CN-121980834-A - Design method of motor flat copper wire stator winding

Abstract

The invention relates to the technical field of motor design and manufacture, in particular to a design method of a flat copper wire stator winding of a motor; the method comprises the steps of constructing a basic data source layer, integrating stator slot space data, electromagnetic boundary data and wire physical parameters, constructing a topology generation layer, planning winding space distribution and end connection paths, wherein a transposition connection module plans a wire interlayer connection relation in a slot, an end topology module plans end welding point space layout, constructing a dynamic adjustment layer, establishing a three-dimensional space matrix based on the end face of a stator core, setting a step dislocation mechanism comprising step dislocation quantity and design tolerance, adjusting end welding point axial height distribution, and generating and outputting a stator winding three-dimensional design model or manufacturing parameters based on adjustment results to achieve electromagnetic optimization, end space avoidance and uniformity of welding accessibility.

Inventors

• WU WEI

Assignees

• 福建大酉新能源电机科技股份有限公司

Dates

Publication Date

20260505

Application Date

20260409

Claims (9)

1. 1. The design method of the flat copper wire stator winding of the motor is characterized by comprising the following steps: constructing a basic data source layer, and integrating stator slot space data, electromagnetic boundary data and physical parameters of a lead; Constructing a topology generation layer, and planning winding space distribution and end connection paths based on integrated stator slot space data, electromagnetic boundary data and conductor physical parameters, wherein the topology generation layer comprises a transposition connection module and an end topology module, the transposition connection module plans a conductor interlayer connection relationship in a slot, and the end topology module plans an end welding point space layout; constructing a dynamic adjustment layer, establishing a three-dimensional space matrix by taking the end face of the stator core as a datum reference surface, setting a step dislocation mechanism based on the three-dimensional space matrix, wherein the step dislocation mechanism comprises a preset step dislocation amount and a design tolerance, and adjusting the axial height distribution of the end welding point according to the step dislocation mechanism; based on the adjusted axial height distribution of the end welding points and the planned winding space distribution, a three-dimensional design model or manufacturing parameters of the stator winding are generated and output.
2. 2. The method of designing a stator winding of a flat copper wire for an electrical machine according to claim 1, further comprising, before inputting the stator slot space data, the electromagnetic boundary data, and the wire physical parameters into the base data source layer: Preprocessing the stator slot space data, the electromagnetic boundary data and the wire physical parameters to obtain the preprocessed stator slot space data, the preprocessed electromagnetic boundary data and the preprocessed wire physical parameters, wherein the preprocessing comprises the steps of extracting leakage magnetic flux density characteristic values, extracting preset bending limit radiuses and data dimension reduction mapping, and the data dimension reduction mapping is to convert a space coordinate system of the physical stator dimensions in the stator slot space data and eliminate geometric redundancy.
3. 3. The method for designing a stator winding of a flat copper wire of a motor according to claim 1, wherein the transposition connection module is used for planning inter-layer connection relation of wires in a slot based on a preset asymmetric transposition connection logic combined with electromagnetic field distribution characteristics in electromagnetic boundary data; Initializing a preset connection matrix according to the number of layers and phases of stator slots, refining the preset connection matrix to each stator slot through an asymmetric transposition connection logic, extracting an electromagnetic high-frequency magnetic leakage area and a weak magnetic leakage area of each stator slot from electromagnetic boundary data, extracting a wire stay length from a wire physical parameter, and planning an interlayer span of each stator slot by combining the extracted data, wherein the connection matrix comprises a cross-layer connection matrix; The interlayer connection relation is forcedly defined through a cross-layer connection matrix, and electromagnetic equivalent spiral transposition of the same phase winding on the circumference of the stator is quantized by utilizing short pitch configuration with a span smaller than a polar distance and long pitch configuration with a span larger than the polar distance; Spatial position data is processed through electromagnetic field distribution characteristics, and the current sharing planning results of the wires in different areas are refined according to the relation between the leakage flux density of the electromagnetic high-frequency leakage region and the weak leakage region and the interlayer span.
4. 4. The method for designing a stator winding of a flat copper wire for a motor according to claim 1, wherein the end topology module is configured to divide each end of the stator winding into an odd slot end welding point and an even slot end welding point, and decompose the spatial distribution of the end connection paths to obtain the three-dimensional coordinates of each end welding point; The end topology module is specifically used for evaluating the space layout of the end welding point by combining the number of winding layers, the circumferential size of the stator, the extension length of the end straight section and the interference prevention principle which are analyzed from the space data of the stator slot and the physical parameters of the lead, wherein the evaluation process comprises the following steps: And carrying out overall welding height prediction by using a preset stepped end topological model, extracting the axial offset and the circumferential physical distance of an end connecting path, and evaluating the interference-free feasibility and the final axial height of various stepped dislocation layouts by combining the axial offset and the circumferential physical distance.
5. 5. The method of claim 1, wherein the step misalignment mechanism comprises a first height plane, a second height plane, and a transition plane, the first height plane being an axial height at which the odd slot end welds are located, the second height plane being an axial height at which the even slot end welds are located, the transition plane being a wire bend region connecting the first height plane and the second height plane.
6. 6. The method of designing a stator winding of a flat copper wire for an electrical machine according to claim 5, wherein adjusting the axial height distribution of the end welds according to a step misalignment mechanism comprises: Selecting a target dislocation height according to design requirements, and based on the target dislocation height, utilizing a topology generation layer to re-optimize and arrange an end connection path meeting the target dislocation height; acquiring preset welding process constraint conditions, taking the welding process constraint conditions as dynamic input, dynamically adjusting the height distribution, wherein the welding process constraint conditions comprise three-dimensional dynamic zooming laser welding parameters, switching to a corresponding step dislocation mechanism in real time when the mechanical interference of the end part or the welding height exceeding a preset welding height threshold value is monitored, and re-planning the future end part connecting line path and the end part welding point distribution through real-time calculation and simulation by utilizing a topology generation layer; and automatically updating a planning result based on a data synchronization mechanism of a preset asymmetric transposition connection logic and a preset stepped end topological model.
7. 7. The method of designing a motor flat copper wire stator winding according to claim 6, wherein the adjusting of the axial height distribution of the end-portion welding points when the end-portion welding points are in the first height plane comprises: setting the axial height of the welding point at the end part of the odd number groove to be kept at the current level, setting the relation between the welding penetration and the axial height according to a preset tolerance range, and mapping based on the space data of the stator groove to realize the output of the coordinates of the end part welding point; When the end welding point is positioned on the second height plane, carrying out axial height distribution adjustment of the end welding point, and comprising the following steps: Setting a plan for pushing axial offset, arranging welding points at the ends of even slots in a staggered manner, calculating circumferential spacing extremum without physical interference according to the spacing between adjacent slots and the width of a wire, arranging the welding points at the ends of the even slots in a staggered manner according to the circumferential spacing extremum, predicting the height drop of the welding points at the ends and the occupation ratio of the welding points at the ends in the whole end space by combining a preset stepped end topological model with the extension length of straight sections of the ends, and setting a preset fluctuation threshold, wherein the preset fluctuation threshold is the maximum allowable relative change ratio of the height drop or the space occupation ratio under different design layers; The method comprises the steps of predicting the height drop of an end welding point and the change rate of the duty ratio of the end welding point in the whole end space along with the increase of the number of layers in a prediction result, wherein the change rate is smaller than a preset fluctuation threshold value; When the end welding point is in the transitional connection plane, carrying out axial height distribution adjustment of the end welding point, including: And (3) assuming that the space interference conflict occurs, simulating a future avoidance path by utilizing a three-dimensional space matrix, evaluating the influence of the space interference conflict on the insulation creepage distance and the overall welding height of the end part, and adjusting the axial height distribution of the welding point of the end part based on the evaluation result, wherein the space interference conflict comprises physical overlapping.
8. 8. The method of designing a flat copper wire stator winding for an electric machine of claim 1, further comprising a closed loop verification feedback step, the closed loop verification feedback step comprising: three-dimensional point cloud data of the end wire are collected through visual positioning equipment, and actual space coordinates of each end welding point are extracted; verifying whether the step dislocation amount accords with the design tolerance based on the actual space coordinates; injecting pulse width modulation waveforms through high-frequency impedance testing equipment, and collecting transient voltage data and transient current data of the end part; Processing transient voltage data and transient current data by utilizing fast Fourier transformation, and extracting fundamental wave current components and higher harmonic current components; And calculating an actual alternating current resistance based on the fundamental wave current component and the higher harmonic current component, and feeding back the actual alternating current resistance to the basic data source layer for parameter correction.
9. 9. The method for designing a stator winding of a flat copper wire of a motor according to claim 8, wherein feeding back an actual ac resistance to a base data source layer for parameter correction comprises: Setting a first alternating current resistance threshold value and a second alternating current resistance threshold value, wherein the first alternating current resistance threshold value is larger than the second alternating current resistance threshold value; if the actual alternating current resistance is larger than the first alternating current resistance threshold value, judging that local circulation exists in the inter-layer connection relation of the wires in the groove, and triggering the transposition connecting module to re-plan the inter-layer span; If the actual alternating current resistance is smaller than the second alternating current resistance threshold value, judging that the inter-layer connection relation of the wires in the slots reaches electromagnetic equilibrium, and outputting a final winding design scheme; If the actual alternating current resistance is larger than or equal to the second alternating current resistance threshold value and smaller than or equal to the first alternating current resistance threshold value, the design is judged to be in a critical state, and the sampling frequency of the high-frequency impedance testing equipment is increased to acquire transient voltage data and transient current data again.

Description

Design method of motor flat copper wire stator winding Technical Field The invention relates to the technical field of motor design and manufacture, in particular to a design method of a flat copper wire stator winding of a motor. Background In the design of stator windings of a new energy automobile driving motor and a high-power density motor, a flat copper wire winding gradually becomes a common scheme of the structural design of a stator due to higher slot filling rate and better electric conductivity; At present, the design of the flat copper wire stator winding generally supports conventional modeling based on the wire arrangement and end connection relation in the slot, and if the end welding layout, the high-frequency electromagnetic distribution and the manufacturing equipment adaptation under the high-layer number of windings are required to be considered, the design is usually completed in a mode of respectively carrying out electromagnetic design, structural design and process design so as to obtain a corresponding winding scheme; However, when the high-layer number flat copper wire stator winding is designed in the mode, data are required to be repeatedly converted among different design links, so that the connection relation among the layers in the groove, the space path of the end part and the welding height distribution are difficult to uniformly cooperate, the winding topology cannot be dynamically adjusted according to the magnetic leakage distribution, the wire bending constraint and the welding process constraint, the problems of insufficient high-frequency alternating current loss control, higher risk of end part interference and poor welding accessibility exist, meanwhile, the processing mode lacks effective integral planning on the space distribution of the three-dimensional end welding spot, the problems of frequent path rollback and lower design convergence efficiency easily occur when the layer number is increased, and the problems of low design stability and engineering suitability exist due to the fact that a great amount of manual check and local correction are performed by a designer, and the requirements of high-groove full rate and quick development of the multi-layer flat copper wire stator winding are difficult to be adapted. Disclosure of Invention The invention aims to provide a design method of a motor flat copper wire stator winding, which solves the following technical problems: the problems of physical interference caused by local welding spot overlapping, bending area collision or insufficient insulation distance due to the fact that the traditional end welding spots are concentrated on the same plane are avoided, meanwhile, the problems of unbalanced branch induction potential and high-frequency alternating current loss caused by the fact that all parallel branches stay in different magnetic leakage intensity areas for a long time are avoided, electromagnetic optimization in a groove, end space avoidance and welding accessibility of a manufacturing end are more easily integrated into the same design flow, conversion of a winding design scheme from two-dimensional connection logic to three-dimensional manufacturable topology is achieved, and three-dimensional dynamic zoom laser welding equipment on a production line is effectively adapted. The aim of the invention can be achieved by the following technical scheme: the design method of the flat copper wire stator winding of the motor comprises the following steps: constructing a basic data source layer, and integrating stator slot space data, electromagnetic boundary data and physical parameters of a lead; Constructing a topology generation layer, and planning winding space distribution and end connection paths based on integrated stator slot space data, electromagnetic boundary data and conductor physical parameters, wherein the topology generation layer comprises a transposition connection module and an end topology module, the transposition connection module plans a conductor interlayer connection relationship in a slot, and the end topology module plans an end welding point space layout; constructing a dynamic adjustment layer, establishing a three-dimensional space matrix by taking the end face of the stator core as a datum reference surface, setting a step dislocation mechanism based on the three-dimensional space matrix, wherein the step dislocation mechanism comprises a preset step dislocation amount and a design tolerance, and adjusting the axial height distribution of the end welding point according to the step dislocation mechanism; based on the adjusted axial height distribution of the end welding points and the planned winding space distribution, a three-dimensional design model or manufacturing parameters of the stator winding are generated and output. Optionally, before inputting the stator slot space data, the electromagnetic boundary data and the wire physical parameters into the basic data source lay