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EP-4742506-A1 - CONTINUOUS WINDING ASSEMBLY

EP4742506A1EP 4742506 A1EP4742506 A1EP 4742506A1EP-4742506-A1

Abstract

The present disclosure relates to a continuous winding assembly, and more particularly, to a continuous winding assembly wound on a motor stator. The continuous winding assembly of the present disclosure satisfies the balance of back electromotive force and inductance by having windings between each parallel circuit, which are interconnected to form a series winding, and adopt a specific pitch and shape, and allows each wire to be connected to be positioned in the same phase to enable welding without twisting, thereby having the effect of easily forming a series winding without a terminal assembly.

Inventors

  • LEE, JAE MIN

Assignees

  • Hyundai Mobis Co., Ltd.

Dates

Publication Date
20260513
Application Date
20251104

Claims (10)

  1. A continuous winding assembly applied to a stator, the stator including, for each pole of a rotor, a predetermined group of slots adjacent and provided at continuous positions to the poles of the rotor, the continuous winding assembly comprising: a first winding portion that includes a plurality of windings extending along a circumferential direction of the stator and arranged in parallel with each other, each of which is wound by being inserted one by one into the slots included in a slot group; and a second winding portion that is electrically connected to the first winding portion, and includes the plurality of windings extending along the circumferential direction of the stator and arranged in parallel with each other, each of which is wound by being inserted one by one into the slots included in the slot group, wherein each of the windings of the first winding portion and each of the windings of the second winding portion are connected in a one-to-one correspondence with each other, but are connected to each other by being in direct contact with each other, the windings are inserted into the slots by forming a plurality of layers in a radial direction, each of the windings included in the first winding portion does not intersect each other within the same layer, and each of the windings included in the second winding portion does not intersect each other within the same layer.
  2. The continuous winding assembly of claim 1, wherein an end of the second winding portion is inserted into the slot group adjacent to the slot group into which an end of the winding of the first winding portion is inserted.
  3. The continuous winding assembly of claim 1 or 2, wherein the winding includes: a plurality of slot insertion portions that are inserted into the slots and extend in an axial direction of a motor; a jump portion that is provided between the plurality of slot insertion portions and extends by a predetermined pitch; and at least two single-layer parts that are wound on one of the layers, and the single-layer partincludes the slot insertion portions that are inserted one by one per slot group adjacent to all the poles, and at least one layer jump part that is provided between two or more of the single-layer parts and crosses two or more of the layers.
  4. The continuous winding assembly of claim 3, wherein the jump portions included in the first winding portion and the second winding portion have one pitch value selected from among 7 pitches, 9 pitches, and 11 pitches, the jump portions of each parallel winding included in the first winding portion do not intersect each other, and the jump portions of each parallel winding included in the second winding portion do not intersect each other.
  5. The continuous winding assembly of claim 3 or 4, wherein the layer jump parts included in the first winding portion and the second winding portion have one pitch value selected from among 8 pitches, 9 pitches, and 10 pitches.
  6. The continuous winding assembly of any one of claims 3 to 5, wherein a total number of the layers in which the first winding portion and the second winding portion are wound is a multiple of 3.
  7. The continuous winding assembly of claim 6, wherein a number N1 of the layer jump parts included in each parallel winding of the first winding portion and a number N2 of the layer jump parts included in each parallel winding of the second winding portion follow the following Equation. N 1 = p k − 1 N 2 = q m − k − 1 (Here, N1: The number of layer jump parts of the winding of the first winding portion N2: The number of layer jump parts of the winding of the second winding portion p, q: Constants (integers greater than or equal to 1) m: Total number of layers (multiples of 3) k: The number of odd-numbered layers based on the radial direction)
  8. The continuous winding assembly of any one of claims 3 to 7, wherein when a total number of poles of the motor is S, the layer jump part is formed between the slot insertion portion where each of the windings is wound for an nSth time and the slot insertion portion where each of the windings is wound for an nS+1th time (n is a natural number).
  9. The continuous winding assembly of any one of claims 3 to 8, wherein the single-layer part of the first winding portion is wound on an odd-numbered layer based on the radial direction, and the single-layer part of the second winding portion is wound on an even-numbered layer based on the radial direction.
  10. The continuous winding assembly of any one of claims 3 to 9, wherein the layer jump part traverses either the odd-numbered or the even-numbered layer in the radial direction.

Description

TECHNICAL FIELD The following disclosure relates to a continuous winding assembly, and more particularly, to a continuous winding assembly wound on a motor stator. BACKGROUND In motor design, applying each winding maximizes a slot filling ratio, enabling miniaturization of a motor. When inserting each winding into a slot, unlike a circular wire, there is a layer concept, and an inductance varies for each layer. In addition, since a back electromotive force phase is different for each slot, when applying a parallel circuit, a balanced winding layout design is essential to eliminate the inductance difference and back electromotive force phase difference between parallels. When such an imbalance occurs, a circulating current may occur, which may lead to motor overheating. Accordingly, the rules for arranging coils in slots and layers were very limited. Like hairpin windings, continuous windings also require winding layout that considers the inductance balance and the back electromotive force phase balance. However, the hairpin windings should be arranged at the same pitch due to restrictions on welded parts, whereas the continuous windings have the advantage of high freedom in arranging pitches on both sides of the crown because there are no welded parts. However, this degree of freedom may also act as a disadvantage that increases the complexity of design. In particular, when a terminal assembly is required, it may be disadvantageous in terms of cost and quality due to increased material costs, the increased number of welding operations, and process complexity. In addition, when connecting windings between parallel circuits using continuous windings to form a series winding, as illustrated in FIGS. 1 and 2, there were cases where the connection structure of the windings between the parallel circuits was misaligned in order to maintain the balance of the back electromotive force and inductance. In other words, as illustrated in FIG. 2, since the windings of the same phase (same color) should be connected to each other when the windings are arranged, there was a problem that the terminal assembly had to be used to implement this. [Related Art Document] [Patent Document] (Patent Document 1) US Patent No. 7269888 "Method of making cascaded multilayer stator winding with interleaved transitions" SUMMARY An embodiment of the present disclosure is directed to providing a continuous winding assembly that satisfies a balance of back electromotive force and inductance by having windings between each parallel circuit, which are interconnected to form a series winding, and adopt a specific pitch and shape, and allows each wire to be connected to be positioned in the same phase to enable welding without twisting, thereby easily forming a series winding without a terminal assembly. Means for solving the Problems In one general aspect, a continuous winding assembly applied to a stator, the stator including, for each pole of a rotor, a predetermined group of slots adjacent and provided at continuous positions to the poles of the rotor includes: a first winding portion that includes a plurality of windings extending along a circumferential direction of the stator and arranged in parallel with each other, each of which is wound by being inserted one by one into the slots included in the slot group; and a second winding portion that is electrically connected to the first winding portion, and includes the plurality of windings extending along the circumferential direction of the stator and arranged in parallel with each other, each of which is wound by being inserted one by one into the slots included in the slot group, in which each of the windings of the first winding portion and each of the windings of the second winding portion are connected in a one-to-one correspondence with each other, but are connected to each other by being in direct contact with each other, the windings are inserted into the slots by forming a plurality of layers in a radial direction, each of the windings included in the first winding portion does not intersect each other within the same layer, and each of the windings included in the second winding portion does not intersect each other within the same layer. An end of the second winding portion may be inserted into the slot group adjacent to the slot group into which an end of the winding of the first winding portion is inserted. The winding may include: a plurality of slot insertion portions that are inserted into the slots and extend in an axial direction of a motor; a jump portion that is provided between the slot insert parts and extends by a predetermined pitch; and at least two single-layer parts that are wound on the one layer, and the one single-layer part may include the slot insertion portions that are inserted one by one per slot group adjacent to all the poles, and at least one layer jump part that is provided between two or more of the single-layer parts and crosses two or more of the la