DE-112024002575-T5 - Flat wire stator and drive motor with such a stator

DE112024002575T5DE 112024002575 T5DE112024002575 T5DE 112024002575T5DE-112024002575-T5

Abstract

This application discloses a flat-wire stator assembly and a drive motor relating to the technical field of drive motors. It comprises a stator iron core and a winding, wherein a through-hole is located in the stator iron core and several installation slots are arranged on the inner wall of the through-hole along its circumference. Each phase winding consists of at least three parts, the first, second, and third parts being distributed along the direction of the installation slot that points towards the bottom of the slot. The equivalent distance of the first part to the third part corresponds to the pole spacing, and the winding centerlines of the first and third parts are located on either side of the winding centerline of the second part. The centerline of the first and third parts of the winding is at least one installation slot away from the centerline of the second part of the winding. By dividing the winding in the installation slot into at least three parts and changing the centerline of different parts of the winding to alter the winding distribution, the harmonic of the winding counter-electromotive force can be reduced to optimize the torque ripple in both the high and low speed ranges.

Inventors

James Wang
Steven Shang
Sun Dan

Assignees

Mahle Automotive Technologies (Suzhou) Co., Ltd.
MAHLE INTERNATIONAL GMBH

Dates

Publication Date: 20260513
Application Date: 20240508
Priority Date: 20230616

Claims (12)

A flat-wire stator component characterized in that the stator component comprises a stator core and a winding, wherein the stator core is provided with a through-hole for installation and the inner wall of the through-hole is provided with several installation slots along its circumference, each installation slot extending along the axial direction of the stator core, and a portion of the winding is embedded in the installation slots while a portion of the winding is located outside the installation slots, each installation slot having n radially spaced layers of slots; each phase of the winding comprises at least three parts, wherein a first part, a second part, and a third part are sequentially distributed along the direction of the installation slot, which points to the bottom of the slot on n slot layers. The first part has a layer a, the second part has a layer b, and the third part has a layer c, where a+b+c ≤ n and n is a positive integer; The equivalent distance of the first part to the third part corresponds to the pole spacing, and the winding centerlines of the first part and the third part are each located on either side of the winding centerline of the second part; the winding centerline of the first and third parts is at least one installation slot away from the winding centerline of the second part.
flat wire stator component according to Claim 1 , characterized in that the winding centerline of the first and third part is distributed symmetrically around the winding centerline of the second part and the number of installation slots in which the winding centerline of the first and third part is not aligned with the winding centerline of the second part is equal to x.
flat wire stator component according to Claim 2 , characterized in that 1 ≤ x ≤ 2.
flat wire stator component according to Claim 1 , characterized by the fact that n is an even number.
flat wire stator component according to Claim 4 , characterized in that a, b and c are all even numbers.
flat wire stator component according to Claim 1 , characterized in that, if each phase of the winding consists of three parts, a+b+c=n.
flat wire stator component according to Claim 6 , characterized in that, if n=8, a=2, b=4, c=2 or a=4, b=2, c=2 or a=2, b=2, c=4.
flat wire stator component according to Claim 1 , characterized in that the installation slot is a rectangular slot.
Flat wire stator element according to Claim 1 , characterized in that the number of slots in the installation slot is Q=2mpq, where p is the number of pole pairs of the stator element, m is the number of phases of the stator element and q is the number of slots per pole per phase.
flat wire stator component according to Claim 9 , characterized in that Q=54, p=3, m=3.
flat wire stator component according to Claim 1 , characterized in that the winding has at least two phases and insulating elements are arranged between adjacent two winding structures belonging to different phases within the same installation slot.
drive motor, which is one of the ones in the Claims 1 until 11 The claimed flat wire stator components comprise, characterized in that the drive motor comprises a rotor component located in a space enclosed by the inner wall of the installation through-hole.

Description

Technical field This application relates to the technical field of the drive motor, in particular a flat wire stator arrangement and a drive motor. State of the art As national requirements for vehicle emissions become increasingly stringent, particularly in the automotive sector, new energy vehicles will gradually replace traditional internal combustion engine vehicles. As key drive components in new energy vehicles, the performance of the drive motors directly impacts vehicle comfort, and the motor's torque pulsation directly affects the user's driving experience. Therefore, improving the drive motor's torque pulsation is crucial for enhancing overall vehicle comfort. Flat wire motors are increasingly used in new energy vehicles due to their advantages, such as high full-slot rate, small size at the lower end, high thermal efficiency, and other aspects. However, existing flat wire motor stator assemblies are mostly spaced-wound. They typically consist of stator cores with installation slots that open around the core's circumference, and two adjacent installation slots forming stator teeth wound onto the core. In a spaced-wound structure, the equivalent distance between phase bands of the same phase winding at adjacent poles is equal to the distance between them. However, the spaced-wound structure can result in the drive motor having a higher anti-potential harmonic, which in turn leads to higher torque pulsation, negatively impacting the overall comfort of the vehicle. Currently, some manufacturers divide the motor's stator winding into two parts to reduce torque pulsation, with the centerlines of the two winding sections offset. This results in a reduction of torque pulsation. In practice, however, it has been shown that using the above-mentioned method with too many windings makes the optimization of torque pulsation in the low-speed range less pronounced. Therefore, there is an urgent need for a flat wire stator assembly and a drive motor to optimize torque pulsation in both the high and low speed ranges. Summary of the invention This application relates to a flat wire stator arrangement and a drive motor to solve the problem of non-optimized torque pulsation in both the high and low speed ranges. To solve one or more of the above-mentioned technical problems, the following technical solutions are used in this application: Firstly, this application provides a flat-wire stator arrangement comprising: a stator core and windings, wherein the stator core is provided with an installation through-hole, the inner wall of the installation through-hole is provided with several installation slots around its circumference, each extending in the direction of the axis of the stator core, parts of the winding are embedded in the installation slots, parts of the winding are located outside the installation slots, and each of the installation slots has n layers of radially spaced slots; The winding in each phase consists of at least three parts, wherein the first, second and third parts are distributed over n layers of the groove in the direction of the notch of the fastening groove, which points towards the bottom of the groove, wherein the first part has a number of layers, the number of layers of the second part is b, the number of layers of the third part is c, where a+b+c ≤ n and n is the integer; The centerline of the winding in Part I and Part III is distributed symmetrically to the centerline of the winding in Part II, with the centerline of the winding in Part I and Part III being offset from the centerline of the winding in Part II by the number of installation slots, which corresponds to x. Furthermore, the center line of the winding in Part I and Part III is distributed symmetrically to the center line of the winding in Part II, and the center line of the winding in Part I and Part III is offset from the center line of the winding in Part II by the number of installation slots equal to x. Furthermore, 1 ≤ x ≤ 2. Furthermore, n is even. Furthermore, a, b and c are even numbers. Furthermore, if the winding in question consists of three parts per phase, then a+b+c=n. Furthermore, if n=8, then a=2, b=4, c=2 or a=4, b=2, c=2 or a=2, b=2, c=4. Furthermore, the described installation slots are rectangular slots. Furthermore, the number of slots of the installation slots is Q=2mpq, where p is the pole pair of the stator assembly and m is the number of phases of the stator assembly and q is the number of slots per phase per pole. Furthermore, Q=54, p=3, m=3. Furthermore, the winding has at least two phases, with insulation between adjacent two-layer winding structures belonging to different phases in the same installation slots. Secondly, the application provides a drive motor comprising the following: rotor assembly, wherein the rotor assembly is arranged in the space formed by the inner wall of the through-hole. Based on the specific embodiment provided in this application, the following technical effects are di