaped conductor sections, the span sectional areas of the U-shaped conductor sections are equal.

13. A stator module, wound by using the winding method for a winding according to claim 1 .

Assignees

• Byd Co Ltd

Inventors

• Lin Huanwei
• You Bin
• Qi Wenming

Classifications

• H02K15/33

  Connecting winding sections; Forming leads; Connecting leads to terminals · CPC title

• H02K15/085

  by laying conductors into slotted stators · CPC title

• H02K3/12 Primary

  arranged in slots · CPC title

• H02K3/28 Primary

  Layout of windings or of connections between windings (windings for pole-changing H02K17/06, H02K17/14, H02K19/12, H02K19/32) · CPC title

• H02K15/0421 Primary

  and consisting of single conductors, e.g. hairpins · CPC title