EP-4738661-A1 - CONTINUOUS WINDING ASSEMBLY

EP4738661A1EP 4738661 A1EP4738661 A1EP 4738661A1EP-4738661-A1

Abstract

The present invention relates to a continuous winding assembly (1000), and more particularly, to a continuous winding assembly for winding on a motor stator. The continuous winding assembly of the present invention combines three types of windings (100, 200, 300) of different lengths to form parallel windings and applies equivalent series turns to allow application to odd-numbered layers, and further achieves electromagnetic balance between the windings even with standard-pitch continuous hairpin windings, thereby suppressing circulating currents and maximizing manufacturing efficiency.

Inventors

YEON, JUN MO

Assignees

Hyundai Mobis Co., Ltd.

Dates

Publication Date: 20260506
Application Date: 20251028

Claims (10)

A continuous winding assembly applied to a stator including a predetermined slot group disposed adjacent to a pole of a rotor and at continuous positions, one slot group per pole of the rotor, the assembly comprising: a plurality of first winding parts electrically connected at one end thereof to a current input terminal and disposed with a standard pitch; a plurality of second winding parts electrically connected at one end thereof to a neutral point and disposed with a standard pitch; and a plurality of third winding parts electrically connected at one end and the other end thereof to the plurality of first winding parts and the plurality of second winding parts, respectively, and disposed with a standard pitch, wherein a total number of layers in which the plurality of first winding parts, the plurality of second winding parts, and the third winding parts are wound is odd.
The continuous winding assembly of claim 1, wherein each of the plurality of first winding parts, the plurality of second winding parts, and the third winding parts is wound across a plurality of slot groups included in the stator, and continuously traverses a plurality of slots, one slot per slot group.
The continuous winding assembly of claim 1 or 2, wherein the plurality of first winding parts include a first-1 terminal electrically connected to the current input terminal and a first-2 terminal electrically connected to the plurality of third winding parts wherein the plurality of second winding parts include a second-1 terminal electrically connected to the neutral point and a second-2 terminal electrically connected to the plurality of third winding parts and wherein the plurality of third winding parts include a third-1 terminal electrically connected to the first-2 terminal and a third-2 terminal electrically connected to the second-2 terminal, the plurality of first winding parts, the plurality of second winding parts, and the third winding parts being all disposed in equal numbers and coupled in a one-to-one correspondence.
The continuous winding assembly of any one of claims 1 to 3, wherein a current direction of the plurality of second winding parts is opposite to current directions of the plurality of first winding parts and the plurality of third winding parts.
The continuous winding assembly of any one of claims 1 to 4, wherein the plurality of first winding parts are wound in odd-numbered layers from a radially inner side a the radially outer side of a plurality of slots, and the plurality of second winding parts are wound in even-numbered layers from the radially inner side to the radially outer side of the plurality of slots.
The continuous winding assembly of claim 5, wherein the plurality of third winding parts are wound in a outermost radially odd-numbered layer of the plurality of slots, a portion of the outermost odd-numbered layer is wound with a portion of the plurality of first winding parts, and remaining portion of the outermost odd-numbered layer not wound with the plurality of first winding parts are wound with a portion of the plurality of third winding parts.
The continuous winding assembly of any one of claims 3 to 6, wherein the third-1 terminal is wound in a slot adjacent to the first-2 terminal among the plurality of slots, the third-1 terminal and the first-2 terminal being welded together, and the third-2 terminal is wound in a slot adjacent to the second-2 terminal among the plurality of slots, the third-2 terminal and the second-2 terminal being welded together.
The continuous winding assembly of any one of claims 3 to 7, wherein the plurality of first winding parts, the plurality of second winding parts, and the plurality of third winding parts 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 by a standard pitch.
The continuous winding assembly of any one of claims 3 to 8, wherein the plurality of first winding parts have a longer extended length than the plurality of second winding parts, and the plurality of second winding parts have a longer extended length than the plurality of third winding parts.
The continuous winding assembly of claim 8, wherein a number of the slots in which the plurality of first winding parts, the plurality of second winding parts, and the plurality of third winding parts are wound satisfies the following equation: L 1 = p 2 n − 1 + p 2 L 2 = p 2 n − 1 L 3 = p 2 , where L 1 is the number of slot insertion portions of the plurality of first winding parts, L 2 is the number of slot insertion portions of the plurality of second winding parts, L 3 is the number of slot insertion portions of the plurality of third winding parts, p is the number of poles, and n is the number of layers per slot.

Description

BACKGROUND OF THE INVENTION Field of the Invention The present invention relates to a continuous winding assembly, and more particularly, to a continuous winding assembly for winding on a motor stator. Description of the Related Art Continuous hairpin windings are composed of a plurality of conductors traversing continuously multiple slots, providing advantageous features in quality control and productivity by minimizing welding points. Typically, one phase includes two or more parallel windings, each formed of two conductors with opposing current directions. This structure is applicable only to motors with an even number of layers, which imposes design constraints on the selection of the number of equivalent series turns, a critical parameter in motor design. As illustrated in FIG. 1, the number of equivalent series turns is a key factor that determines torque and output, where a larger number of equivalent series turns increases low-speed torque but reduces output torque at high speed. Selecting an appropriate number of series turns within limited current and voltage ranges has been a fundamental challenge in motor design. The equivalent series turns of a hairpin winding are calculated by combining the number of slots, the number of phases, the number of layers, and the number of parallel circuits, and under actual mass-production conditions, the selectable series turns are limited. Such limitations reduce design flexibility. For example, under mass-production feasible conditions, the maximum number of layers is 10 and the maximum number of parallel circuits is approximately 4, under which the selectable equivalent series turns are limited to multiples of 8, namely 8, 16, 24, 32, 40, 48, and 64. Moreover, for two or more parallel windings forming a single phase, the back electromotive force must be maintained with the same magnitude and phase, but any imbalance generates circulating currents that degrade motor performance. To resolve back electromotive force imbalance between parallel windings, each parallel winding must change its position within the slot group, and non-standard pitches must be applied for odd-numbered layers. This requires different conductor patterns for each parallel winding, increasing the number of conductor types and introducing complexity in the manufacturing process. Consequently, the prior art faces significant limitations in design and manufacturing due to restrictions on the number of equivalent series turns and imbalance among parallel windings. New designs and techniques are required to overcome these problems. Documents of Related Art (Patent Document 1) Korean Published Patent 10-2021-0031762, "Winding Weaving Method of Electromechanical Components" SUMMARY OF THE INVENTION The present invention has been conceived to solve the above problems, and it is an object of the invention to provide a continuous winding assembly in which three types of windings of different lengths are combined to form parallel windings and the equivalent series turns are applied to allow application to odd-numbered layers, and in which electromagnetic balance between the windings can be achieved even with standard-pitch continuous hairpin windings, thereby suppressing circulating currents while maximizing manufacturing efficiency. In order to accomplish the above objects, a continuous winding assembly applied to a stator including a predetermined slot group disposed adjacent to a pole of a rotor and at continuous positions, one slot group per pole of the rotor, according to an embodiment of the present invention includes a plurality of first winding parts electrically connected at one end thereof to a current input terminal and formed with a standard pitch, a plurality of second winding parts electrically connected at one end thereof to a neutral point and formed with a standard pitch, and a plurality of third winding parts electrically connected at one end and the other end to the plurality of first winding parts and the plurality of second winding parts, respectively, and formed with a standard pitch, wherein the total number of layers in which the plurality of first winding parts, the plurality of second winding parts, and the third winding parts are wound is odd. In addition, each of the plurality of first winding parts, the plurality of second winding parts, and the third winding parts is wound across a plurality of slot groups included in the stator, and continuously traverses a plurality of slots, one slot per slot group. In addition, the first winding part includes a first-1 terminal electrically connected to the current input terminal and a first-2 terminal electrically connected to the third winding part, the second winding part includes a second-1 terminal electrically connected to the neutral point and a second-2 terminal electrically connected to the third winding part, and the third winding part includes a third-1 terminal electrically connected to the first-2 terminal and a third-2 t