WO2024032001A1 - 定子、扁线电机、动力总成和车辆 - Google Patents

定子、扁线电机、动力总成和车辆 Download PDF

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Publication number
WO2024032001A1
WO2024032001A1 PCT/CN2023/084051 CN2023084051W WO2024032001A1 WO 2024032001 A1 WO2024032001 A1 WO 2024032001A1 CN 2023084051 W CN2023084051 W CN 2023084051W WO 2024032001 A1 WO2024032001 A1 WO 2024032001A1
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WIPO (PCT)
Prior art keywords
phase
stator
winding
flat wire
slot
Prior art date
Application number
PCT/CN2023/084051
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English (en)
French (fr)
Inventor
林迎前
蒋奎
汪昱
罗先
Original Assignee
华为数字能源技术有限公司
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Publication of WO2024032001A1 publication Critical patent/WO2024032001A1/zh

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Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • H02K3/12—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors arranged in slots
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/12—Stationary parts of the magnetic circuit
    • H02K1/16—Stator cores with slots for windings
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • H02K3/28—Layout of windings or of connections between windings
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K2213/00—Specific aspects, not otherwise provided for and not covered by codes H02K2201/00 - H02K2211/00
    • H02K2213/03—Machines characterised by numerical values, ranges, mathematical expressions or similar information
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K29/00—Motors or generators having non-mechanical commutating devices, e.g. discharge tubes or semiconductor devices
    • H02K29/03—Motors or generators having non-mechanical commutating devices, e.g. discharge tubes or semiconductor devices with a magnetic circuit specially adapted for avoiding torque ripples or self-starting problems
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/60—Other road transportation technologies with climate change mitigation effect
    • Y02T10/64—Electric machine technologies in electromobility

Definitions

  • This application relates to the technical field of motor windings, specifically a stator, a flat wire motor, a powertrain and a vehicle.
  • Flat wire motors have advantages such as high copper content, which can help dissipate heat from the motor windings, improve the voltage resistance of the windings, and reduce the length of the winding ends, thereby improving the motor torque density and power density. Therefore, flat wire motors have become an important measure to promote vehicle lightweighting, increase the cruising range of electric vehicles, improve vehicle space utilization and reduce powertrain costs.
  • the winding method of the stator winding of the existing flat wire motor is mostly full-pitch winding.
  • the motor includes a stator core, a stator slot is provided in the circumferential direction of the stator core, and the stator winding is wound on the stator iron through the stator slot. on the core.
  • the flat wire motor with an integral pitch structure has a high harmonic winding coefficient, and the torque fluctuates greatly during operation, which worsens the noise, vibration and acoustic roughness (NVH) of the motor, and reduces the motor's performance.
  • Existing methods can reduce the harmonic winding coefficient of the flat wire motor by setting the stator winding to a short-pitch winding, thereby improving the NVH performance of electric vehicles.
  • the existing short-pitch windings of flat wire motors are limited by the winding form. It is difficult to obtain a higher fundamental winding coefficient while effectively weakening the harmonic winding coefficient and reducing the performance of the motor.
  • This application provides a stator, a flat wire motor, a powertrain and a vehicle, and provides a flat wire short-pitch winding structure that effectively weakens the harmonic winding coefficient on the basis of ensuring a high fundamental winding coefficient, thereby improving the motor performance.
  • this application provides a stator for a flat wire motor.
  • the stator includes a stator core and a stator winding.
  • the inner wall of the stator core is evenly provided with a plurality of stator slots in the circumferential direction.
  • the stator winding includes a stator inserted in the stator slot.
  • Flat wire conductors there are N layers of flat wire conductors in any stator slot, where N is an even number greater than or equal to 4; each flat wire conductor is connected separately to form an m-phase winding, and each phase winding includes multiple layers along the stator core
  • Phase units arranged evenly and spaced in the circumferential direction.
  • Each phase unit of each phase winding includes at least two phase strips.
  • Each phase strip of any phase unit includes two adjacent layers of flat wire conductors. The phases of any phase unit One stator slot is misaligned between adjacent strips.
  • the stator of this application includes a stator core and a stator winding.
  • the stator core is provided with a plurality of stator slots for arranging flat wire conductors, and there are N layers of flat wire conductors in any stator slot.
  • Each flat wire conductor is connected to An m-phase winding is formed.
  • Each phase winding includes multiple phase units, and each phase unit is evenly spaced along the circumferential direction of the stator core. In any phase unit of each phase winding, two adjacent layers of flat wire conductors are formed. One phase band, and one stator slot is offset between adjacent phase bands.
  • This setting structure can make the equivalent pitch of the flat wire motor obtained smaller than the pole pitch of the flat wire motor.
  • the obtained stator winding is a short-pitch winding.
  • the flat wire motor with this structure can have a higher fundamental wave winding coefficient to improve the output performance of the flat wire motor and at the same time.
  • the flat wire motor with this structure also has a lower harmonic winding coefficient, thereby suppressing the torque fluctuation of the flat wire motor, reducing the back electromotive force harmonics, and improving the overall output performance of the flat wire motor.
  • Applying flat wire motors with the above properties to electric vehicles can effectively improve the smoothness of electric vehicle operation and improve the unevenness of electric vehicles.
  • each phase strip of any phase unit only includes two adjacent layers of flat wire conductors, which can simplify the linear types of the stator windings and make the stator windings twist in the same direction at the welding end, thus simplifying the processing difficulty. , easy to connect.
  • adjacent phase strips of any phase unit are offset by one stator slot in the clockwise direction or in the counterclockwise direction. In this implementation, adjacent phase strips in the same phase unit are dislocated in one direction. In a possible implementation of the present application, adjacent phase strips of any phase unit are offset by one stator slot in the clockwise and counterclockwise directions. In this implementation, adjacent phase strips in the same phase unit can alternate between clockwise and counterclockwise directions, or dislocations can be generated in the clockwise direction first, and then in the counterclockwise direction, or dislocations can be generated first in the clockwise direction, and then in the counterclockwise direction. Dislocations are generated in the counterclockwise direction, and then dislocations are generated in the clockwise direction.
  • any phase unit moves along the axis perpendicular to the stator core.
  • the direction is set symmetrically to the mid-perpendicular line.
  • each phase winding is divided into N/2 parts along the axis direction of the stator core, and two adjacent layers of flat wire conductors in each part are connected to form a coil layer. Consists of two coil layers.
  • adjacent coil layers are connected through a single jumper, that is, a cross-layer connection is achieved through a single jumper, which helps to simplify the flat wire winding. structure for easy implementation.
  • the opposite sides of the stator winding along the axial direction of the stator core are respectively the plug-in end and the welding end.
  • the span of a single jumper between different coil layers Equal, so that the twisting angles of the welding ends are the same, thus simplifying the twisting and welding processes and helping to simplify the manufacturing process of the stator windings.
  • multiple flat wire conductors can be arranged on the stator slot in the same direction, so that the twist angle of the stator winding at the welding end is consistent, thereby avoiding the problem caused by inconsistent twist angles at the welding end. Problems such as twisting and complicated welding further effectively simplify the design of the stator winding and facilitate implementation.
  • each phase winding includes at least one branch, that is, each phase winding may include one branch, two parallel branches, three parallel branches, or multiple parallel branches.
  • each parallel branch includes flat wire conductors distributed in different layers of the phase strips of the same layer of each adjacent phase unit, and the same phase strip Each of the flat wire conductors is evenly distributed in different parallel branches. In this way, the potential balance between the parallel branches in each phase winding can be maintained and circulating current between the branches can be avoided.
  • the stator winding may be a three-phase winding, and the three-phase winding includes a U-phase winding, a V-phase winding, and a W-phase winding.
  • the number of stator slots on the inner wall of the stator core is Z
  • the number of phases of the stator winding is m
  • the number of poles of the stator winding is 2p
  • P is an integer
  • the number of stator slots per pole per phase is q
  • the number Z of stator slots may be 48 or 54.
  • the number of layers of the flat wire conductor may be 6 or 10.
  • the number of poles 2p of the flat wire conductor may be 6 or 8.
  • the present application provides a flat wire motor.
  • the flat wire motor includes a rotor and the stator of the first aspect of the present application.
  • the rotor is disposed in a space surrounded by the inner wall of the stator core.
  • the stator of the present application can have a lower harmonic winding coefficient on the basis of a higher fundamental winding coefficient
  • the flat wire motor including the stator of the present application can have small vibration, low noise, and low stray noise. Small loss and temperature rise Low characteristics.
  • this application provides a power assembly, which includes a reducer and the flat wire motor of the second aspect of this application, and the flat wire motor is drivingly connected to the reducer.
  • the present application provides a vehicle, which includes the powertrain of the third aspect of the present application.
  • Figure 1 shows the phase distribution diagram of a traditional short-pitch winding with a pitch of 8
  • Figure 2 shows the phase distribution diagram of a traditional short-pitch winding with a pitch of 7;
  • Figure 3 is a schematic three-dimensional structural diagram of a stator of a flat wire motor according to an embodiment of the present application
  • Figure 4 is a schematic front structural view of a stator of a flat wire motor according to an embodiment of the present application
  • FIG. 5 is a schematic top structural view of the stator core according to an embodiment of the present application.
  • Figure 6 is a schematic structural diagram of a hairpin coil according to an embodiment of the present application.
  • Figure 7 is a schematic structural diagram of a flat wire inserted into a stator slot according to an embodiment of the present application.
  • Figure 8 is a phase band distribution diagram of the U-phase winding according to an embodiment of the present application.
  • Figure 9 is a phase band distribution diagram of the U-phase winding according to another embodiment of the present application.
  • Figure 10 is an expanded view of a single branch of the U-phase winding in Figure 8.
  • Figure 11 is a schematic diagram of the connection structure of branch 2;
  • Figure 12 is an enlarged schematic diagram of the connection structure of some flat wire conductors in Figure 11;
  • Figure 13 is a schematic structural diagram of the motor stator core and U-phase winding according to one embodiment of the present application.
  • Figure 14 is a schematic structural diagram of the motor stator core and U-phase winding according to one embodiment of the present application.
  • Figure 15 is a comparison diagram of the torque ripple at the peak torque operating point of the winding, full-pitch winding and traditional short-pitch winding motor in Embodiment 1.
  • the driving motors of new energy vehicles are mainly permanent magnet synchronous motors.
  • the motor stator can be divided into round wire conductors and flat copper wire conductors according to the cross-sectional shape of the stator winding. Flat copper wire conductors are used.
  • the motor is called a flat wire motor.
  • the flat wire motor can effectively improve the slot full rate, power density and torque density.
  • Multi-layer and multi-branch solutions are conducive to reducing the eddy current losses of flat wires and improving motor performance.
  • Stator refers to the stationary part of the motor, its function is to generate a rotating magnetic field.
  • Rotor refers to the rotating component in the motor, which is used to convert electrical energy into mechanical energy.
  • Number of poles That is, the number of magnetic poles of the motor.
  • the magnetic poles are divided into N poles and S poles.
  • 1 N pole and 1 S pole are called a pair of magnetic poles, that is, the number of pole pairs is 1, so the number of pole pairs of the motor is 1, 2, 3, 4, then the number of poles of the motor is 2, 4, 6, 8.
  • Number of slots per pole per phase q The number of slots occupied by each phase winding under each magnetic pole is called the number of slots per pole per phase.
  • the winding method of the stator winding includes full-pitch winding and short-pitch winding.
  • the full-pitch winding means that the pitch of the sub-windings is equal to the pole pitch
  • the short-pitch winding means that the pitch of the sub-windings is smaller than the pole pitch.
  • Figure 3 is a schematic three-dimensional structural diagram of the stator of the flat wire motor according to one embodiment of the present application.
  • Figure 4 is a schematic front structural diagram of the stator of the flat wire motor according to one embodiment of the present application.
  • the stator includes a stator core 10 and a stator winding 20 .
  • FIG. 5 is a schematic top view of the stator core according to an embodiment of the present application.
  • the inner wall of the stator core 10 is provided with a plurality of stator slots 11.
  • the number of stator slots 11 can be represented by Z, and Z can be It is a natural number that is a multiple of 3. Specifically, 48 or 54 can be selected.
  • Z stator slots 11 are provided on the inner wall of the stator core 10 and are evenly arranged along the circumferential direction of the inner wall of the stator core 10.
  • Any stator slot 11 is in the axial direction of the stator core 10 ( As shown in FIG. 1 , it extends in the Z direction and penetrates the inner wall of the stator core 10 along the axial direction of the stator core 10 .
  • the stator core 10 is divided into an insertion end 10a and an insertion end 10b along its axial direction, and any stator slot 11 can extend from the insertion end 10a to the insertion end 10b.
  • the stator winding 20 includes a flat wire conductor 21 inserted in the stator slot 11 , and the cross section of the flat wire conductor 21 may be rectangular.
  • the flat wire conductor 21 may be formed by a hairpin coil.
  • Figure 6 is a schematic structural diagram of a hairpin coil according to an embodiment of the present application.
  • the hairpin coil 22 includes a leg portion 221 located inside the stator slot 11 and a connecting portion 222 and a bent portion 223 located outside the stator slot 11 .
  • the connecting portion 222 The formation can be U-shaped or V-shaped.
  • the hairpin coil 22 can be inserted into the stator slot 11 and then the hairpin coil 22 can be bent to form the bent portion 223. After the insertion is completed, the hairpin coil 22 is inserted into the leg portion 221 of the stator slot 11. The flat wire conductor 21 is formed. After bending, the twisting directions of the bent portion 223 of the hairpin coil 22 remain consistent. Wherein, after the hairpin coil 22 is inserted into the stator slot 11, its connecting portion 222 forms the insertion end 20a of the stator winding 20, and the bending portion 223 forms the welding end 20b of the stator winding 20.
  • FIG. 7 is a schematic structural diagram of a flat wire inserted into a stator slot according to an embodiment of the present application.
  • N layers of flat wire conductors 21 can be provided in any stator slot 11 , and N can be 6, 8, 10 or 12, or a natural number greater than 12.
  • N is 6, that is, each stator slot 11 is provided with 6 layers of flat wire conductors 21 .
  • the number of layers of the rectangular wire conductor 21 shown in FIG. 7 is only an example. In addition to 6 layers of rectangular wire conductors 21, 10 layers of rectangular wire conductors 21 can also be provided.
  • the flat wire conductors 21 inserted in the stator slot 11 can form an m-phase winding through group connection, and m can be 2, 3, 4, 5, or 6, etc., that is, the number of phases of the corresponding flat wire motor can be two-phase, three-phase, four-phase, five-phase or six-phase or more.
  • the stator windings can be divided into first-phase windings, second-phase windings and third-phase windings, which correspond to U-phase windings, V-phase windings and W-phase windings respectively.
  • any phase winding can include multiple phase units.
  • phase unit of the first phase winding, the phase unit of the second phase winding, and the phase unit of the third phase winding are along the inner wall of the stator core.
  • phase unit of each phase winding is a pole phase
  • the number of stator slots corresponding to each phase unit is the number of slots per pole and phase.
  • stator winding can be a single-phase winding, a three-phase winding, or a six-phase winding.
  • any phase unit of the U-phase winding includes at least two Phase strips
  • each phase strip of any phase unit may include two adjacent layers of flat wire conductors 21, and the adjacent phase strips of any phase unit are offset by one stator slot.
  • N is an even number greater than or equal to 4. Therefore, in any phase unit, the N-layer flat wire conductor 21 can be divided into N/P phase strips.
  • each stator slot 11 is provided with 6 layers of flat wire conductors 21, and two adjacent layers of flat wire conductors can form a phase strip, and the number of phase strips can be three.
  • each stator slot 11 is provided with 10 layers of flat wire conductors 21, and two adjacent layers of flat wire conductors 21 form a phase strip, and the number of phase strips can be five.
  • adjacent phase strips of any phase unit are offset by one stator slot 11 in the clockwise direction or in the counterclockwise direction, that is, the stator slots 11 of the same phase unit are
  • the directions of the stator slots 11 that are offset between adjacent phase strips are the same, so that the equivalent pitch of the stator winding is smaller than the pole pitch of the stator winding to the greatest extent.
  • the pitch of the traditional short-pitch winding is 8 or 7 respectively.
  • the flat wire motor in the embodiment of the present application While obtaining a high fundamental winding coefficient, the harmonic winding coefficient of the motor can be effectively reduced.
  • Figure 9 is a phase band distribution diagram of the U-phase winding according to another embodiment of the present application.
  • the first few adjacent phase strips can be sequentially displaced by one stator slot in the clockwise direction, and the subsequent adjacent phase strips can be sequentially displaced by one stator slot 11 in the counterclockwise direction; or , the first few adjacent phase bands can be sequentially displaced by one stator slot in the counterclockwise direction, and the subsequent adjacent phase bands can be sequentially displaced by one stator slot 11 in the clockwise direction; or, between adjacent phase bands, One stator slot 11 can be shifted alternately in the clockwise direction and the counterclockwise direction.
  • any phase unit is aligned along the center vertical line perpendicular to the axis of the stator core. Symmetrical setup.
  • the direction of the number of dislocation grooves between adjacent phase zones is not limited in this application. Free combination to flexibly meet different motor design needs to suppress motor torque fluctuations and reduce harmonic winding coefficients, thereby improving motor performance.
  • each phase winding includes at least one branch.
  • each parallel branch includes flat wire conductors of different layers distributed in the same layer phase strip of each adjacent phase unit, where, and each parallel branch in the same phase strip The flat wire conductors are evenly distributed in different parallel branches, so that the potential balance between the parallel branches of each phase can be maintained.
  • each phase winding of the stator winding 20 is composed of two parallel circuits. Take the two parallel branches of the U phase as an example, denoted as branch 1 and branch 2.
  • the flat conductors of different layers in the same phase band belong to different parallel branches, and the adjacent phase units have Flat wire conductors of different layers in the same layer phase band belong to different parallel branches.
  • the two phase belts belong to two different phase units.
  • the phase belt composed of grooves 1, 2, and 3 The band is recorded as phase band A, and the phase band composed of 10, 11 and 12 is called phase band B.
  • the first layer of flat wire conductors in phase band A belongs to branch 1
  • the second layer of flat wire conductors in phase band A belongs to branch 1.
  • the first layer flat wire conductor in phase band B belongs to branch 2
  • the second layer flat wire conductor in phase band B belongs to branch 1.
  • different layers of flat wire conductors are arranged in branch 1 and branch 2, so that branch 1 and branch 2 can maintain potential balance and reduce the generation of circulating current.
  • each phase winding of the stator winding 20 is composed of four parallel circuits, which are respectively recorded as branch 1, branch 2, branch 3 and branch 4.
  • branch 1 taking branch 1 as an example, in the phase band composed of slots 7 and 8, the flat wire conductor of the second layer of slot 7 belongs to branch 1, and the flat wire conductor of the first layer of slot 8 belongs to branch 2, 8
  • the 2nd layer flat wire conductor of slot belongs to branch 3, and the 1st layer flat wire conductor of slot 7 belongs to branch 4.
  • the flat wire conductors of other layers can be connected according to Figure 9 to form different parallel branches.
  • each phase winding is divided into N/2 parts along the axis direction of the stator core. Two adjacent layers of flat wire conductors in each part are connected to form a coil layer. Each part includes two coil layer.
  • adjacent coil layers are connected through a single jumper, that is, a cross-layer connection is achieved through a single jumper, which helps to simplify the structure of the stator winding. , thus facilitating implementation.
  • Figure 10 is an expanded view of a single branch of the U-phase winding in Figure 8.
  • the opposite sides of the stator winding 20 along the axial direction of the stator core 10 are plug ends 20a.
  • the welding end 20b, on the welding end 20b side the spans of the single jumpers between different coil layers are equal, so that the twisting angles of the welding end 20b are the same, which can simplify the twisting, welding and coating processes.
  • An embodiment of the present application also provides a flat wire motor.
  • the flat wire motor includes a rotor and a stator of the embodiment of the present application.
  • the rotor is disposed in a space surrounded by the inner wall of the stator core.
  • An embodiment of the present application also provides a power assembly, which includes a reducer and the above-mentioned flat wire motor.
  • the flat wire motor and the reducer are connected in transmission.
  • the drive shaft of the flat wire motor and the input shaft of the reducer can be connected through transmission components such as couplings to output the driving force from the flat wire motor to the reducer.
  • the vehicle provided by the embodiment of the present application includes the above-mentioned power assembly.
  • the above-mentioned power assembly is arranged in the vehicle and provides operating power for the vehicle.
  • the vehicle may be a new energy vehicle driven by electric energy, for example.
  • new energy vehicles can specifically be hybrid electric vehicles, pure electric vehicles or fuel cell electric vehicles, etc., or they can be vehicles that use high-efficiency energy storage devices such as supercapacitors, flywheel batteries or flywheel energy storage devices as the source of electric energy.
  • stator winding of the embodiment of the present application will be described in detail below with reference to specific embodiments.
  • This embodiment is a stator winding and a stator containing the stator winding.
  • the stator also includes a stator core, wherein, The stator core has 54 stator slots, the number of conductor layers in the stator slots is 6, and the number of stator winding poles is 6.
  • the stator winding is divided into U phase, V phase and W phase, and the number of parallel branches provided for each phase winding is 2.
  • Each phase winding can be divided into 6 poles, that is, 6 phase units, and the number of slots per pole is 3.
  • the distribution diagram of each phase band in the U-phase winding in this embodiment can be referred to Figure 8.
  • each stator slot contains 6 layers of flat wire conductors.
  • the first layer is the slot bottom layer of the stator slot, and the sixth layer is the slot layer.
  • "+" represents current flowing into the conductor
  • "-" represents current flowing out of the conductor.
  • two adjacent layers of flat wire conductors form a phase strip, that is, each phase unit of each phase winding can be divided into three phase strips, and adjacent phase strips of the same phase unit are offset by one.
  • the stator slots and the misalignment direction are moved by 1 slot along the x-direction in the figure, so that the equivalent pitch of the stator winding is 7, achieving a short-pitch effect.
  • the x direction in Figure 8 can be clockwise or counterclockwise in an actual stator core.
  • phase band A1 the phase band composed of the first and second layer flat wire conductors in slots 1, 2, and 3 is recorded as phase band A1
  • phase band composed of slots 54, 1 the phase band composed of slots 54, 1
  • phase zone A2 The phase zone composed of the 3rd and 4th layer flat wire conductors in slot 2
  • phase zone A2 the phase zone composed of the 5th and 6th layer flat wire conductors in slots 53, 54 and 1 is marked as phase zone A2.
  • phase band A3 the phase band composed of the first and second layer flat wire conductors in slots 10, 11, and 12 is recorded as phase band B1
  • the phase band composed of the third layer in slots 9, 10, and 11 is The phase band formed by the 4th layer flat wire conductor is marked as phase band B2
  • the phase band formed by the 5th and 6th layer flat wire conductors in slots 8, 9, and 10 is marked as phase band B3,...
  • phase band F1 the phase band composed of the first and second layer flat wire conductors in slots 46, 47, and 48 is recorded as phase band F1
  • the third and second layers in slots 45, 46, and 47 are The phase band composed of the fourth layer of flat wire conductors
  • phase band F2 the phase band composed of the fifth and sixth layers of flat wire conductors in slots 44, 45, and 46 is marked as phase band F3.
  • FIG. 11 is a schematic diagram of the connection structure of branch 2.
  • Figure 12 is an enlarged schematic diagram of the connection structure of some flat wire conductors in Figure 11.
  • the 28-slot 5-layer flat wire conductor is connected to the 37-slot 6-layer flat wire conductor, and then connected to the 46-slot 5-layer flat wire conductor, then connect 1 slot 6-layer flat wire conductor, then connect 8 slot 5-layer flat wire conductor, then connect 17 slot 6-layer flat wire conductor, then connect 26 slot 5-layer flat wire conductor, then connect 35 slot 6-layer flat wire conductor, then connect 44 slot 5-layer flat wire conductor, then connect 53 slot 6-layer flat wire conductor, then connect 9 slot 5-layer flat wire conductor, then connect 18 slot 6-layer flat wire conductor, then connect 27 slot 5-layer flat wire conductor, then connect 36 slot 6-layer flat wire conductor, then connect 45 slot 5-layer flat wire conductor, then connect 54 slot 6-layer flat wire conductor, then connect 10 slot 5-layer flat wire conductor, then connect 19 slot
  • the 4-layer flat wire conductor has completed the traversal of the 5-layer and 6-layer flat wire conductors.
  • the connection methods of the flat wire conductors of other layers can be referred to Figure 8, Figure 11 and Figure 12,
  • FIG 12 is a schematic diagram of the connection structure of a location in branch 2.
  • the 10-slot 5-layer flat wire conductor is connected to the 19-slot 4-layer flat wire conductor to complete the cross-wire connection between adjacent coil layers, that is, from the phase strip composed of the 5th and 6th layer flat wire conductors to 3 , a phase strip composed of 4 layers of flat wire conductors, and the span is also 9.
  • the span is also 9. Therefore, it can be seen from Figure 10 to Figure 12 that each hairpin coil is in the stator
  • the span of the welding ends of the windings is 9, which allows the twisting directions of each hairpin coil at the welding ends to be consistent and reduces the difficulty of processing.
  • phase band distribution in Figure 8 is only an exemplary illustration. Replace the "+” and “-” symbols in Figure 8, for example, change “U + “ in Figure 8 to "U - “ at the same time, and Change “U - “ to "U + ", and make corresponding modifications to the V phase and W phase, both of which are within the protection scope of this application.
  • Figures 13 and 14 are schematic structural diagrams of the stator core and U-phase winding of the motor in this embodiment.
  • Figure 13 focuses on the characteristics of the plug-in end
  • Figure 14 focuses on the characteristics of the welding end.
  • the welding end of the stator winding is connected by a single jumper between adjacent coil layers.
  • a single jumper is used between the second layer and the third layer, and between the fourth and fifth layers.
  • Cross-wire connection, and the span of the welding end is maintained at 9. Therefore, the span and twist angle of the winding welding end are the same, and each welding point is distributed symmetrically around the circumference.
  • This embodiment is a stator winding and a stator containing the stator winding.
  • the stator also includes a stator core.
  • the stator core has 48 stator slots, the number of conductor layers in the stator slots is 10, and the stator winding has 48 stator slots.
  • the number of poles is 8.
  • the stator winding is divided into U phase, V phase and W phase, and the number of parallel branches provided for each phase winding is 4.
  • Each phase winding can be divided into 8 phase units, and the number of slots per pole and phase is 2.
  • the phase band distribution diagram of the U-phase winding in this embodiment can be referred to Figure 9.
  • each stator slot contains 10 layers of flat wire conductors, of which the first layer is the bottom layer of the stator slot and the sixth layer is the slot layer. "+” represents current flowing into the conductor, and "-" represents current flowing out of the conductor.
  • two adjacent layers of flat wire conductors form a phase strip, that is, each phase unit of each phase winding can be divided into five phase strips.
  • the 1st and 2nd layer flat wire conductors form the first phase band
  • the 3rd and 4th layer rectangular wire conductors form the second phase band opposite to each other
  • the 5th and 4th layer rectangular wire conductors form the second phase band.
  • the 6-layer flat wire conductors form the third phase band
  • the 7th and 8th layers of flat wire conductors form the fourth phase band
  • the 9th and 10th layers of flat wire conductors form the fifth phase band.
  • the second phase strip (such as the phase strip composed of the 3rd layer flat wire conductor and the 4th layer flat wire conductor of 8 slots and 9 slots) is relative to the first phase strip (such as the 7 slots and 8 slots).
  • the phase strip composed of the first layer flat wire conductor and the second layer flat wire conductor is offset by 1 slot in the opposite direction to the x direction in the figure, and the third phase zone (such as the fifth layer flat wire conductor of the 9-slot and 10-slot and the phase strip composed of the 6th layer flat wire conductor) relative to the second phase strip (such as the phase strip composed of the 3rd layer flat wire conductor and the 4th layer flat wire conductor of 8 slots and 9 slots) along the x direction in the figure
  • the fourth phase strip (such as the phase strip composed of the 7th-layer flat wire conductor and the 8th-layer flat wire conductor in slots 8 and 9) is displaced by 1 slot in the opposite direction.
  • the phase strip composed of the 5th layer flat wire conductor and the 6th layer flat wire conductor of the slot is offset by 1 slot along the
  • the phase strip composed of the 10th layer flat wire conductor is displaced in the x direction in the figure relative to the fourth phase zone (such as the phase zone composed of the 7th layer flat wire conductor and the 8th layer flat wire conductor of 8 slots and 9 slots).
  • 1 slot As shown in Figure 9, in this arrangement, the equivalent pitch of the stator winding is 7, thereby achieving the short-pitch effect.
  • the x direction in Figure 9 can be clockwise or counterclockwise in an actual stator core.
  • stator winding shown in Figure 9 when connecting each parallel branch, different flat conductors of the phase strips of the same layer can be connected first. After the connection between the first phase strips of different phase units is completed, The flat wire conductors between different coil layers are connected by a single jumper. For example, after the flat wire conductors of the first phase strip are connected, the flat wire conductors of the first phase strip can be connected to the flat wire conductors of the second phase strip. connect.
  • the span of a single jumper on the welding end side of each layer of flat wire conductor is 8. Therefore, the stator winding in this embodiment can keep the span completely consistent at the welding end, which is always 8, so that the twisting angles of the wire legs of the hairpin coils are the same, and the twisting, welding and coating processes are simplified.
  • the four parallel branches in each phase winding evenly traverse the flat conductors of the phase strips that can be arranged, so the number of parallel branches can maintain potential balance and no circulating current will occur.
  • Example 1 From the comparison data between Example 1 and traditional short-pitch windings in Table 1, it can be seen that the equivalent pitch of Example 1 is 7, but the fundamental winding coefficient is much higher than that of the traditional short-pitch winding with an equivalent pitch of 7, which is close to Compared with the traditional short-pitch winding with an equivalent pitch of 8, the impact of short pitch on the average torque is greatly reduced; in addition, the 5th, 7th, 11th and 13th harmonic winding coefficients of Embodiment 1 are much lower than those of the traditional Short-distance windings have a stronger attenuation effect on the 5th, 7th, 11th and 13th harmonics of the armature side magnetic field.
  • Figure 15 is a comparison chart of torque fluctuations at the peak torque operating point of the winding, full-pitch winding and traditional short-pitch winding motors in Embodiment 1.
  • the torque ripple of the motor using short-pitch windings is significantly reduced.
  • the peak value of the torque ripple peak using the full-pitch winding motor is 17.3 Nm
  • the peak value of the torque ripple peak using the traditional short-pitch winding (equivalent pitch is 8) motor and the short-pitch winding motor of Embodiment 1 is 10.4 Nm respectively.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Windings For Motors And Generators (AREA)

Abstract

本申请涉及电机绕组技术领域，具体涉及一种定子、扁线电机、动力总成和车辆，以使基波绕组系数较高且谐波绕组系数较低。该定子包括定子铁芯和定子绕组，定子铁芯的内壁周向均匀开设有多个定子槽，定子绕组包括插设于定子槽内的扁线导体，任一定子槽内均设有N层扁线导体，其中，N为大于等于4的偶数；各扁线导体分别连接以形成m相绕组，每相绕组包括多个沿定子铁芯的周向均匀且间隔设置的相单元，每相绕组的任一相单元中包括至少两个相带，任一相单元的各相带包括相邻两层扁线导体，任一相单元的相邻相带之间错位一个定子槽。该定子绕组为短距绕组，进而在电机运行时具有很好的转矩波动抑制作用，降低电机的反电势谐波，提升电机的性能。

Description

定子、扁线电机、动力总成和车辆
相关申请的交叉引用
本申请要求在2022年08月12日提交中国专利局、申请号为202210970372.1、申请名称为“定子、扁线电机、动力总成和车辆”的中国专利申请的优先权，其全部内容通过引用结合在本申请中。
技术领域
本申请涉及电机绕组技术领域，具体涉及一种定子、扁线电机、动力总成和车辆。
背景技术
扁线电机因具有高铜满率，可利于电机绕组散热、能够提高绕组的耐压能力以及降低绕组端部长度等方面的优势，进而可以提升电机转矩密度和功率密度。因此，扁线电机成为了促进汽车轻量化、提升电动汽车的续航里程、提升汽车的空间利用率和降低动力总成成本的一个重要举措。
目前，现有的扁线电机定子绕组的绕制方式多为整距绕组，具体的，电机包括定子铁芯，定子铁芯的周向上开设有定子槽，定子绕组通过定子槽绕设在定子铁芯上。其中，整距结构的扁线电机具有较高的谐波绕组系数，运行时转矩波动较大，恶化了电机的噪声、振动与声振粗糙度(noise vibration harshness，NVH)，降低了电机的性能。现有方法可以通过将定子绕组设置为短距绕组以降低扁线电机的谐波绕组系数，进而提升电动汽车NVH性能。然而现有扁线电机的短距绕组，短距设置方式受限于绕组形式，难以在获得较高基波绕组系数的同时，有效削弱谐波绕组系数，降低了电机的性能。
发明内容
本申请提供了一种定子、扁线电机、动力总成和车辆，提供了一种扁线短距绕组结构在保证基波绕组系数较高的基础上，有效削弱谐波绕组系数，从而提升电机的性能。
第一方面，本申请提供一种扁线电机的定子，该定子包括定子铁芯和定子绕组，定子铁芯的内壁周向均匀开设有多个定子槽，定子绕组包括插设于定子槽内的扁线导体，任一定子槽内均设有N层扁线导体，其中，N为大于等于4的偶数；各扁线导体分别连接以形成m相绕组，每相绕组包括多个沿定子铁芯的周向均匀且间隔设置的相单元，每相绕组的任一相单元中包括至少两个相带，任一相单元的各相带包括相邻两层扁线导体，任一相单元的相邻相带之间错位一个定子槽。
本申请的定子包括定子铁芯和定子绕组，定子铁芯设有多个定子槽用于设置扁线导体，且任一定子槽内均设有N层扁线导体，各扁线导体分别连接以形成m相绕组，每相绕组包括多个相单元，且各相单元沿定子铁芯的周向均匀且间隔设置，其中，每相绕组的任一相单元中，相邻两层扁线导体组成一个相带，且相邻相带之间错位一个定子槽，该设置结构可使获得的扁线电机的等效节距小于扁线电机的极距，所获得的定子绕组为短距绕组，经测试，该结构的扁线电机，可具有较高基波绕组系数，以提高扁线电机的输出性能，同 时，该结构的扁线电机，还具有较低的谐波绕组系数，进而抑制扁线电机的转矩波动，降低反电动势谐波，提升扁线电机的综合输出性能。将具有上述性能的扁线电机应用于电动汽车中，可有效提高电动汽车运行的平稳性，改善电动汽车的不平顺性。
另外，本申请的定子中，任一相单元的各相带只包括相邻两层扁线导体，可简化定子绕组的线型种类，使定子绕组在焊接端的扭头方向一致，从而可简化加工难度，方便连接。
在本申请一种可能的实现方式中，任一相单元的相邻相带之间均沿顺时针方向或均沿逆时针方向错位一个定子槽。该实现方式中，同一相单元内的相邻相带之间均朝一个方向产生错位。在本申请一种可能的实现方式中，任一相单元的相邻相带之间沿顺时针方向和逆时针方向错位一个定子槽。该实现方式中，同一相单元内的相邻相带之间可按顺时针和逆时针交替进行，也可先沿顺时针方向产生错位，然后再按逆时针方向产生位错，也可先沿逆时针方向产生错位，然后再按顺时针方向产生位错。在一种可选实现方式中，当任一相单元的相邻相带之间沿顺时针方向和逆时针方向错位一个定子槽时，任一所述相单元沿垂直所述定子铁芯的轴线方向的中垂线对称设置。其中，本申请中对各相邻相带之间的错位槽数的方向不做限定，可以自由组合，适用范围更广。
在本申请一种可能的实现方式中，每相绕组沿定子铁芯的轴线方向均分为N/2个部分，每部分中相邻的两层扁线导体相连接形成一个线圈层，每部分包括两个线圈层。在本申请一种可能的实现方式中，每相绕组中，相邻线圈层之间通过单根跨线连接，也即通过单根跨线实现了跨层连接，这样有助于简化扁线绕组结构，便于实现。
在本申请一种可能的实现方式中，定子绕组沿定子铁芯的轴线方向的相对两侧分别为插线端和焊接端，在焊接端侧，不同线圈层之间单根跨线的跨距相等，以使焊接端的扭头角度相同，从而简化了扭头和焊接工艺，有助于简化定子绕组的制造工艺。
在本申请一种可能的实现方式中，可以使多个扁线导体按照同样的方向设置在定子槽上，使定子绕组在焊接端的扭头角度保持一致，从而避免了焊接端扭头角度不一致而导致的扭头和焊接复杂等问题，进一步有效简化了定子绕组的设计，便于实现。
在本申请一种可能的实现方式中，每相绕组中均包括至少一条支路，即每相绕组中可包括一条支路、两条并联支路、三条并联支路或者多条并联支路。当每相绕组中均包括至少两条支路时，各所述并联支路包括分布在各相邻所述相单元的同层所述相带中的不同层的扁线导体，且同一相带中的各所述扁线导体均匀分布于不同的并联支路中。这样，可使每相绕组中各个并联支路之间保持电势平衡，避免支路间产生环流。
在本申请一种可能的实现方式中，定子绕组可为三相绕组，三相绕组包括U相绕组、V相绕组和W相绕组。
其中，定子铁芯的内壁开设定子槽的数量为Z，定子绕组的相数为m，定子绕组的极数为2p，且P为整数，每极每相定子槽的个数为q，所述Z、所述m、所述2p和所述q之间满足：q＝Z/2pm。在本申请一种可能的实现方式中，定子槽的数量Z可为48或54。在本申请一种可能的实现方式中，扁线导体的层数可为6或10。在本申请一种可能的实现方式中，扁线导体的极数2p可为6或8。
第二方面，本申请提供一种扁线电机，该扁线电机包括转子和本申请第一方面的定子，转子设于定子铁芯的内壁所围设形成的空间内。
由于本申请的定子可在具有较高基波绕组系数较高的基础上，具有较低的谐波绕组系数，因此，包含本申请定子的扁线电机，可具有振动小、噪声低、杂散损耗小、以及温升 低的特点。
第三方面，本申请提供一种动力总成，该动力总成包括减速器和本申请第二方面的扁线电机，扁线电机与减速器传动连接。
第四方面，本申请提供一种车辆，该车辆包括如本申请第三方面的动力总成。
上述第三方面和第四方面可以达到的技术效果，可以参照上述第一方面中的相应效果描述，这里不再重复赘述。
附图说明
图1为节距为8的传统短距绕组的相带分布图；
图2为节距为7的传统短距绕组的相带分布图；
图3为本申请一种实施例扁线电机的定子的三维结构示意图；
图4为本申请一种实施例扁线电机的定子的正视结构示意图；
图5为本申请一种实施例的定子铁芯的俯视结构示意图；
图6为本申请一种实施例的发卡线圈的结构示意图；
图7为本申请一种实施例的扁线导体插设于定子槽内的俯视结构示意图；
图8为本申请一种实施例的U相绕组的相带分布图；
图9为本申请另一种实施例的U相绕组的相带分布图；
图10为图8中U相绕组的单支路展开图；
图11为一种支路2的连接结构示意图；
图12为图11中部分扁线导体的放大连接结构示意图；
图13为本申请一种实施例电机定子铁芯和U相绕组的结构示意图；
图14为本申请一种实施例电机定子铁芯和U相绕组的结构示意图；
图15为实施例1的绕组、整距绕组和传统短距绕组电机峰值扭矩工况点的转矩波动对比图。
附图标记：
10-定子铁芯；10a-插入端；10b-插出端；11-定子槽；20-定子绕组；20a-插线端；
20b-焊接端；21-扁线导体；22-发卡线圈；221-腿部；222-连接部；223-弯折部。
具体实施方式
为了使本申请的目的、技术方案和优点更加清楚，下面将结合附图对本申请作进一步地详细描述。
以下实施例中所使用的术语只是为了描述特定实施例的目的，而并非旨在作为对本申请的限制。如在本申请的说明书和所附权利要求书中所使用的那样，单数表达形式“一个”、“一种”、“所述”、“上述”、“该”和“这一”旨在也包括例如“一个或多个”这种表达形式，除非其上下文中明确地有相反指示。
在本说明书中描述的参考“一个实施例”或“一些实施例”等意味着在本申请的一个或多个实施例中包括结合该实施例描述的特定特征、结构或特点。由此，在本说明书中的不同之处出现的语句“在一个实施例中”、“在一些实施例中”、“在其他一些实施例中”、“在另外一些实施例中”等不是必然都参考相同的实施例，而是意味着“一个或多个但不是所 有的实施例”，除非是以其他方式另外特别强调。术语“包括”、“包含”、“具有”及它们的变形都意味着“包括但不限于”，除非是以其他方式另外特别强调。
目前，新能源汽车的驱动电机主要以永磁同步电机为主，在永磁同步电机中，电机定子按照定子绕组的截面形状可分为圆形线导体和扁铜线导体，采用扁铜线导体的电机称为扁线电机。扁线电机可有效提高槽满率，提高功率密度和转矩密度。随着新能源汽车行业的快速发展，对于扁线电机层数、并联支路数以及绕组形式的要求越来越高，多层、多支路的方案有利于减小扁线涡流损耗、提高电机高速运行时的效率，同时也能增加绕组串联匝数的多样性，对电机性能大有裨益。但随着定子绕组结构形式的增多，尤其是具有平衡多支路的短距绕组，结构也更加复杂，实现难度增大；参照图1和图2，现有的具有短距结构的定子绕组结构受限于绕组连接形式，难以兼顾高基波绕组系数以及低谐波绕组系数，从而使扁线电机的附加损耗较高，效率较低，且振动和噪声较大。为解决上述问题，本申请实施例提供一种扁线电机定子。
为方便理解，以下先对本申请中出现的专业名词作如下解释说明。
定子：是指电机中静止不动的部分，其作用在于产生旋转磁场。
转子：是指电机中的旋转部件，作用在于实现电能与机械能的转换。
极数：即电机的磁极数，磁极分N极和S极，一般把1个N极和1个S极称为一对磁极，也就是极对数为1，所以，电机的极对数为1、2、3、4，则电机的极数为2、4、6、8。
极距：绕组的极距是指每个磁极所占圆周表面的距离，对交流电动机而言，是指沿定子铁芯内圆每个磁极所占的槽距，以槽数表示，则极距f等于定子槽数Z与磁极数2p的比值，即f＝z/2p。
节距：是指单个线圈两有效边所占的槽数，例如节距y＝6，即线圈两有效边相隔6槽，就是两有效边分别嵌在第1槽和第7槽。
每极每相槽数q：每相绕组在每个磁极下所占有的槽数称为每极每相槽数。
另外，定子绕组的绕设方式包括有整距绕组和短距绕组，其中，整距绕组是指定子绕组的节距等于极距，短距绕组是指定子绕组的节距小于极距。
图3为本申请一种实施例扁线电机的定子的三维结构示意图，图4为本申请一种实施例扁线电机的定子的正视结构示意图，如图3和图4所示，在本申请一种实施例中，该定子包括定子铁芯10和定子绕组20。
图5为本申请一种实施例的定子铁芯的俯视结构示意图，如图5所示，该定子铁芯10的内壁设有多个定子槽11，定子槽11的数量可用Z表示，Z可为3的倍数的自然数，具体可选48个或54个。一并参照图1-3，Z个定子槽11设于定子铁芯10的内壁，且沿定子铁芯10的内壁的周向均匀设置，任一定子槽11在定子铁芯10的轴线方向(如图1中所示Z向)延伸，并沿定子铁芯10的轴线方向贯通定子铁芯10的内壁。定子铁芯10沿其轴线方向分为插入端10a和插出端10b，任一定子槽11可自插入端10a延伸至插出端10b。
参照图3和图4，在本申请一种实施例中，定子绕组20包括插设于定子槽11内的扁线导体21，扁线导体21的横截面可为矩形。其中，扁线导体21可由发卡线圈形成。图6为本申请一种实施例的发卡线圈的结构示意图。如图6所示，在本申请一种实施例中，该发卡线圈22包括设有定子槽11内的腿部221和设于定子槽11外的连接部222和弯折部223，连接部222的形成可为U型或V型。其中，一并参照图3和图6，在本申请一种实 施例中，可将发卡线圈22插设于定子槽11后再对发卡线圈22进行折弯以形成弯折部223，插设完成后，发卡线圈22插设于定子槽11内的腿部221形成扁线导体21。折弯后，发卡线圈22的弯折部223的扭头方向保持一致。其中，发卡线圈22插设于定子槽11后，其连接部222形成定子绕组20的插线端20a，弯折部223形成定子绕组20的焊接端20b。
图7为本申请一种实施例的扁线导体插设于定子槽内的俯视结构示意图。如图7所示，在本申请一种实施例中，任一定子槽11内可设置N层扁线导体21，N可为6、8、10或12，或为大于12的自然数。如图7所示，在本申请一种实施例中，N为6，即，每个定子槽11内设有6层扁线导体21。可理解的是，图7所示扁线导体21的层数仅为示例性说明，除可设置6层扁线导体21外，还可设置10层扁线导体21。
继续参照图3和图7，在本申请一种实施例中，插设于定子槽11内的扁线导体21通过分组连接可形成m相绕组，m可为2、3、4、5、或6等，即对应的扁线电机的相数可为两相、三相、四相、五相或六相或更多相。以三相绕组为例，定子绕组可分为第一相绕组、第二相绕组和第三相绕组，分别对应U相绕组、V相绕组和W相绕组。m相绕组中，任一相绕组均可包括多个相单元，在连接时，第一相绕组的相单元、第二相绕组的相单元和第三相绕组的相单元沿定子铁芯的内壁依次呈周期排列设置。其中，每相绕组的每一相单元为一极相，每一相单元所对应的定子槽数为每极每相槽数。
其中，可以理解的是，本申请中不对扁线电机的相数做具体限定，定子绕组可为单相绕组，可以是三相绕组，也可以是六相绕组。
图8为本申请一种实施例的U相绕组的相带分布图，一并参照图7和图8，在本申请一种实施例中，U相绕组的任一相单元中包括至少两个相带，任一相单元的各相带可包括相邻两层扁线导体21，任一相单元的相邻相带之间错位一个定子槽。其中，N为大于等于4的偶数，从而，在任一相单元中，N层扁线导体21可分为N/P个相带。以N为6为例，每个定子槽11内设有6层扁线导体21，且相邻2层扁线导体可组成一个相带，相带数可为3个。以N为10为例，每个定子槽11内设有10层扁线导体21，且相邻2层扁线导体21组成一个相带，相带数可为5个。
继续参照图8，本申请实施例的扁线电机的定子中，任一相单元的相邻相带之间均沿顺时针方向或均沿逆时针方向错位一个定子槽11，即同一相单元的各相邻相带之间错位的定子槽11的方向相同，从而最大程度上使定子绕组的等效节距小于定子绕组的极距，相比于传统短距的每相绕组的任一相单元中仅包括两个相带，且任一相单元的相邻相带之间错位一个或者两个定子槽，即传统短距绕组的节距分别为8或者7，本申请实施例的扁线电机在获得高基波绕组系数的同时，可有效降低电机的谐波绕组系数。
图9为本申请另一种实施例的U相绕组的相带分布图，参照图9，在本申请一种实施例中，同一相单元的多个相带中，自一个定子槽的第1层至第N层方向，前几个相邻相带之间可先沿顺时针方向依次错位一个定子槽，后几个相邻相带之间再沿逆时针方向依次错位一个定子槽11；或者，前几个相邻相带之间可先沿逆时针方向依次错位一个定子槽，后几个相邻相带之间再沿顺时针方向依次错位一个定子槽11；或者，相邻相带之间可交替按照顺时针方向和逆时针方向依次错位一个定子槽11。需要说明的是，当同一相单元的相邻相带之间采用上述沿顺时针方向和逆时针方向的组合错位一个定子槽时，任一相单元沿垂直定子铁芯的轴线方向的中垂线对称设置。
其中，需要说明的是，本申请中对各相邻相带之间的错位槽数的方向不做限定，可以 自由组合，灵活地满足不同电机设计需求，以抑制电机的转矩波动、降低谐波绕组系数，从而提升电机性能。
在本申请一种实施例中，每相绕组中均包括至少一条支路。当每相绕组包括两条及以上的并联支路时，各并联支路包括分布在各相邻相单元的同层相带中的不同层的扁线导体，其中，且同一相带中的各所述扁线导体均匀分布于不同的并联支路中，从而可使每相各个并联支路之间保持电势平衡。
如图8所示，在本申请一种实施例中，定子绕组20的每相绕组分别由两条并联电路组成。以U相的两条并联支路为例，记为支路1和支路2，其中的同一相带中的不同层的扁线导体分属于不同的并联支路，且相邻相单元中的同层相带的不同层的扁线导体分属于不同的并联支路。其中，以1、2、3槽组成的相带和以10、11、12组成的相带为例，两个相带分属于两个不同的相单元，将1、2、3槽组成的相带记为相带A，将10、11和12组成的相带为相带B，则相带A中的第1层扁线导体属于支路1，相带A中的第2层扁线导体属于支路2，相带B中的第1层扁线导体属于支路2，相带B中的第2层扁线导体属于支路1。以此设置不同层的扁线导体于支路1和支路2中，从而可使支路1和支路2保持电势平衡，减少环流的产生。
如图9所示，在本申请另一种实施例中，定子绕组20的每相绕组分别由四条并联电路组成，分别记为支路1、支路2、支路3和支路4。其中，以支路1为例，7槽和8槽组成的相带中，7槽的第2层的扁线导体属于支路1，8槽的第1层扁线导体属于支路2，8槽的第2层扁线导体属于支路3，7槽的第1层扁线导体属于支路4。其他的层的扁线导体的连接可参照图9进行连接，以形成不同的并联支路。
在本申请一种实施例中，每相绕组沿定子铁芯的轴线方向均分为N/2个部分，每部分中相邻的两层扁线导体相连接形成一个线圈层，每部分包括两个线圈层。在本申请一种可能的实现方式中，每相绕组中，相邻线圈层之间通过单根跨线连接，也即通过单根跨线实现了跨层连接，有助于简化定子绕组的结构，从而便于实现。
图10为图8中U相绕组的单支路展开图，参照图10，在本申请一种实施例中，定子绕组20沿定子铁芯10的轴线方向的相对两侧分别为插线端20a和焊接端20b，在焊接端20b侧，不同线圈层之间单根跨线的跨距相等，以使焊接端20b的扭头角度相同，可简化扭头、焊接和涂覆工艺。
本申请实施例还提供一种扁线电机，该扁线电机包括转子和本申请实施例的定子，转子设于定子铁芯的内壁所围设形成的空间内。
本申请实施例还提供一种动力总成，该动力总成包括减速器和上述的扁线电机。其中，扁线电机和减速器传动连接。具体地，扁线电机的驱动轴与减速器的输入轴可通过联轴器等传动件实现传动连接，以将驱动力自扁线电机输出至减速器。
本申请实施例提供的车辆，包括上述的动力总成，上述的动力总成设置于车辆内，并为车辆提供运行动力。具体地，本实施例中，车辆可具体为以电能进行驱动的新能源车辆，比如。其中，新能源车辆具体可以是混合动力电动车辆、纯电动车辆或燃料电池电动车辆等，也可以是采用超级电容器、飞轮电池或飞轮储能器等高效储能器作为电能来源的车辆。
以下将结合具体的实施例对本申请实施例的定子绕组做详细说明。
实施例1
本实施例为一种定子绕组及含有该定子绕组的定子，该定子还包括定子铁芯，其中， 定子铁芯的定子槽为54个，定子槽内导体层的层数为6层，定子绕组的极数为6。定子绕组分为U相、V相和W相，每相绕组设置的并联支路的数量均为2个。每相绕组可分为6极相，即6个相单元，每极每相槽数为3个，该实施例U相绕组中各相带分布图可参照图8。
如图8所示，每个定子槽内含有6层扁线导体。其中第1层为定子槽的槽底层，第6层为槽口层。“+”代表电流流入导体，“-”代表电流流出导体。其中，任一相单元中，相邻的两层扁线导体组成一个相带，即每相绕组的每个相单元可分为三个相带，同一相单元的相邻相带之间错位一个定子槽，且错位方向均沿图中x方向移动1个槽，从而可使定子绕组的等效节距为7，实现了短距的效果。需要说明的是，图8中的x方向在实际的定子铁芯中可为顺时针方向或逆时针方向。
其中，每相绕组的两个并联支路均将所能布置的相带和扁线导体层位置进行遍历，因此各并联支路数均能保持电势平衡，不会产生环流。以图8中所示相带分布为例，将1槽、2槽、3槽中的第1层和第2层扁线导体组成的相带记为相带A1，将54槽、1槽、2槽中的第3层和第4层扁线导体组成的相带记为相带A2，将53槽、54槽、1槽中的第5层和第6层扁线导体组成的相带记为相带A3；将10槽、11槽、12槽中的第1层和第2层扁线导体组成的相带记为相带B1，将9槽、10槽、11槽中的第3层和第4层扁线导体组成的相带记为相带B2，将8槽、9槽、10槽中的第5层和第6层扁线导体组成的相带记为相带B3，……，依次类推，将46槽、47槽、48槽中的第1层和第2层扁线导体组成的相带记为相带F1，将45槽、46槽、47槽中的第3层和第4层扁线导体组成的相带记为相带F2，将44槽、45槽、46槽中的第5层和第6层扁线导体组成的相带记为相带F3。在连接时，相邻相单元中的同层相带中的不同层的扁线导体分布于不同的并联支路，且同一相带中的各扁线导体均匀分布于不同的并联支路中，例如相带A1和相带B1中，若相带A1中的第1层扁线导体属于支路1，则相带A1中的第2层扁线导体属于支路2，相带B1中的第1层扁线导体属于支路2，相带B1中的第2层扁线导体属于支路1。依次类推，将各个相带中的扁线导体分别连接于不同的支路中。图11为一种支路2的连接结构示意图，图12为图11中部分扁线导体的放大连接结构示意图，一并参照图8、图11和图12，在连接时，可利用单根跨线，在定子绕组的各焊接端进行各线圈层的连接。其中，作为示例性说明，支路2中，以5层和6层扁线导体的连接方式为例进行说明，28槽5层扁线导体，连接37槽6层扁线导体，然后连接46槽5层扁线导体，然后连接1槽6层扁线导体，然后连接8槽5层扁线导体，然后连接17槽6层扁线导体，然后连接26槽5层扁线导体，然后连接35槽6层扁线导体，然后连接44槽5层扁线导体，然后连接53槽6层扁线导体，然后连接9槽5层扁线导体，然后连接18槽6层扁线导体，然后连接27槽5层扁线导体，然后连接36槽6层扁线导体，然后连接45槽5层扁线导体，然后连接54槽6层扁线导体，然后连接10槽5层扁线导体，然后连接19槽4层扁线导体，至此完成5层和6层扁线导体的遍历。其他层的扁线导体的连接方式可参照图8、图11和图12，在此不再一一展开说明。
图12为支路2中一处部位的连接结构示意图。如图12所示10槽5层扁线导体连接19槽4层扁线导体，完成相邻线圈层之间的跨线连接，即从5、6层扁线导体组成的相带跨接到3、4层扁线导体组成的相带，跨距也为9。另外，从10槽3层扁线导体跨接到19槽2层扁线导体时，跨距也为9。由此，从图10至图12中可以看出，各发卡线圈在定子 绕组焊接端的跨距均为9，由此可使各发卡线圈在焊接端的扭头方向保持一致，降低加工难度。
需要说明的是，图8中的相带分布仅为示例性说明，对调图8中的“+”“-”符号，例如同时将图8中的“U+”改为“U-”，并将“U-”改为“U+”，V相和W相的也做相应修改后，均在本申请的保护范围内。
图13和图14为本实施例电机定子铁芯和U相绕组的结构示意图，其中，图13重点体现插线端的特点，图14重点体现焊接端的特点，如图13所示，在插线端，相邻线圈层之间无需额外的跨线进行连接。如图14所示，定子绕组的焊接端，相邻线圈层之间采用单根跨线连接，具体为第二层与第三层之间，以及第四层到第五层之间通过单根跨线连接，且焊接端跨距均保持为9，因而，绕组焊接端跨距和扭头角度相同，各个焊接点圆周对称分布。
实施例2
本实施例为一种定子绕组及含有该定子绕组的定子，该定子还包括定子铁芯，其中，定子铁芯的定子槽为48个，定子槽内导体层的层数为10，定子绕组的极数为8。定子绕组分为U相、V相和W相，每相绕组设置的并联支路的数量均为4个。每相绕组可分为8个相单元，每极每相槽数为2个，以U相绕组为例，该实施例U相绕组的相带分布图可参照图9。
如图9所示，每个定子槽内含有10层扁线导体，其中第1层为定子槽的槽底层，第6层为槽口层。“+”代表电流流入导体，“-”代表电流流出导体。其中，任一相单元中，相邻的两层扁线导体组成一个相带，即每相绕组的每个相单元可分为五个相带。如图9所示，在任一相单元中，第1层和第2层扁线导体组成第一相带，第3层和第4层扁线导体组成第二相带相对，第5层和第6层扁线导体组成第三相带，第7层和第8层扁线导体组成的第四相带，第9层和第10层扁线导体组成的第五相带。在同一相单元中，第二相带(如8槽和9槽的第3层扁线导体和第4层扁线导体组成的相带)相对于第一相带(如7槽和8槽的第1层扁线导体和第2层扁线导体组成的相带)沿与图中x方向相反的方向错位1个槽，第三相带(如9槽和10槽的第5层扁线导体和第6层扁线导体组成的相带)相对于第二相带(如8槽和9槽的第3层扁线导体和第4层扁线导体组成的相带)沿与图中x方向相反的方向错位1个槽，第四相带(如8槽和9槽的第7层扁线导体和第8层扁线导体组成的相带)相对于第三相带(如8槽和9槽的第5层扁线导体和第6层扁线导体组成的相带)沿与图中x方向错位1个槽，第五相带(如7槽和8槽的第9层扁线导体和第10层扁线导体组成的相带)相对于第四相带(如8槽和9槽的第7层扁线导体和第8层扁线导体组成的相带)沿与图中x方向错位1个槽。如图9所示，该设置方式中，定子绕组的等效节距为7，从而实现短距的效果。需要说明的是，图9中的x方向在实际的定子铁芯中可为顺时针方向或逆时针方向。
其中，图9所示定子绕组中，每条并联支路在连接时，可先连接同层相带的不同的扁线导体，在完成不同相单元的第一相带之间的连接后，可通过单根跨线连接不同线圈层之间的扁线导体，例如当第一相带的各个扁线导体连接完毕后，可将第一相带的扁线导体与第二相带的扁线导体连接。该连接方式中，各层扁线导体在焊接端侧单根跨线的跨距均为8。由此，本实施例中的定子绕组在焊接端可以使跨距保持完全一致，均保持为8，从而使得发卡线圈的线腿的扭头角度相同，简化了扭头、焊接和涂覆工艺。
其中，每相绕组中四个并联支路均将所能布置的相带的扁线导体均匀遍历，因此各并联支路数均能保持电势平衡，不会产生环流。
对上述实施例中的定子绕组、整距绕组、节距为8传统短距绕组(如图1所示)、以及节距为7传统短距绕组(如图2所示)的绕组系数和电机的转矩波动进行仿真计算，计算结果如下：
表1
由表1中实施例1和传统的短距绕组的对比数据可知，实施例1的等效节距为7，但是基波绕组系数远高于传统等效节距为7的短距绕组，接近于传统等效节距为8的短距绕组，极大减小了短距对平均转矩的影响；另外，实施例1的5、7、11以及13次谐波绕组系数远低于传统的短距绕组，对电枢侧磁场5、7、11以及13次谐波的削弱作用更强。
图15为实施例1的绕组、整距绕组和传统短距绕组电机峰值扭矩工况点的转矩波动对比图，如图15所示，采用短距绕组的电机其转矩波动均大幅下降，采用整距绕组电机的转矩波动峰的峰值为17.3Nm，采用传统短距绕组(等效节距为8)电机和实施例1的短距绕组电机的转矩波动峰的峰值则分别为10.4Nm和9.7Nm，分别下降40％和44％，显然实施例1的扁线短距绕组结构的转矩波动抑制效果更好。
以上，仅为本申请的具体实施方式，但本申请的保护范围并不局限于此，任何熟悉本技术领域的技术人员在本申请揭露的技术范围内，可轻易想到变化或替换，都应涵盖在本申请的保护范围之内。因此，本申请的保护范围应以权利要求的保护范围为准。

Claims (13)

  1. 一种扁线电机的定子，其特征在于，包括定子铁芯和定子绕组，所述定子铁芯的内壁周向均匀开设有多个定子槽，所述定子绕组包括插设于所述定子槽内的扁线导体，任一所述定子槽内均设有N层所述扁线导体，其中，N为大于等于4的偶数；
    各所述扁线导体分别用连接以形成m相绕组，每相绕组包括多个沿所述定子铁芯的周向均匀且间隔设置的相单元，每相绕组的任一所述相单元中包括至少两个相带，任一所述相单元的各所述相带包括相邻两层所述扁线导体，任一所述相单元的相邻所述相带之间错位一个定子槽。
  2. 根据权利要求1所述的定子，其特征在于，任一所述相单元的相邻所述相带之间均沿顺时针方向或均沿逆时针方向错位一个定子槽。
  3. 根据权利要求1所述的定子，其特征在于，任一所述相单元的相邻所述相带之间沿顺时针方向和逆时针方向错位一个定子槽。
  4. 根据权利要求3所述的定子，其特征在于，任一所述相单元沿垂直所述定子铁芯的轴线方向的中垂线对称设置。
  5. 根据权利要求1-4任一项所述的定子，其特征在于，每相绕组沿所述定子铁芯的轴线方向均分为N/2个部分，每部分中相邻的两层所述扁线导体相连接形成一个线圈层，每部分包括两个所述线圈层。
  6. 根据权利要求5所述的定子，其特征在于，每相绕组中，相邻所述线圈层之间通过单根跨线连接。
  7. 根据权利要求5或6所述的定子，其特征在于，所述定子绕组沿所述定子铁芯的轴线方向的相对两侧分别为插线端和焊接端，在所述焊接端侧，不同所述线圈层之间单根跨线的跨距相等。
  8. 根据权利要求1-7任一项所述的定子，其特征在于，每相绕组均包括至少一条支路。
  9. 根据权利要求8所述的定子，其特征在于，每相绕组包括至少两条支路时，各所述并联支路包括分布在各相邻所述相单元的同层所述相带中的不同层的扁线导体，且同一相带中的各所述扁线导体均匀分布于不同的并联支路中。
  10. 根据权利要求1-9任一项所述的定子，其特征在于，所述定子铁芯内壁的定子槽的数量为Z，定子绕组的相数为m，定子绕组的极数为2p，且P为整数，每极每相定子槽的个数为q，所述Z、所述m、所述2p和所述q之间满足：q＝Z/2pm。
  11. 一种扁线电机，其特征在于，包括转子和如权利要求1-10任一项所述的定子，所述转子设于所述定子铁芯的内壁所围设形成的空间内。
  12. 一种动力总成，其特征在于，包括减速器和如权利要求11所述的扁线电机，所述扁线电机与所述减速器传动连接。
  13. 一种车辆，其特征在于，包括如权利要求12所述的动力总成。
PCT/CN2023/084051 2022-08-12 2023-03-27 定子、扁线电机、动力总成和车辆 WO2024032001A1 (zh)

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