KR-20260065470-A - Continuous winding assembly

KR20260065470AKR 20260065470 AKR20260065470 AKR 20260065470AKR-20260065470-A

Abstract

The present invention relates to a continuous winding assembly, and more specifically, to a continuous winding assembly wound on a motor stator. The continuous winding assembly of the present invention forms a parallel winding by combining three types of windings of different lengths and enables application to odd layers by applying a corresponding number of series turns. Furthermore, it enables electromagnetic equilibrium between windings even with a continuous hairpin winding of standard pitch, thereby suppressing circulating current and maximizing manufacturing efficiency.

Inventors

연준모

Assignees

현대모비스 주식회사

Dates

Publication Date: 20260508
Application Date: 20250311
Priority Date: 20241101

Claims (10)

A continuous winding assembly applied to a stator comprising a predetermined slot group provided at a position adjacent to and continuous with respect to the poles of the rotor, one slot per pole of the rotor, A plurality of first winding parts formed with a standard pitch and electrically connected to a current input terminal; A plurality of second winding parts formed with a standard pitch, each electrically connected to a neutral point; A plurality of third winding parts formed with a standard pitch, wherein one end and the other end are in communication with the first winding part and the second winding part; A continuous winding assembly characterized in that the total number of layers wound with the first winding part, the second winding part, and the third winding part is an odd number.
In Article 1, Each of the above-mentioned first winding part, the above-mentioned second winding part, and the above-mentioned third winding part is, A continuous winding assembly characterized by being wound on a plurality of slot groups included in the stator, and passing through a plurality of slots continuously, one slot per slot of the slot group.
In Article 1, The above-mentioned first winding part is, The 1-1 end electrically connected to the above current input terminal and It includes first and second ends electrically connected to the third winding part, and The above second winding part is, The 2-1 end electrically connected to the above neutral point and It includes a 2-2 end electrically connected to the above-mentioned 3rd winding part, and The above third winding part is, The 3-1 end electrically connected to the above 1-2 end and It includes a third-2 end electrically connected to the above second-2 end, and A continuous winding assembly characterized in that the first winding part, the second winding part, and the third winding part are all provided in equal numbers and are combined in a one-to-one correspondence with each other.
In Paragraph 3, The current direction of the above second winding part is, A continuous winding assembly characterized by having a current direction opposite to that of the first winding part and the third winding part.
In Paragraph 4, The above-mentioned first winding part is wound on the odd-numbered layer based on the outer side from the radial inner side of the slot, and A continuous winding assembly characterized in that the second winding part is wound on an even-numbered layer based on the radial inner side to the outer side of the slot.
In Paragraph 5, The above third winding part is wound on the odd-numbered layer, which is the outermost radially of the slot, and A portion of the odd-numbered layer, which is the outermost radially, is wound with a portion of the first winding part, and A continuous winding assembly characterized in that a portion of the first winding part that is not wound among the odd-numbered layers at the outermost radial side is wound with a portion of the third winding part.
In Paragraph 6, The above 3-1 end is wound in a slot adjacent to the above 1-2 end, and the above 3-1 end and the above 1-2 end are welded together. A continuous winding assembly characterized in that the 3-2 end is wound in a slot adjacent to the 2-2 end, and the 3-2 end and the 2-2 end are welded together.
In Paragraph 3, The above-mentioned first winding part, the above-mentioned second winding part, and the above-mentioned third winding part are, A plurality of slot insertion parts that are inserted into the above slot and extend in the axial direction of the motor, and A continuous winding assembly characterized by including a jump portion provided between the above-mentioned slot insertion portions and extended by a standard pitch.
In Paragraph 3, The first winding part has a longer extension length than the second winding part, and A continuous winding assembly characterized in that the second winding part has a longer extension length than the third winding part.
In Paragraph 8, A continuous winding assembly characterized in that the number of slots in which the first winding part, the second winding part, and the third winding part are wound follows the following formula. formula : ( : Number of slot insertion parts of the first winding part above : Number of slot insertion parts of the above second winding part : Number of slot insertion parts of the above third winding part p : pole number n: Number of layers per slot)

Description

Continuous winding assembly The present invention relates to a continuous winding assembly, and more specifically, to a continuous winding assembly wound on a motor stator. Continuous hairpin windings consist of multiple conductors passing through multiple slots in succession, offering advantages in quality control and productivity by minimizing welds. Generally, a single phase is composed of two or more parallel windings, with each parallel winding consisting of two conductors with opposite current directions. This structure is applicable only to motors with an even number of layers, which imposes design constraints on selecting the equivalent series turn count, a critical factor in motor design. As illustrated in Fig. 1, the equivalent series turn count is a key element determining torque and output; while a larger equivalent series turn count increases low-speed torque, it decreases output torque at high speeds. Selecting an appropriate series turn count within a limited current and voltage range has been a fundamental challenge in motor design. The equivalent number of series turns of a hairpin winding is calculated by combining the number of slots, constants, the number of layers, and the number of parallel circuits, but the number of series turns selectable under actual mass production conditions was limited. There was a problem that design flexibility was reduced due to these limitations. For example, at a mass production level, the number of layers was up to 10 layers and the number of parallels was up to 4, and under those conditions, the equivalent number of series turns selectable were only multiples of 8: 8, 16, 24, 32, 40, 48, and 64. Furthermore, while back EMFs of equal magnitude and phase must be maintained between two or more parallel windings forming a single phase, imbalances can generate circulating currents, potentially degrading motor performance. To resolve back EMF imbalances in parallel windings, each parallel winding had to be repositioned within a slot group, and non-standard pitches had to be applied for odd-numbered layers. This required conductors with different patterns for each parallel winding, increasing the variety of conductors and potentially leading to complexity in the manufacturing process. Consequently, existing technologies face significant limitations in design and manufacturing due to restrictions on the number of equivalent series turns and issues regarding imbalances between parallel windings. New designs and technologies are required to address these problems. Figure 1 shows the motor TN curve according to torque and speed. FIG. 2 is a schematic diagram illustrating one of the parallel windings of the continuous winding assembly of the present invention. FIG. 3 is a schematic diagram illustrating the first winding part, the second winding part, and the third winding part of the present invention. FIG. 4 is a partial schematic diagram illustrating the 1-1 end and the 2-1 end of the present invention. FIG. 5 is a partial schematic diagram illustrating the first-2 end, the second-2 end, and the third winding part of the present invention. FIG. 6 is a schematic diagram illustrating the entire winding of the continuous winding assembly of the present invention. FIG. 7 is a partial schematic diagram illustrating the first-1 end and the second-1 end of the entire winding of the continuous winding assembly of the present invention. FIG. 8 is a partial schematic diagram illustrating the first-2 end, second-2 end, and third winding part of the entire winding of the tineus winding assembly of the present invention. Hereinafter, the technical concept of the present invention will be explained in more detail using the attached drawings. Prior to this, terms and words used in this specification and claims should not be interpreted as being limited to their ordinary or dictionary meanings, and should be interpreted in a meaning and concept consistent with the technical concept of the present invention, based on the principle that the inventor can appropriately define the concept of the terms to best describe his invention. Hereinafter, the basic configuration of the continuous winding assembly (1000) of the present invention will be described with reference to FIG. 2. The present invention is applied to a stator comprising a predetermined group of slots (S) provided in a position adjacent to and continuous with respect to the poles of the rotor, one per pole of the rotor, and may include a first winding part (100), a second winding part (200), and a third winding part (300) as shown in FIG. 2. Multiple first winding parts (100), second winding parts (200), and third winding parts (300) may be included. FIG. 2 shows all of the multiple layer-specific slots (S) of the stator of the present invention unfolded. (The number of slots (S) is shown as the number of slots (S) of the stator * the number of layers.) More specifically, one end of the first winding part (100) may be elect