CN-122001127-A - Continuous winding assembly

Abstract

The present invention relates to a continuous winding assembly, and more particularly, to a continuous winding assembly for winding on a motor stator. The continuous winding assembly of the present invention combines three different length windings to form a parallel winding and applies equivalent series turns to allow application to odd layers and achieves electromagnetic balance between windings even in a standard pitch continuous hairpin winding, thereby suppressing circulating currents and maximizing manufacturing efficiency.

Inventors

• Yan Junmo

Assignees

• 现代摩比斯株式会社

Dates

Publication Date

20260508

Application Date

20251030

Priority Date

20241101

Claims (10)

1. 1. A continuous winding assembly for use with a stator, the stator including a predetermined set of slots disposed at successive locations adjacent poles of a rotor, one slot set for each pole of the rotor, the continuous winding assembly comprising: A plurality of first winding portions electrically connected to the current input terminal at one end thereof and arranged at a standard pitch; a plurality of second winding portions electrically connected to the neutral point at one end thereof and arranged at a standard pitch, and A plurality of third winding portions electrically connected at one end and the other end thereof to the plurality of first winding portions and the plurality of second winding portions, respectively, and arranged at a standard pitch, Wherein the total number of layers in which the plurality of first winding portions, the plurality of second winding portions, and the third winding portion are wound is an odd number.
2. 2. The continuous winding assembly of claim 1, wherein each of the plurality of first winding portions, the plurality of second winding portions, and the third winding portion is wound on a plurality of slot groups included in the stator and continuously traverses a plurality of slots, one slot per slot group.
3. 3. The continuous winding assembly of claim 1, Wherein the plurality of first winding portions includes a 1-1 st terminal electrically connected to the current input terminal and a 1-2 st terminal electrically connected to the plurality of third winding portions, Wherein the plurality of second winding portions includes a 2-1 terminal electrically connected to the neutral point and a 2-2 terminal electrically connected to the plurality of third winding portions, and Wherein the plurality of third winding portions includes a 3-1 st terminal electrically connected to the 1-2 st terminal and a 3-2 rd terminal electrically connected to the 2-2 nd terminal, the plurality of first winding portions, the plurality of second winding portions, and the third winding portions are all arranged in equal numbers and coupled in a one-to-one correspondence.
4. 4. The continuous winding assembly of claim 3, wherein a current direction of the plurality of second winding portions is opposite to a current direction of the plurality of first winding portions and the plurality of third winding portions.
5. 5. The continuous winding assembly of claim 4, wherein the plurality of first winding portions are wound in odd layers from radially inward to radially outward of the plurality of slots, and the plurality of second winding portions are wound in even layers from radially inward to radially outward of the plurality of slots.
6. 6. The continuous winding assembly of claim 5, wherein the plurality of third winding portions are wound in a radially outermost odd layer of the plurality of slots, a portion of the outermost odd layer being wound with a portion of the plurality of first winding portions, and a remaining portion of the outermost odd layer not being wound with the plurality of first winding portions being wound with a portion of the plurality of third winding portions.
7. 7. The continuous winding assembly of claim 6, wherein the 3-1 st terminal is wound in a slot of the plurality of slots adjacent to the 1-2 st terminal, the 3-1 st terminal and the 1-2 st terminal are welded together, and the 3-2 rd terminal is wound in a slot of the plurality of slots adjacent to the 2-2 nd terminal, the 3-2 nd terminal and the 2-2 nd terminal are welded together.
8. 8. The continuous winding assembly of claim 3, wherein the plurality of first winding portions, the plurality of second winding portions, and the plurality of third winding portions are inserted into a plurality of slots, and include a plurality of slot insertion portions extending in an axial direction of the motor, and jump portions disposed between the slot insertion portions and extending at a standard pitch.
9. 9. The continuous winding assembly of claim 3, wherein the plurality of first winding portions have longer extension lengths than the plurality of second winding portions, and the plurality of second winding portions have longer extension lengths than the plurality of third winding portions.
10. 10. The continuous winding assembly of claim 8, wherein the number of slots in which the plurality of first winding portions, the plurality of second winding portions, and the plurality of third winding portions are wound satisfies the following equation: Equation(s) , Where L 1 is the number of slot insertions of the plurality of first winding portions, L 2 is the number of slot insertions of the plurality of second winding portions, L 3 is the number of slot insertions of the plurality of third winding portions, p is the number of poles, and n is the number of layers per slot.

Description

Continuous winding assembly Technical Field The present invention relates to a continuous winding assembly, and more particularly, to a continuous winding assembly for winding on a motor stator. Background The continuous hairpin winding is comprised of a plurality of conductors that continuously traverse a plurality of slots, providing advantageous features in quality control and productivity by minimizing welds. Typically, one phase comprises two or more parallel windings, each formed by two conductors having opposite current directions. This structure is only suitable for motors with an even number of layers, which imposes design constraints on the choice of equivalent series turns, a key parameter in motor design. As shown in fig. 1, the number of equivalent series turns is a key factor in determining torque and output, with a larger number of equivalent series turns increasing low speed torque but decreasing output torque at high speed. Selecting an appropriate number of series turns over a limited current and voltage range has been a fundamental challenge in motor design. The equivalent series turns of the hairpin winding are calculated by the number of comprehensive slots, the number of phases, the number of layers and the number of parallel loops, and the selectable series turns are limited under the actual mass production condition. This limitation reduces design flexibility. For example, at a practical mass production, the maximum number of layers is 10 and the maximum number of parallel loops is about 4, under which conditions the selectable equivalent number of series turns is limited to a multiple of 8, i.e., 8, 16, 24, 32, 40, 48, and 64. In addition, for two or more parallel windings forming a single phase, the back emf must remain the same magnitude and phase, but any imbalance will create a circulating current that reduces motor performance. To address back emf imbalance between parallel windings, each parallel winding must change its position within the slot group and a non-standard pitch must be applied to the odd layers. This requires a different conductor pattern for each parallel winding, increasing the number of conductor types and introducing complexity in the manufacturing process. Thus, the prior art faces significant limitations in design and manufacturing due to the limitation of equivalent series turns and the imbalance between parallel windings. New designs and techniques are needed to overcome these problems. Literature of related art (Patent document 1) korean patent laid-open No. 10-2021-0031762, "WINDING WEAVING Method of Electromechanical Components (winding braiding method of electromechanical parts)". Disclosure of Invention The present invention has been conceived to solve the above-mentioned problems, and an object of the present invention is to provide a continuous winding assembly in which three windings of different lengths are combined to form a parallel winding and equivalent series turns are applied to allow application to odd layers, and in which electromagnetic balance between windings can be achieved even with a standard pitch continuous hairpin winding, thereby suppressing circulating currents while maximizing manufacturing efficiency. In order to achieve the above object, according to one embodiment of the present invention, there is provided a continuous winding assembly applied to a stator including a predetermined slot group disposed at a continuous position adjacent to poles of a rotor, one slot group for each pole of the rotor, the continuous winding assembly including a plurality of first winding portions electrically connected to a current input terminal at one end thereof and disposed at a standard pitch, a plurality of second winding portions electrically connected to a neutral point at one end thereof and disposed at a standard pitch, and a plurality of third winding portions electrically connected to the plurality of first winding portions and the plurality of second winding portions at one end and the other end thereof, respectively, and disposed at a standard pitch, wherein the total number of layers in which the plurality of first winding portions, the plurality of second winding portions, and the third winding portions are wound is an odd number. In addition, each of the plurality of first winding portions, the plurality of second winding portions, and the third winding portion is wound on a plurality of slot groups included in the stator, and continuously crosses a plurality of slots, one slot for each slot group. In addition, the plurality of first winding portions includes a1 st-1 terminal electrically connected to the current input terminal and a1 st-2 terminal electrically connected to the plurality of third winding portions, the plurality of second winding portions includes a 2 nd-1 terminal electrically connected to the neutral point and a 2 nd-2 terminal electrically connected to the plurality of third winding portions, and the pluralit