Patent ID: 12191728

DETAILED DESCRIPTION

Reference will now be made in detail to the present embodiments, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers are used in the drawings and the description to refer to the same or like parts. The “clockwise winding” disclosed herein is to help understand the relative position of the inserting/protruding wire, and it can also be understood as “counterclockwise winding” based on the relative position of the inserting/protruding wire. In other words, from the perspective of mechanical configuration, there is no so-called inserting/protruding wire. From the perspective of the circuit configuration, the positive [+] contact can be referred as an inserting, and the negative [−] (neutral) contact can be referred as a protruding wire.

Reference is made toFIG.1, which illustrates a circuit diagram of a motor stator according to an embodiment of the present disclosure. Circuit50includes U, V, and W phase windings. Each (U, V, W) phase winding includes parallel-connected windings Y1to YN. The negative end (YN out) of each winding YN is connected to the neutral terminal52. In other words, each winding has YN number of ends connected to the neutral terminal(s), and the positive end (YN in) of each winding YN is connected to a corresponding phase terminal (for example, the phase terminals of the U, V, and W phases). In other words, each winding has YN number of ends connected to the phase terminals.

Reference is made toFIG.2, which illustrates a side view of a motor stator100according to an embodiment of the present disclosure. The circuit50is to be implemented with a stator core110and a plurality of hairpin wires120. Specifically, the legs (120b,120c) of the plural hairpin wires120are inserted into corresponding (phase) slots from the insertion side110a(also referred as first side) of the stator core110, and protruded out from the extension side110b(also referred as second side) of the stator core110and appropriately bent. After the hairpin wires120are installed on the stator core110, a bent portion120ais located at the insertion side110aof the stator core110, and the legs (120b,120c) are located at the extension side110b. When all the hairpin wires120belonging to the same winding are inserted into the corresponding (phase) slots, the corresponding legs (120b,120c) can be connected (e.g., by welding), so that all the hairpin wires120of the same winding are connected to each other. In some embodiments of the present disclosure, the negative end and the positive end of the winding composed of the hairpin wires120are extended from the insertion side110aof the stator core110, and are respectively connected to the neutral terminal and the phase terminal. In some embodiments of the present disclosure, the negative end and the positive end of the winding composed of the hairpin wires120can be protruded from the insertion side110aor the extension side110bof the stator core110, and are respectively connected to the neutral terminal and the phase terminal. In some embodiments of the present disclosure, all the leg ends (for example,120b,120c) of the hairpin wires, located in immediately-adjacent two of the slot-position layers and protruding from the extension side110b, are connected to form a span of a pole pitch on the extension side110b.

Reference is made toFIG.3, which illustrates a top view of a 72 slot stator core of a motor stator according to an embodiment of the present disclosure. The top view of the stator core is the top view of the insertion side of the stator core. The stator core110is used to realize a motor stator with 8 polar regions, 72 (phase) slots (A, B, C), and 6 slot-position layers. Each (phase) slot (A, B, C) includes a plurality of radially adjacent slot-positions (i.e., “squares” in each (phase) slot (A, B, C)), and each slot-position can accommodate one hairpin wire. All slot-positions surround the rotor accommodating space150in the circumferential direction, and form a plurality of slot-position layers (L1to L6) adjacent in the radial direction. The 8 polar regions equally divide the stator core110in the circumferential direction, and each polar region has U, V, and W phases. For example, the first polar region has U1, V1, and W1phases, and the second polar region has U2, V2, and W3phases . . . . The 8th polar region has U8, V8, and W8phases. Each phase has a plurality of Q (phase) slots, such as circumferentially adjacent phase slot A (left), phase slot B (middle), and phase slot C (right) in the circumferential direction. The quantity of phase slots for a single phase is three (i.e., Q=3). The 72 slots in this embodiment are equal to: 8 (polar region)×3 (phase/polar region)×3 (slot/phase). 72 (phase) slots and the slot-positions contained therein surround the rotor accommodating space150in the circumferential direction, and each (phase) slot extends from the rotor accommodating space150in radial direction of the stator core. Each (phase) slot allows 6 hairpin wires to be inserted into 6 slot-position layers from the outside to the inside for L1to L6layers. The ring-shaped stator core110defines a rotor accommodating space150for accommodating the rotor. The L6layer is closest to the rotor accommodating space150as a radially-innermost one of the slot-position layers, and the L1layer is the farthest from the rotor accommodating space150as a radially-outmost one of the slot-position layers. In some embodiments of the present disclosure, the (phase) slots in the polar regions have the same or nearly the same cross-sectional dimensions, and the spacing between the (phase) slots is also the same or nearly the same, but not being limited to thereto.

Reference is made toFIG.4, which illustrates one of the windings configured in U phases of a 72-slot motor stator according to an embodiment of the present disclosure. A motor stator with 8 polar regions, 72 (phase) slots, and 6 slot-position layers is realized by the stator core110, and each of U, V, and W phases has 8 parallel-connected windings, and the number of parallel-connected windings is equal to a total number of the polar regions. Taking the U phase as an example, the wire of winding Y1(such as the wire122inFIG.2) is routed into the L1layer of the phase slot A of the U1phase on the insertion side of the stator core, and then connected to the L2layer of the phase slot A of the U2phase on the extension side of the stator core, then connected to the L1layer of the phase slot B of the U3phase on the insertion side of the stator core, then connected to the L2layer of the phase slot B of the U4phase on the extension side of the stator core, and then connected to the L1layer of phase slot C of the U5phase on the insertion side of the stator core, and connected to the L2layer of the phase slot C of the U6phase on the extension side of the stator core. At this point, the wire of winding Y1has passed through the phase slots A, B, and C of the L1layer once, and has also passed through the phase slots A, B, and C of the L2layer once. Then a trans-layer connection wire T1is used to connect the L2layer of the phase slot C of the U6phase to the L3layer of the phase slot A of the U7phase on the insertion side of the stator core, and then connected to the L4layer of the phase slot A of the U8phase on the extension side of the stator core, then connected to the L3layer of phase slot B of the phase U1on the insertion side of the stator core, then connected to the L4layer of phase slot B of phase U2on the extension side of the stator core, and then connected to the L3layer the phase slot C of the U3phase on the insertion side of the stator core, and then connected to the L4layer of phase slot C of the U4phase on the extension side of the stator core. The wire of winding Y1has passed through the phase slots A, B, and C of the L3layer once after jumping slot-position layer by the trans-layer connection wire T1, and has also passed through the phase slots A, B, and C of the L4layer once. Then a trans-layer connection wire T2is used to connect the L4layer of the phase slot C of the U4phase to the L5layer of the phase slot A of the U5phase on the insertion side of the stator core, and then connected to the L6layer of the phase slot A of the U6phase on the extension side of the stator core, then connected to the L5layer of the phase slot B of the U7phase on the insertion side of the stator core, then connected to the L6layer of the phase slot B of the U8phase on the extension side of the stator core, and then connected to the L5layer of the phase slot C of the U1phase on the insertion side of the stator core, then connected to the L6layer of phase slot C of the U2phase on the extension side of the stator core. The wire of winding Y1has passed through the phase slots A, B, and C of the L5layer once after jumping slot-position layer by the trans-layer connection wire T2, and also passed through the phase slots A, B, and C of the L6layer once, and the wire of the winding Y1at this point (the L6layer of the phase slot C of the U2phase) is routed out (for example, the wire124inFIG.2is out). Winding Y1contains plural transpolar hairpin wires (for example, hairpin wires120inFIG.2). These transpolar hairpin wires have a common span or the same span, and only use different types of wires at the inlet and outlet ends (for example, the hairpin wires122,124inFIG.2). The legs of the transpolar hairpin wires (for example, the legs120band120cof the hairpin wires120inFIG.2) are connected to each other on the extension side of the stator core (for example, the extension side110binFIG.2) to form a winding. It can be seen fromFIG.4that the wire of winding Y1first circulates through phase slots A, B, and C in a clockwise direction on layers L1to L2in sequence, and then circulates through phase slots A, B and C in a clockwise direction on layers L3to L4in sequence, and then circulates through phase slots A, B, and C in a clockwise direction on the L5to L6layer in sequence. Moreover, the winding rules of the wires of winding Y1on the L1to L2, L3to L4, and L5to L6layers are the same. In some embodiments of the present disclosure, within two adjacent slot-position layers (such as L1to L2, L3to L4, or L5to L6), and the winding Y1is routed through the same phase slot (A, B or C) of the same phases across the polar regions (e.g., U1to U8) but through slot-positions in different slot-position layers on the extension side, and routed through the adjacent phase slots (e.g., phase slot A to phase slot B or phase slot B to phase slot C) of the same phase across the polar regions but through slot-positions in different slot-position layers on the insertion side. In some embodiments of the present disclosure, the two legs (such as the legs120band120cof the hairpin wires120inFIG.2) of each transpolar hairpin wires (such as the hairpin wires120inFIG.2) in the winding Y1cross two adjacent slot-position layers (such as L1to L2, L3to L4, or L5to L6), and insert into slot-positions in different slot-position layers of the adjacent phase slots (phase slot A to phase slot B or phase slot B to phase slot C) of the same phases (such as U1to U8) across the polar regions. For example, the first leg and the second leg of each transpolar hairpin wires cross the two adjacent slot-position layers, and insert into a first phase slot and a second phase slot respectively of the same phases across the polar regions where the second phase slot is immediately adjacent to a third phase slot that is spaced from the first phase slot by one pole pitch. This winding method, on the insertion side of the stator core, connects from the phase slot A to the phase slot B on adjacent Un phases (n=1 to 8), and then from the phase slot B to the phase slot C, and change slot-position layers (for example, L2to L1, L4to L3, or L6to L5) when connecting phase slots. When winding on the the extension side of the stator core, it maintains the same phase slot of the same phases across the polar regions, and only crosses the two adjacent slot-position layers, such as connecting from the L1layer to the L2layer, from the L3layer to the L4layer or from the L5layer to the L6layer. In some embodiments of the present disclosure, when an inlet end of the winding Y1is inserted into a leftmost one (phase slot A) of the phase slots of the same phases (U1to U8) of the polar regions, an outlet end of the winding Y1is inserted onto a rightmost one of the phase slots (phase slot C) of the same phases of the polar regions. In other words, on the extension side, the winding Y1passes through the same phases of all the polar regions with a pole pitch span, and on the insertion side, the winding Y1passes through the first phase slot and the second phase of the same phase slots of all the polar regions, where the second phase slot is immediately-adjacent to the third phase slot that is spaced from the first phase slot by one pole pitch.

Based upon using the winding rules on L1to L2layers, L3to L4layers and L5to L6layers, the hairpin wires used on the L1to L2layer, L3to L4layer and L5to L6layer have the same slot pitch across the insertion side except for the size of the trans-layer connection wire, such that a common size of hairpin wires can be used to connect. Specifically, the pole pitch or full pitch of the L1to L2layers, L3to L4layers, and L5to L6layers is obtained by 72 (slots) divided by 8 (polar regions), which is equal to 9 slots. A common span (or common pitch) of the transpolar hairpin wires on the insertion side is 10 (9+1) slots. In other words, the common span (such as 10) is equal to a quotient, which is obtained by dividing a total number of the (phase) slots (such as 72) by a total number of polar regions (such as 8), plus 1. In addition to the transpolar hairpin wires, a span of the trans-layer connection wires T1and T2on the insertion side is 7 slots, and the span of the trans-layer connection wire can be obtained from the common span 10 slots minus the quantity of the phase slots in each phase (Q=3). In some embodiments of the present disclosure, trans-layer connection wires T1and T2cross two adjacent slot-position layers, and two ends of the trans-layer connection wire are arranged in a leftmost phase slot and a rightmost phase of the same phases across the polar regions. In some embodiments of the present disclosure, the winding Y1includes a plurality of (sub) windings connected to each other by the trans-layer connection wires T1and T2, one end of one of the (sub) windings is arranged in the slot-position layer (such as L6), which is radially closest to the rotor accommodating space as a radially-innermost one of the slot-position layer, or the slot-position layer (such as L1), which is radially farthest from the rotor accommodating space as a radially-outmost one of the slot-position layers, to be connected to the phase terminals or the neutral terminals.

Reference is made toFIG.5, which illustrates two of the windings configured in U phases of a 72-slot motor stator according to an embodiment of the present disclosure. Continuing from the winding Y1inFIG.4, the wires of winding Y2follow the same winding rules. After entering the L1layer of the phase slot A of the U2phase from the insertion side of the stator core, the wires of winding Y2are routed through within L1to L2layers in a clockwise direction, alternately through the phase slots A, B, and C once. After a trans-layer connection wire, the wires of winding Y2are then alternately routed through the phase slots A, B, and C once on the L3to L4layer in a clockwise direction. After another trans-layer connection wire, the wires of winding Y2are then alternately routed through the phase slots A, B, and C once on the L5to L6layers in a clockwise direction, and finally routed out from the L6layer of the phase slot C of the U3phase.

Reference is made toFIG.6, which illustrates 8 windings configured in U phases of a 72-slot motor stator according to an embodiment of the present disclosure. Continuing from the winding Y1and Y2inFIG.5, the windings Y3to Y8are executed according to the same winding rules of the windings Y1and Y2to occupy all the U-phase slots and slot-positions. Therefore, the winding Y3is routed into the L1layer of the phase slot A of the U3phase from the insertion side of the stator core, and routed out from the L6layer of the phase slot C of the U4phase. The winding Y4is routed into the L1layer of the phase slot A of the U4phase from the insertion side of the stator core, and routed out from the L6layer of the phase slot C of the phase U5. The winding Y5is routed into the L1layer of the phase slot A of the U5phase from the insertion side of the stator core, and routed out from the L6layer of the phase slot C of the phase U6. The winding Y6is routed into the L1layer of the phase slot A of the U6phase from the insertion side of the stator core, and routed out from the L6layer of the phase slot C of the U7phase. The winding Y7is routed into the L1layer of the phase slot A of the U7phase from the insertion side of the stator core, and routed out from the L6layer of the phase slot C of the U8phase. The winding Y8is routed into from the insertion side of the stator core from the L1layer of the phase slot A of the U8, and routed out from the L6layer of the phase slot C of the U1phase. The wires of the windings Y1to Y8occupy all phase slots and slot-positions of U1to U8phases. Connecting the negative end (YN−out) of Y1to Y8to the neutral terminal NC, and connecting the positive end (YN+in) of Y1to Y8to the phase terminal of the U phase to form U-phase parallel-connected windings Y1to Y8.

Reference is made toFIGS.7and8. Continuing from the U-phase windings inFIG.6, 8 windings of V-phase and W-phase are also executed using the same winding principle to occupy all phase slots and slot-positions of V1to V8and W1to W8, forming V-phase parallel-connected windings Y1to Y8and W-phase parallel-connected windings Y1to Y8.

Reference is made toFIG.9, which illustrates 8 windings configured in U, V, W phases of a 72-slot motor stator according to an embodiment of the present disclosure. The positive ends (YN+) of the U-phase, V-phase, and W-phase 8 windings (Y1to Y8) are respectively connected to corresponding U-phase, V-phase, and W-phase phase terminals, while The negative ends (YN−) of the U-phase, V-phase, and W-phase 8 windings (Y1to Y8) are all connected to the neutral terminal NC.

The U-phase, V-phase, and W-phase 8 windings inFIG.9are all routed according to the same winding rules illustrated inFIG.4such that the span of the trans-layer connection wire on the insertion side is all 7 slots, and the common span (common pitch) of the transpolar hairpin wires on the insertion side is 10 slots.

Reference is made toFIG.10, which illustrates one of the windings configured in U phases of a 72-slot motor stator using same-layer connection wires (joining wire) according to an embodiment of the present disclosure. Continuing from the U-phase windings Y1and Y2inFIGS.4and5, the U-phase winding Y1in this embodiment uses a same-layer connection wire IJW1to connect the U-phase windings Y1and Y2inFIGS.4and5to form a winding YIJ1.

Reference is made toFIG.11, which illustrates 4 windings configured in U phases of a 72-slot motor stator using inner same-layer connection wires according to an embodiment of the present disclosure. The same-layer connection wire inFIG.10is applied to the U-phase 8 windings inFIG.6to form the U-phase 4 windings.

Specifically, a same-layer connection wire IJW1is used to connect inner wire ends of the U-phase windings Y1and Y2inFIG.6, and s same-layer connection wire IJW2is used to connect inner wire ends of the U-phase windingd Y3and Y4inFIG.6, a same-layer connection wire IJW3is used to connect inner wire ends of the U-phase windings Y5and Y6inFIG.6, and a same-layer connection wire IJW4is used to connect inner wire ends of the U-phase winding Y7and Y8inFIG.6to form windings YIJ1to YIJ4of U phase. The two ends of the same-layer connection wires (IJW1to IJW4) are arranged in the same slot-position layer (L6) that is closest to the rotor accommodating space in the radial direction, and the span is a pole pitch (a distance between two phase slots C of the same phases across adjacent polar regions). Connecting the negative end (YIJN−out) of YIJ1to YIJ4to the neutral terminal NC, and connecting the positive end (YIJN+in) of YIJ1to YIJ4to the phase terminals of the U phase to form a parallel-connected U-phase windings YIJ1to YIJ4. For the V-phase and W-phase 8 windings inFIGS.7and8, the same-layer connection wires can also be used to connect the inner wire ends of the winding to achieve the parallel connection of the V-phase and W-phase winding YIJ1to YIJ4. This embodiment has the same winding rules as the winding inFIG.6such that the span of the trans-layer connection wire on the insertion side is 7 slots, while the common pitch of the transpolar hairpin wires on the insertion side is 10 slots. In addition, the span of the same-layer connection wire on the insertion side is 9 slots (full pitch).

Reference is made toFIG.12, which illustrates 4 windings configured in U phases of a 72-slot motor stator using outer same-layer connection wires according to an embodiment of the present disclosure. This embodiment also uses the same-layer connection wire to connect the U-phase 8 windings inFIG.6to form U-phase 4 windings. Different from the same-layer connection wire configuration inFIGS.10and11, same-layer connection wires in this embodiment is used to connect outer wire ends of the windings. Specifically, a same-layer connection wire OJW1is used to connect the outer wire ends of the U-phase windings Y1and Y2inFIG.6, and a same-layer connection wire OJW2is used to connect the outer wire ends of the U-phase windings Y3and Y4inFIG.6. A same-layer connection wire OJW3is used to connect the outer wire ends of the U-phase winding Y5and Y6inFIG.6and a same-layer connection wire OJW4is used to connect the outer wire ends of the U-phase windings Y7and Y8inFIG.6to form U-phase windings YOJ1to YOJ4in this embodiment. The two ends of the same-layer connection wires (OJW1to OJW4) are arranged on the same slot-position layer (i.e., L1) that is farthest from the rotor accommodating space in the radial direction, and the spans are all a pole pitch (a distance between two phase slots A of the same phases across adjacent polar regions). Connecting the negative ends (YOJN−out) of YOJ1to YOJ4to the neutral terminal NC, and connecting the positive end (YOJN+in) of YOJ1to YOJ4to the phase terminals of the U phase to form a parallel-connected U-phase windings YOJ1to YOJ4. For the V-phase and W-phase 8 windings inFIGS.7and8, the same-layer connection wires can also be used to connect the outer wire ends of the windings to achieve the parallel connection of the V-phase and W-phase windings YOJ1to YOJ4.

Reference is made toFIG.13, which illustrates 2 windings configured in U phases of a 72-slot motor stator using inner and outer same-layer connection wires according to an embodiment of the present disclosure. Continuing from the U-phase windings YOJ1to YOJ4inFIG.12, a same-layer connection wire IJW1is used in this embodiment to connect the inner side ends of the U-phase windings YOJ1to YOJ2inFIG.11, and a same-layer connection wire IJW2is used to connect the inner wire ends of the U-phase windings YOJ3and YOJ4inFIG.11to form the U-phase windings YOIJ1and YOIJ2in this embodiment. Connecting the negative ends of YOIJ1and YOIJ2(YOIJN−out) to the neutral terminal NC, and connect the positive ends of YOIJ1and YOIJ2(YOIJN+in) to the phase terminals of the U phase to form a parallel-connected U-phase windings YOIJ1and YOIJ2.

Reference is made toFIG.14, which illustrates one of the windings configured in U phases of a 72-slot motor stator according to another embodiment of the present disclosure. The winding method of this embodiment is slightly different from the winding method of the U phase inFIG.4. Specifically, after the wire of winding Y1is routed into the L2layer of the phase slot A of the U1phase from the insertion side of the stator core, it is then connected to the L1layer of the phase slot A of the U2phase on the extension side of the stator core, then connected to the L2layer of phase slot B of phase U3on the insertion side of the stator core, then connected to the L1layer of phase slot B of the phase U4on the extension side of the stator core, and then connected to the L2layer of the phase slot C of the U5phase on the insertion side of the stator core, and then connected to the L1layer of the phase slot C of the U6phase on the extension side of the stator core. At this point, the wires of winding Y1has passed through the phase slots A, B, and C of the L1layer once, and has also passed through the phase slots A, B, and C of the L2layer once. A trans-layer connection wire T1is then used to connect the L1layer of phase slot C of phase U6to the L4layer of phase slot A of the phase U7on the insertion side of the stator core, and then connected to the L3layer of the phase slot A of the phase U8on the extension side of the stator core, then connected to the L4layer of the phase slot B of the U1phase on the insertion side of the stator core, and connected to the L3layer of the phase slot B of the U2phase on the extension side of the stator core, then connected to the L4layer of phase slot C of the phase U3on the insertion side of the stator core, and then connected to the L3layer of the phase slot C of the phase U4on the extension side of the stator core. After the trans-layer connection wire T1, the wire of winding Y1has passed through the phase slots A, B, and C of the L3layer once, and also passed the phase slots A, B, and C of the L4layer once. A trans-layer connection wire T2is then used to connect the L3layer of the phase slot C of the U4phase to the L6layer of the phase slot A of the U5phase on the insertion side of the stator core, and then connected to the L5layer of the phase slot A of the phase U6on the extension side of the stator core, and then connected to the L6layer of phase slot B of phase U7on the insertion side of the stator core, and connected to the layer L5of phase slot B of phase U8on the extension side of the stator core, and then connected to the L6layer of the phase slot C of the U1phase on the insertion side of the stator core, and then connected to the L5layer of the phase slot C of the U2phase on the extension side of the stator core. After the trans-layer connection wire T2, the wire of winding Y1has passed through the phase slots A, B, and C of the L5layer once, and also passed through the phase slots A, B, and C of the L6layer once, and is routed out at this point (The L5layer of phase slot C of the phase U2). Similar to the embodiments inFIGS.4to13, the same winding rules can be applied to the other windings of the U, V, and W phases. Although the winding method of this embodiment is slightly different from the winding method of the foregoing embodiments inFIGS.4to13, the common span (common pitch) of the transpolar hairpin wires on the insertion side is still 10 (9+1) slots, and the span of the trans-layer connection wires T1and T2on the insertion side is also 7 slots.

Reference is made toFIG.15, which illustrates one of the windings configured in U phases of a 72-slot motor stator according to still another embodiment of the present disclosure. The winding method of this embodiment is slightly different from the winding method of the U phase inFIG.4. Specifically, the wire of winding Y1is routed from from the L1layer of the phase slot A of the U1phase on the insertion side of the stator core, and then connected to the L2layer of the phase slot A of the U2phase on the extension side of the stator core, then connected to the L1layer of phase slot B of the phase U3on the insertion side of the stator core, then connected to the L2layer of phase slot B of phase U4on the extension side of the stator core, and then connected to the L1layer of the phase slot C of the U5phase on the insertion side of the stator core, and then connected to the L2layer of the phase slot C of the U6phase on the extension side of the stator core. At this point, the wire of winding Y1has passed through the phase slots A, B, and C of the L1layer once, and has also passed through the phase slots A, B, and C of the L2layer once. A trans-layer connection wire T1is then used to connect the L2layer of the phase slot C of the phase U6to the L4layer of phase slot A of the phase U7on the insertion side of the stator core, and then connected to the L3layer of the phase slot A of the phase U8on the extension side of the stator core, then connected to the L4layer of the phase slot B of the U1phase on the insertion side of the stator core, and connected to the L3layer of the phase slot B of the U2phase on the extension side of the stator core, and then connected to the L4layer of the phase slot C of the phase U3on the insertion side of the stator core, and then connected to the L3layer of the phase slot C of the phase U4on the extension side of the stator core. After the trans-layer connection wire T1, the wire of winding Y1has passed through the phase slots A, B, and C of the L3layer once, and also passed the phase slots A, B, and C of the L4layer once. A trans-layer connection wire T2is then used to connect the L3layer of phase slot C of the phase U4to the L5layer of phase slot A of the phase U5on the insertion side of the stator core, and then connected to L6layer of phase slot A of phase U6on the extension side of the stator core, then connected to L5layer of phase slot B of the phase U7on the insertion side of the stator core, and then connected to L6layer of the phase slot B of the phase U8on the extension side of the stator core, then connected to the L5layer of the phase slot C of the U1phase on the insertion side of the stator core, and then connected to the L6layer of the phase slot C of the U2phase on the extension side of the stator core. After the trans-layer connection wire T2, the wire of winding Y1has passed through the phase slots A, B, and C of the L5layer once, and also passed the phase slots A, B, and C of the L6layer once, and routed out at this point (L6layer of phase slot C of phase U2). The main difference between the winding method of this embodiment and the winding method of the U phase inFIG.4lies in the winding principle of the L3to L4layer. Similar to the embodiments inFIGS.4to13, the same winding rules in this embodiment can be applied to the other windings of the U, V, and W phases. Although the winding method of this embodiment is slightly different from that of the U phase inFIG.4, the common span (common pitch) of the transpolar hairpin wires on the insertion side is still 10 (9+1) slots, while the span of the trans-layer connection wires T1and T2on the insertion side is also 7 slots.

Reference is made toFIG.16illustrates one of the windings configured in U phases of a 72-slot motor stator according to still another embodiment of the present disclosure. The winding method of this embodiment is slightly different from the winding method of the U phase inFIG.4. Specifically, after the wire of winding Y1is routed into the L1layer of the phase slot C of the phase U1from the insertion side of the stator core, it is then connected to the L2layer of the phase slot C of the phase U2on the extension side of the stator core, then connected to the L1layer of phase slot B of the phase U3on the insertion side of the stator core, then connected to the L2layer of phase slot B of the phase U4on the extension side of the stator core, and then connected to the L1layer of phase slot A of the U5phase on the insertion side of the stator core, and then connected to the L2layer of the phase slot A of the U6phase on the extension side of the stator core. At this point, the wire of winding Y1has passed through the phase slots A, B, and C of L1layer once, and also passed through the phase slots A, B, and C of the L2layer once. The difference from the previous embodiment is that a sequence of crossing the phase slots is from C to B to A. A trans-layer connection wire T1is then used to connect the L2layer of phase slot A of phase U6to the L3layer of phase slot C of phase U7on the insertion side of the stator core, and then connected to the L4layer of phase slot C of the phase U8on the extension side of the stator core, and connected to the L3layer of phase slot B of phase U1on the insertion side of the stator core, and the L4layer of phase slot B of the phase U2on the extension side of the stator core, and then connected to the L3layer of phase slot A of U3phase on the insertion side of the stator core, and then connected to the L4layer of phase slot A of the phase U4on the extension side of the stator core. After the trans-layer connection wire T1, the wire of winding Y1has passed through the phase slots A, B, and C of the L3layer once, and also passed the phase slots A, B, and C of the L4layer once, the sequence is from C to B to A for the phase slots. A trans-layer connection wire T2is then used to connect the L4layer of phase slot A of the phase U4to the L5layer of phase slot C of the phase U5on the insertion side of the stator core, and then connected to the L6layer of the phase slot C of the phase U6on the extension side of the stator core, then connected to L5layer of phase slot B of the phase U7on the insertion side of the stator core, and then connected to layer L6of phase slot B of U8phase on the extension side of the stator core, then connected to the L5layer of phase slot A of the phase U1on the insertion side of the stator core, and then connected to the L6layer of phase slot A of the phase U2on the extension side of the stator core. After the trans-layer connection wire T2, the wire of winding Y1has passed through the phase slots A, B, and C of the L5layer once, and also passed the phase slots A, B, and C of the L6layer once, the sequence is from from C to B to A for the phase slots, and routed out at this point. In some embodiments of the present disclosure, when an inlet end of winding Y1is inserted into a rightmost one (e.g., phase slot C) of the phase slots of the same phases of the polar regions (e.g., U1to U8), an outlet end of winding Y1is inserted a leftmost one (e.g., phase slot A) of the phase slots of the same phases of the polar regions. As in the foregoing embodiments, the same winding rules in this embodiment can be applied to the other windings of the U, V, and W phases. The pole pitch or full pitch calculation method of this embodiment is obtained by dividing 72 slots by 8 (polar regions), which is 9 slots. The common span (common pitch) of transpolar hairpin wires on the insertion side is 8 (9-1) slots. In other words, when the inlet end of the winding Y1is inserted into the rightmost one (such as phase slot C) of the phase slots of the same phases (such as U1to U8), the common span (8) is equal to a quotient (9), which is obtained by dividing a total number of these (phase) slots (72) by a total number of polar regions (8), minus 1. In addition to the transpolar hairpin wires, the span of the trans-layer connection wires T1and T2is 11 slots on the insertion side. The span (11 slots) of the trans-layer connection wire can be obtained from the common span 8 slots plus the quantity (Q=3) of phase slots for each phase.

Reference is made toFIG.17, which illustrates one of the windings configured in U phases of a 72-slot motor stator according to still another embodiment of the present disclosure. The winding method of this embodiment is slightly different from the winding method of the U phase inFIG.4. Specifically, the wire of winding Y1is routed into the L1layer of the phase slot A of the U1phase on the insertion side of the stator core from, and then connected to the L2layer of the phase slot A of the U2phase on the extension side of the stator core, then connected to the L1layer of phase slot B of the phase U3on the insertion side of the stator core, then connected to the L2layer of phase slot B of the phase U4on the extension side of the stator core, and then connected to the L1layer of the phase slot C of the U5phase on the insertion side of the stator core, and then connected to the L2layer of the phase slot C of the U6phase on the extension side of the stator core. At this point, the wire of winding Y1has passed through the phase slots A, B, and C of the L1layer once, and also passed the phase slots A, B, and C of the L2layer once, and the sequence of the phase slots is from A to B to C. A trans-layer connection wire T1is then used to connect the L2layer of the phase slot C of the U6phase to the L3layer of the phase slot C of the U7phase on the insertion side of the stator core, and then connected to the L4layer of phase slot C of the phase U8on the extension side of the stator core, and connected to the L3layer of phase slot B of the phase U1on the insertion side of the stator core, and connected to the L4layer of phase slot B of the phase U2on the extension side of the stator core, then connected to the L3layer of phase slot A of the phase U3on the insertion side of the stator core, and then connected to the L4layer of phase slot A of the phase U4on the extension side of the stator core. After the trans-layer connection wire T1, the wire of winding Y1has passed through the phase slots A, B, and C of the L3layer once, and also passed the phase slots A, B, and C of the L4layer once, but the sequence is from C to B to A for the phase slots. A trans-layer connection wire T2is then used to connect the L4layer of phase slot A of phase U4to the L5layer of the phase slot A of the phase U5on the insertion side of the stator core, and then connected to L6layer of phase slot A of the phase U6on the extension side of the stator core, then connected to the L5layer of phase slot B of the U7phase on the insertion side of the stator core, and then connected to the L6layer of phase slot B of the U8phase on the extension side of the stator core, then connected to the L5layer of the phase slot C of the U1phase on the insertion side of the stator core, and then connected to the L6layer of the phase slot C of the U2phase on the extension side of the stator core. After the trans-layer connection wire T2, the wire of winding Y1has passed through the phase slots A, B, and C of the L5layer once, and also passed the phase slots A, B, and C of the L6layer once, the sequence is from A to B to C for the phase slots, and routed out at this point. The main difference between the winding method of this embodiment and the winding method of the U phase inFIG.4lies in the winding principle of the L3to L4layer. As in the foregoing embodiment, the same winding rules in this embodiment can be applied to the other windings of the U, V, and W phases. The pole pitch or full pitch calculation method of this embodiment is is obtained by dividing 72 slots by 8 (polar regions), which is 9 slots. The common span (common pitch) of the transpolar hairpin wires of L1to L2layers and L5to L6layers on the insertion side is 10 (9+1) slots, while the common pitch of the transpolar hairpin wires of L3to L4layers on the insertion side is 8 (9-1) slots. In addition to the transpolar hairpin wires, the span of the trans-layer connection wires T1and T2is 9 slots on the insertion side. In some embodiments of the present disclosure, the trans-layer connection wires T1and T2cross two adjacent slot-position layers, and two ends of the trans-layer connection wire are spaced by a pole pitch. For example, the trans-layer connection wire T1crosses from a phase slot C to another phase slot C of the same phases across adjacent polar regions, and the trans-layer connection wire T2crosses from a phase slot A to another phase slot A of the same phases across adjacent polar regions.

Reference is made toFIG.18, which illustrates one of the windings configured in U phases of a 72-slot motor stator according to still another embodiment of the present disclosure. The winding method of this embodiment is slightly different from the winding method of the U phase inFIG.4. Specifically, the wire of winding Y1is routed into the L1layer of the phase slot A of the U1phase on the insertion side of the stator core, and then connected to the L2layer of the phase slot A of the U2phase on the extension side of the stator core, then connected to the L1layer of phase slot B of the phase U3on the insertion side of the stator core, then connected to the L2layer of the phase slot B of the phase U4on the extension side of the stator core, and then connected to the L1layer of the phase slot C of the U5phase on the insertion side of the stator core, and then connected to the L2layer of the phase slot C of the U6phase on the extension side of the stator core. At this point, the wire of winding Y1has passed through the phase slots A, B, and C of L1layer once, and also passed through the phase slots A, B, and C of the L2layer once, the sequence is from A to B to C. A trans-layer connection wire T1is then used to connect the L2layer of the phase slot C of the U6phase to the L4layer of the phase slot C of the U7phase on the insertion side of the stator core, and then connected to the L3layer of the phase slot C of the phase U8on the extension side of the stator core, then connected to the L4layer of the phase slot B of the U1phase on the insertion side of the stator core, and connected to the L3layer of the phase slot B of the U2phase on the extension side of the stator core, then connected to the L4layer of phase slot A of the phase U3on the insertion side of the stator core, and then connected to the L3layer of the phase slot A of the phase U4on the extension side of the stator core. After the trans-layer connection wire T1, the wire of winding Y1has passed through the phase slots A, B, and C of the L3layer once, and also passed the phase slots A, B, and C of the L4layer once, the sequence is from C to B to A. A trans-layer connection wire T2is then used to connect the L3layer of the phase slot A of the U4phase to the L5layer of the phase slot C of the U5phase on the insertion side of the stator core, and then connected to the L6layer of phase slot C of the phase U6on the extension side of the stator core, then connected to L5layer of phase slot B of phase U7on the insertion side of the stator core, and then connected to layer L6of phase slot B of the phase U8on the extension side of the stator core, then connected to the L5layer of phase slot A of U1on the insertion side of the stator core, and then connected to the L6layer of phase slot A of U2on the extension side of the stator core. After the trans-layer connection wire T2, the wire of winding Y1has passed through the phase slots A, B, and C of the L5layer once, and also passed the phase slots A, B, and C of the L6layer once, the sequence is from C to B to A, and routed out at this point. The main difference between the winding method of this embodiment and the winding method of the U phase inFIG.4lies in the winding principle of the L3to L4layer and the L5to L6layer. The same winding rules in this embodiment can be applied to the other windings of the U, V, and W phases. The pole pitch or full pitch calculation method of this embodiment is obtained by dividing 72 slots by 8 (polar regions), which is 9 slots. The common span (common pitch) of the transpolar hairpin wires of the L1to L2layers on the insertion side is 10 (9+1) slots, while the common span (common pitch) of the transpolar hairpin wires on the insertion side of the L3to L4layers and the L5to L6layers is 8 (9-1) slots. In addition to transpolar hairpin wires, the trans-layer connection wire T1has a 9-slot span on the insertion side, and the trans-layer connection wire T2has an 11-slot span on the insertion side.

When the winding methods inFIGS.13to18is applied to the other windings of the U, V, and W phases, it can also be used with the same-layer connection wire to change the number of parallel-connected windings. In all the embodiments, the radially innermost layer and outermost layer have advantages in the manufacturing process that it is easier to connect the ends from the radially innermost layer and outermost layer to the phase terminal/neutral terminal, or extend to connect to other connection endpoints (e.g., the same-layer connection wire).

Reference is made toFIG.19, which illustrates one of the windings configured in U phases of a 48-slot motor stator according to an embodiment of the present disclosure. Different from the aforementioned 72-slot, 6-layer wire motor stator, this embodiment uses an 8-polar region, 48-slot, 2-layer wire motor stator to implement the circuit50. Each (phase) slot (A, B) includes radially adjacent slot-positions (i.e., “squares” in each (phase) slot (A, B,)), and each slot-position can accommodate one hairpin wire. All slot-positions surround the rotor accommodating space in the circumferential direction, and form a plurality of slot-position layers (L1to L2) adjacent in the radial direction. Each polar region has U, V, and W phases. For example, the first polar region has U1, V1, and W1phases, the second polar region has U2, V2, and W3phases . . . . The 8th polar region has U8, V8, and W8phases. Each phase has multiple phase slots, such as phase slot A (left) and phase slot B (right) in the circumferential direction. The 48 (phase) slots in this embodiment are equal to: 8 (polar region)×3 (phase/polar region)×2 (slot/phase). Each (phase) slot allows 2 hairpin wires to be inserted into 2 slot-position layers from the outside to the inside for L1to L2layers. If you want to implement U, V, and W phases with 8 parallel-connected windings (the number of parallel-connected windings is equal to the total number of polar regions), take the U phase first as an example. The winding Y1wire is routed into the L1layer of the phase slot A of the U1phase on the insertion side of the stator core, and then connected to the L2layer of phase slot A of phase U2on the extension side of the stator core, and then connected to the layer L1of the phase slot B of phase U3on the insertion side of the stator core, then connected to the layer L2of the phase slot B of the phase U4on the extension side of the stator core. At this point, the wire of winding Y1has passed through the phase slots A and B of the L1layer once, and also passed the phase slots A and B of the L2layer once, the sequence is from A to B, and routed out at this point. The pole pitch or full pitch of winding Y1is calculated by dividing 48 slots by 8 (polar regions), which is equal to 6 slots. The common span (common pitch) of the transpolar hairpin wires on the insertion side is 7 (6+1) slots.

Reference is made toFIG.20, which illustrates 8 windings configured in U phases of a 48-slot motor stator according to an embodiment of the present disclosure. Continuing from the winding Y1inFIG.19, the windings Y2to Y8are executed according to the same winding principle. The winding Y2is routed into the L1layer of the phase slot A of the U2phase on the insertion side of the stator core, and routed out from the L2layer of the phase slot B of the U5phase. The winding Y3is routed into the L1layer of the phase slot A of the phase U3on the insertion side of the stator core, and routed out from the L2layer of the phase slot B of the phase U6. The winding Y4is routed into the L1layer of the phase slot A of the phase U4on the insertion side of the stator core, and routed out from the L2layer of the phase slot B of the phase U7. The winding Y5is routed into the L1layer of the phase slot A of the phase U5on the insertion side of the stator core, and routed out from the L2layer of the phase slot B of the U8phase. The winding Y6is routed into the L1layer of the phase slot A of the phase U6on the insertion side of the stator core, and routed out from the L2layer of the phase slot B of the phase U1. The winding Y7is routed into the L1layer of the phase slot A of the phase U7on the insertion side of the stator core from, and routed out from the L2layer of the phase slot B of the phase U2. The winding Y8is routed into the L1layer of the phase slot A of the phase U8on the insertion side of the stator core, and routed out from the L2layer of the phase slot B of the phase U3. U-phase windings Y1to Y8wires occupy all phase slots and slot-positions of U1to U8phases. Connecting the negative ends (YN−out) of Y1to Y8to the neutral terminal NC, and connecting the positive ends (YN+in) of Y1to Y8to the phase terminals of the U phase to form U-phase parallel-connected windings Y1to Y8. The winding methods of windings Y1to Y8inFIG.20are the same as those of winding Y1inFIG.19such that the pole pitch or full pitch of the winding is the same as 6 slots. The common span (common pitch) of transpolar hairpin wires on the insertion side is still 7 (6+1) slots. No trans-layer connection wire is used.

Reference is made toFIGS.21and22, which illustrates 8 windings configured in V phases and W phases of a 48-slot motor stator respectively. Continuing from the U-phase winding inFIG.20, the V-phase and W-phase 8 windings are also executed according the same winding principle to occupy all the phase slots and slot-positions of V1to V8and W1to W8to achieve parallel-connected windings of V and W. Y1to Y8. The winding methods of V-phase and W-phase winding are the same as U-phase winding, so the pole pitch or full pitch of the winding is the same as 6 slots. The common span (common pitch) of the transpolar hairpin wires on the insertion side is 7 (6+1) slots. No trans-layer connection wire is used.

Reference is made toFIG.23, which illustrates 4 windings configured in U phases of a 48-slot motor stator using same-layer connection wires according to an embodiment of the present disclosure. If the aforementioned same-layer connection wire (such as the same-layer connection wire inFIG.9) is applied to the U-phase 8 windings inFIG.20, the U-phase 4 winding in this embodiment can be constructed. Specifically, a same-layer connection wire IJW1is used to connect the inner wire ends of the U-phase windings Y1and Y2inFIG.20, and a same-layer connection wire IJW2is used to connect the inner wire ends of the U-phase windings Y3and Y4inFIG.20. A same-layer connection wire IJW3is used to connect the inner wire ends of the U-phase windings Y5and Y6inFIG.20, and a same-layer connection wire IJW4is used to connect the inner wire ends of the U-phase windings Y7and Y8inFIG.20to form windings YIJ1to YIJ4of U phase in this embodiment. Connecting the negative ends of YIJ1to YIJ4(YIJN−out) to the neutral terminal NC, and connecting the positive ends of YIJ1to YIJ4(YIJN+in) to the phase terminals of the U phase to form a parallel-connected U-phase windings YIJ1to YIJ4. The winding method of the parallel-connected winding YIJ1to YIJ4of this embodiment can also be applied to the V phase and the W phase.

Reference is made toFIG.24, which illustrates one of the windings configured in U phases of a 48-slot motor stator according to another embodiment of the present disclosure. Different from the winding Y1inFIG.19, the winding Y1inFIG.19is routed from phases U1to U4and repeated once to phases U5to U8in the winding of this embodiment. Specifically, the wire of winding YF1is routed into the L1layer of the phase slot A of the U1phase on the insertion side of the stator core, and then connected to the L2layer of the phase slot A of the U2phase on the extension side of the stator core, then connected to the L1layer of phase slot B of phase U3on the insertion side of the stator core, then connected to the L2layer of phase slot B of phase U4on the extension side of the stator core, and connected to the L1layer of phase slot A of U5phase by a trans-layer connection wire T1, and then connected to the L2layer of phase slot A of U6phase on the extension side of the stator core, and then connected to the L1layer of the phase slot B of the U7phase on the insertion side of the stator core, and then connected to the L2layer of the phase slot B of the U8phase on the extension side of the stator core. At this point, the wire of winding YF1has passed through phase slots A and B of the L1layer twice, and also passed through the phase slots A and B of the L2layer twice, the sequence is form A to B, and routed out at this point. Winding YF1inFIG.24and Winding Y1inFIG.19have the same winding method except for the trans-layer connection wire, so the pole pitch or full pitch of the winding is the same as 6 slots. The common span (common pitch) of transpolar hairpin wires on the insertion side is still 7 (6+1) slots. In addition to transpolar hairpin wires, the span of the trans-layer connection wire T1on the insertion side is 5 slots, and the span of the trans-layer connection wire can be obtained from the common span 7 slots minus the number (Q=2) of phase slots for each phase.

Reference is made toFIG.25, which illustrates 4 windings configured in U phases of a 48-slot motor stator according to another embodiment of the present disclosure. Continuing from the winding YF1inFIG.24, the wire of winding YF2follows the same winding rules as the winding YF1. Specifically, the wire of the winding YF2is routed into the L1layer of phase slot A of phase U2on the insertion side of the stator core, and circulated clockwise in phases U2to U5, and passed through the phase slots A and B of the L1to L2layer once. After the trans-layer connection wire, the wire of the winding YF2is circulated clockwise through the phase slots A and B of the L1to L2layer in the U6to U1phases, and routed out from the L2layer of phase slot B of the phase U1. Based upon the same winding method, the winding YF3is routed into the L1layer of the phase slot A of the U3phase on the insertion side of the stator core, and routed out from the L2layer of the phase slot B of the U2phase. The winding YF4is routed into the L1layer of the phase slot A of the phase U4on the insertion side of the stator core, and routed out from the L2layer of the phase slot B of the phase U3. The wires of U-phase windings YF1to YF4occupy all phase slots and slot-positions of U1to U8. Connecting the negative ends (YFN−out) of YF1to YF4to the neutral terminal NC, and connecting the positive ends (YFN+in) of YF1to YF4to the phase terminals of the U phases to form a parallel-connected U-phase winding YF1to YF4. In other embodiments, the winding rule changes inFIGS.14and16can also be applied to the winding of the 48-slot motor stator. The winding methods of winding YF1to YF4inFIG.25are the same as those of winding YF1inFIG.24, so the pole pitch or full pitch of the winding is the same as 6 slots. The common span (common pitch) of transpolar hairpin wires on the insertion side is still 7 (6+1) slots. The span of the trans-layer connection wire on the insertion side is the same as 5 slots.

Reference is made toFIG.26, which illustrates 2 windings configured in U phases of a 48-slot motor stator using same-layer connection wires according to another embodiment of the present disclosure. If the aforementioned same-layer connection wire (such as the same-layer connection wire inFIG.23) is applied to the U-phase 4 windings inFIG.25, the U-phase 2 windings in this embodiment can be constructed. Specifically, a same-layer connection wire IJW1is used to connect the inner wire ends of the U-phase windings YF1and YF2inFIG.25, and a same-layer connection wire IJW2is used to connect the inner wire ends of the U-phase windings YF3and YF4inFIG.25to form the U-phase windings YIJ1and YIJ2in this embodiment. Connecting the negative ends (YIJN−out) of YIJ1and YIJ2to the neutral terminal(s), and connecting the positive end (YIJN+in) of YIJ1and YIJ2to the phase terminal(s) of the U phase to form the U-phase parallel-connected windings YIJ1and YIJ2. The winding method of the parallel-connected winding YIJ1and YIJ2in this embodiment can also be applied to the V phase and the W phase.

In the previous embodiments, 72 slots and 48 slots are used as examples of the hairpin wire stator, but the specific number of slots of the stator is not limited. Each of the U-phase, V-phase, and W-phase has 2 or 3 phase slots, but more than 2 phase slots can meet the requirements of the above-mentioned winding method.

The hairpin wire stator disclosed herein utilizes the above-mentioned winding method to make a single winding routed through the multiple phase slots (such as A, B or A, B, C) within adjacent slot-position layers (such as L1to L2) in the U, V, and W phases with winding through each slot-position by the same number of times, such that all the windings are evenly arranged in each slot-position to avoid the generation of circulating current. In addition, at least one of the winding methods can also make the number of parallel-connected windings of each phase equal to the number of polar regions at most. At least one of the embodiments can reduce the wire types of the hairpin wires, and only need transpolar hairpin wires (common pitch wire) and trans-layer connection wire.

Although the present invention has been described in considerable detail with reference to certain embodiments thereof, other embodiments are possible. Therefore, the spirit and scope of the appended claims should not be limited to the description of the embodiments contained herein.

It will be apparent to those skilled in the art that various modifications and variations can be made to the structure of the present invention without departing from the scope or spirit of the invention. In view of the foregoing, it is intended that the present invention cover modifications and variations of this invention provided they fall within the scope of the following claims.