Stator assembly of hairpin winding motor

Patent metadata

Field	Value
Publication number	US-2025373106-A1
Application number	US-202519298512-A
Country	US
Kind code	A1
Filing date	Aug 13, 2025
Priority date	Apr 26, 2022
Publication date	Dec 4, 2025
Grant date	—

Abstract

A stator assembly includes a stator core including a plurality of slots configured to penetrate through the stator core in a circumferential direction, each of the slots including a plurality of layers in a radial direction; and a plurality of hairpin coils configured to fasten and interconnect to the slots, respectively, to form a coil winding. The hairpin coils include a main coil having a first slot pitch, an anomalous coil having a second slot pitch different from the first slot pitch, and a leader coil. In each of the slots, the main coil is disposed in each of a radially innermost layer of the layers, a radially outermost layer of the layers, and an intermediate layer of the layers between the innermost layer and the outermost layer. The leader coil is disposed in each of the innermost layer and the outermost layer.

First claim

What is claimed is:

1 . A stator assembly comprising:
a stator core including a plurality of slots configured to penetrate through the stator core in a circumferential direction, each of the slots including a plurality of layers in a radial direction; and a plurality of hairpin coils configured to fasten and interconnect to the slots, respectively, to form a coil winding, wherein the hairpin coils include a plurality of main coils having a first slot pitch, a plurality of anomalous coils having a second slot pitch different from the first slot pitch, and a plurality of leader coils, in each of the slots, one of the plurality of main coils is disposed in each of a radially innermost layer of the layers, a radially outermost layer of the layers, and at least one intermediate layer of the layers between the innermost layer and the outermost layer, one of the plurality of leader coils is disposed in each of the innermost layer and the outermost layer, and one of the plurality of anomalous coils is disposed in at least one of the intermediate layers, wherein in two sets of four parallel circuits in which one set includes two parallel circuits, when two hairpin coil bundles included in different parallel circuits included in one set of each phase are a first hairpin coil bundle and a second hairpin coil bundle, respectively, any one of a first anomalous coil which is one of the anomalous coils of the first hairpin coil bundle and a second anomalous coil which is one of the anomalous coils of the second hairpin coil bundle has a short-pitch smaller than the first slot pitch by one pitch, and another one of the anomalous coils has a long-pitch larger than the second slot pitch by one pitch, wherein one leg of the first anomalous coil and one leg of the second anomalous coil are each disposed in a same layer, and another leg of the first anomalous coil and another leg of the second anomalous coil are each disposed in another same layer, wherein the stator core and the plurality of hairpin coils include eight poles of forty-eight slots, and three phases of four parallels, each of the slots includes eight layers, and the main coil is set to six pitches to correspond to a number of the slots for each pole, wherein when a slot to which a phase leader coil of the first hairpin coil bundle is fastened is a first phase lead-out slot, and a slot to which a neutral-point leader coil of the first hairpin coil bundle is fastened is a first neutral point lead-out slot, a slot to which a phase leader coil of the second hairpin coil bundle is fastened is a second phase lead-out slot, and a slot to which a neutral-point leader coil of the second hairpin coil bundle is fastened is a second neutral point lead-out slot, either one of the first anomalous coil and the second anomalous coil has one leg fastened to the first neutral point lead-out slot and another leg fastened to the first phase lead-out slot, and another one of the first anomalous coil and the second anomalous coil has one leg fastened to the second neutral point lead-out slot and another leg fastened to the second phase lead-out slot, wherein two first anomalous coils and two second anomalous coils are provided.

2 . The stator assembly of claim 1 , wherein a head portion of the first anomalous coil and a head portion of the second anomalous coil are stacked on each other while being spaced apart from each other by a predetermined distance in a vertical direction.

3 . The stator assembly of claim 1 , wherein one first anomalous coil and one second anomalous coil are provided, and each of the first and second anomalous coils is disposed in a radial center of a respective slot.

4 . The stator assembly of claim 1 ,
when the two first anomalous coils are a 1-1-th anomalous coil and a 1-2-th anomalous coil, respectively, and the two second anomalous coils are a 2-1-th anomalous coil and a 2-2-th anomalous coil, respectively, the 1-1-th anomalous coil and the 2-1-th anomalous coil span the second and third layers, respectively, from an innermost side of the slot, and the 1-2-th anomalous coil and the 2-2-th anomalous coil span the sixth and seventh layers from the innermost side, respectively.

5 . The stator assembly of claim 4 , wherein the 1-1-th anomalous coil has the long-pitch, the 2-1-th anomalous coil has the short-pitch, the 1-2-th anomalous coil has the short-pitch, and the 2-2-th anomalous coil has the long-pitch, or
the 1-1-th anomalous coil has the short-pitch, the 2-1-th anomalous coil has the long-pitch, the 1-2-th anomalous coil has the long-pitch and the 2-2-th anomalous coil has the short-pitch.

6 . The stator assembly of claim 5 , wherein the main coil of the first hairpin coil bundle and the main coil of the second hairpin coil bundle each include
a first type main coil spanning an eighth layer and a seventh layer from the innermost side, a second type main coil spanning a sixth layer and a fifth layer from the innermost side, a third type main coil spanning a fourth layer and a third layer from the innermost side, a fourth type main coil spanning a second layer and a first layer from the innermost side, and a fifth type main coil spanning the fourth layer and the fifth layer from the innermost side.

Assignees

• Hyundai Mobis Co Ltd

Inventors

• Lee Jae Min
• Jang Ik Sang

Classifications

• H02K3/12 Primary

  arranged in slots · CPC title

• H02K1/165

  Shape, form or location of the slots · CPC title

• H02K15/085

  by laying conductors into slotted stators · CPC title

• H02K3/521

  applicable to stators only · CPC title

• H02K15/063

  Windings for large electric machines, e.g. bar windings (windings consisting of cables H02K15/065) · CPC title