Flat wire stator, manufacturing method thereof and tool used for manufacturing flat wire stator

Abstract

The invention discloses a flat wire stator and a manufacturing method thereof, and a tool used for manufacturing the flat wire stator, the tool is arranged in a stator winding, the tool is opened to support the stator winding, and then a stator core block is inserted between two adjacent vertical winding coil groups to form a stator core. According to the two flat wire stators and the manufacturing method, the stator winding does not need to be shrunk forcibly, the stator winding is not abraded, the percent of pass of the flat wire stators is improved, installation is more convenient, and working efficiency is improved. And the stator winding is integrally formed, so that the upper end and the lower end of the winding do not need to be shaped, the height of the end part of the stator can be shortened, and the motor performance is also improved.

Description

Technical Field

[0001] The present invention relates to the field of new energy vehicle motors, and more specifically, to a flat wire stator for a new energy vehicle, a manufacturing method thereof, and a tooling used for manufacturing the flat wire stator. Background Art

[0002] In response to the fact that the electric drive motor stators of new energy vehicles are mostly converted to flat wire stators, the use of flat wire stators brings many advantages, such as increasing slot fill rate, enhancing heat dissipation capacity, increasing power density and reducing electromagnetic noise, but generally there are hundreds of welding points of flat wires, and the bending angles of each layer of flat wires are different, so multiple molds are required for stamping and manufacturing. The insertion of flat wires is complicated and time-consuming, and hundreds of flat wire end joints need to be welded, which is time-consuming and costly. If any of the joints is welded incorrectly, it will cause the stator to fail. In addition, a larger spacing is required between the welding points, and glue coating and baking must be performed at each welding point, which increases time and space costs.

[0003] Therefore, there is an urgent need to provide a flat wire stator for a new energy gas vehicle that can improve the above-mentioned problems, a manufacturing method thereof, and a tooling used for manufacturing the flat wire stator. Summary of the invention

[0004] In view of this, the present invention provides a flat wire stator and a manufacturing method thereof, and a tooling used for manufacturing the flat wire stator, so as to improve the problems existing in the flat wire stator.

[0005] In one aspect, the present invention provides a flat wire stator, comprising:

[0006] The stator winding is integrally formed and includes N sets of vertical winding coil groups. The outer side of each set of vertical winding coil groups is wrapped with an insulating layer. Each set of vertical winding coil groups includes M coils along the radial direction of the stator winding;

[0007] The stator core includes N stator core sub-blocks. The N stator core sub-blocks are assembled to form the stator core. Two adjacent stator core sub-blocks are assembled to form a stator slot along the axial direction on one side close to the inner wall. The stator slot includes K installation slots along the radial direction. The stator core sub-block is inserted between two adjacent vertical winding coil groups along the radial direction so that the vertical winding coil group is located in the stator slot. The M coils correspond to the installation slots one by one.

[0008] N, M and K are all positive integers.

[0009] Optionally, P stator core sub-blocks form an integrated structure, and Q integrated structures are assembled to form a stator core, where N = P × Q;

[0010] P and Q are both positive integers.

[0011] Optionally, the width of the stator core sub-block near the outer wall in the circumferential direction is greater than the width of the stator core sub-block near the inner wall in the circumferential direction, and a stator slot is formed axially on the side near the inner wall when two adjacent stator core sub-blocks are bonded together.

[0012] Optional, 8≤N≤120.

[0013] The present invention also provides a flat wire stator, comprising:

[0014] The stator winding is integrally formed and includes N sets of vertical winding coil groups. The outer side of each set of vertical winding coil groups is wrapped with an insulating layer. Each set of vertical winding coil groups includes M coils along the radial direction of the stator winding;

[0015] The stator core includes a spirally wound main body, one side of the main body includes stator slots, the stator slots correspond to the positions of the vertically wound coil groups, and along the axial direction, the main body is spirally wound from one end of the vertically wound coil group to the other end of the vertically wound coil group to form the stator core.

[0016] Optionally, when the stator core includes a spirally wound main body, the height of the vertically wound coil group along the axial direction is H, the thickness of the spirally wound main body along the axial direction is d, the number of spirals of the spirally wound main body is k, and H=d×k,

[0017] H, d, and k are all positive numbers.

[0018] Optionally, when the stator core includes a spirally wound elongated strip body, 8≤N≤54.

[0019] The present invention also provides a tool for making a flat wire stator, comprising a rotating platform, a central axis and a supporting assembly, wherein:

[0020] The central axis is connected to one end of the rotating platform;

[0021] The support assembly is evenly distributed around the central axis along the circumferential direction, and the support assembly includes a support arm extending along the axial direction, and the support arm includes a support groove, and the number of the support grooves is N;

[0022] The tooling includes a first state and a second state, wherein:

[0023] In the first state, the support assembly moves along the first direction, and the outer diameter of the support assembly increases; in the second state, the support assembly moves along the second direction, and the outer diameter of the support assembly decreases;

[0024] The first direction and the second direction are both radial directions, and the first direction and the second direction are in opposite directions.

[0025] Optionally, the side of the central axis close to the rotating platform includes a first fixing component, the first fixing component is sleeved on the outside of the central axis, and the side of the central axis away from the rotating platform is fixedly connected to a second fixing component;

[0026] The support assembly is I-shaped and also includes two cross arms extending radially, one of which is rotatably connected to the first fixed assembly, the other cross arm is rotatably connected to the second fixed assembly, and the two cross arms are rotatably connected to the support arms respectively.

[0027] The central shaft is also sleeved with a first limiting member and a second limiting member, the first limiting member is located on a side of the first fixing component close to the rotating platform, the second limiting member is located on a side of the second fixing component away from the rotating platform, and the second limiting member is fixedly connected to the central shaft;

[0028] In the first state, the distance between the first position-limiting member and the second position-limiting member is smaller than the distance between the first position-limiting member and the second position-limiting member in the second state.

[0029] The present invention also provides a method for manufacturing a flat wire stator, using the above-mentioned tooling to manufacture the above-mentioned flat wire stator, comprising:

[0030] Obtaining a stator winding, wherein the stator winding is integrally formed and comprises N sets of vertical winding coil groups, each set of vertical winding coil groups is wrapped with an insulating layer on the outside, and each set of vertical winding coil groups comprises M coils along the radial direction of the stator winding;

[0031] Obtain a tooling device, and place a supporting device of the tooling device inside the stator winding, with the rotating platform exposed to the stator winding;

[0032] The tooling is in a first state, the support assembly moves along a first direction to increase the outer diameter of the support assembly, and the tooling is opened so that each vertical winding coil is at least partially located in the support groove;

[0033] Rotate the rotating platform and insert each stator core sub-block into between two adjacent vertical winding coil groups in turn until N stator core sub-blocks are assembled to form a stator core;

[0034] The tooling is in the second state, the support assembly moves along the second direction to reduce the outer diameter of the support assembly, shrink the tooling, and take the tooling out from the inside of the stator winding.

[0035] The present invention also provides a method for manufacturing a flat wire stator, using the above tooling to manufacture the above flat wire stator, comprising:

[0036] Obtaining a stator winding, wherein the stator winding is integrally formed and comprises N sets of vertical winding coil groups, each set of vertical winding coil groups is wrapped with an insulating layer on the outside, and each set of vertical winding coil groups comprises M coils along the radial direction of the stator winding;

[0037] Obtain a tooling device, and place a supporting device of the tooling device inside the stator winding, with the rotating platform exposed to the stator winding;

[0038] The tooling is in a first state, the support assembly moves along a first direction to increase the outer diameter of the support assembly, and the tooling is opened so that each vertical winding coil is at least partially located in the support groove;

[0039] Rotate the rotating platform, and sequentially spirally wind the spirally wound main body from one end of the vertically wound coil group to the other end of the vertically wound coil group, and insert the vertically wound coil group into the stator slot of the spirally wound main body to form a stator core;

[0040] The tooling is in the second state, the support assembly moves along the second direction to reduce the outer diameter of the support assembly, shrink the tooling, and take the tooling out from the inside of the stator winding.

[0041] Compared with the prior art, the flat wire stator and the manufacturing method thereof, and the tooling used for manufacturing the flat wire stator provided by the present invention achieve at least the following beneficial effects:

[0042] In the stator winding in the prior art, each layer and each angle is composed of different flat wires, and multiple flat wires need to be manufactured by multiple stamping molds. Multiple flat wires are inserted into the stator in the correct order and orientation. Of course, each flat wire needs to be welded to connect the stator winding coil, and there will be hundreds of welding points. Each welding point requires a larger spacing, which will cause the stator end to increase, and each welding point needs to be injected with glue to prevent short circuit, which increases the glue coating process and materials; after the continuous wave stator winding in the prior art is manufactured, it is necessary to first compress the whole into the middle of the annular stator core, and then unfold and insert these continuously wave wound stator windings into the corresponding stator slots, and weld the joints to be bridged and the copper jumper wires of the previous layers. There is no need to insert them into the stator core, cut off the ends and remove the paint film of part of the flat wire before the welding process can be carried out. Furthermore, after the continuous wave stator winding in the prior art is manufactured, the stator winding needs to be forcibly shrunk and then stuffed into the stator slot of the stator core after being shrunk. During this installation process, the stator winding is worn and the qualified rate of the flat wire stator is reduced; and the upper and lower ends of the stator winding in the prior art need to be shaped after being stuffed into the stator core, so that there is a certain gap between the flat wire layers at the end as much as possible; and although the prior art uses insulating glue to adhere between the flat wires by dipping or dripping paint, after the motor has been used for a period of time, it may fall off due to vibration, resulting in insulation failure between the flat wires and a short circuit.

[0043] The stator winding of the present invention is integrally formed, which speeds up the direct forming of the stator winding, and can reduce 95% of the winding welding process, and does not need to use a twisting tool for twisting, does not need to apply paint film to hundreds of flat wires, and also saves the glue coating process. Of course, the motor will not have the problem of debonding and causing insulation failure after long-term use, which improves the reliability of the motor; the present invention installs the tool inside the stator winding, opens the tool, supports the stator winding, and then inserts the stator core block between two adjacent vertical winding coil groups to form a stator core, or spirally winds the spirally wound main body from one end of the vertical winding coil group to the other end of the vertical winding coil group to form a stator core. Both of these flat wire stators and manufacturing methods do not need to force the stator winding to shrink, and there is no wear on the stator winding, which improves the qualified rate of the flat wire stator, and the installation is more convenient, which improves the work efficiency. In addition, since the stator winding of the present invention is integrally formed, there is no need to shape the upper and lower ends of the winding, and the height of the stator end can be shortened, which also improves the performance of the motor.

[0044] The present invention also provides a tooling, wherein the support assembly moves along a first direction to increase the outer diameter of the support assembly, and the tooling is stretched open so that each vertical winding coil is at least partially located in a support groove. The tooling is in a second state, and the support assembly moves along a second direction to decrease the outer diameter of the support assembly, and the tooling is contracted to be taken out from the inside of the stator winding. The tooling structure is more reasonable and easy to use, ensuring that the stator winding will not be deformed during the installation process, facilitating the installation of the stator core block or the spirally wound main body, thereby improving the work efficiency and the qualified rate of the flat wire stator.

[0045] Of course, any product implementing the present invention does not necessarily need to achieve all of the technical effects described above at the same time.

[0046] Further features and advantages of the present invention will become apparent from the following detailed description of exemplary embodiments of the present invention with reference to the attached drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0047] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

[0048] Figure 1 It is a structural schematic diagram of a stator winding provided by the present invention;

[0049] Figure 2 yes Figure 1 A partial enlarged view of the middle E area;

[0050] Figure 3 It is a structural schematic diagram of a flat wire stator provided by the present invention;

[0051] Figure 4It is a structural schematic diagram of a stator core provided by the present invention;

[0052] Figure 5 It is a structural schematic diagram of another flat wire stator provided by the present invention;

[0053] Figure 6 This is a U-phase winding installation method provided by the present invention;

[0054] Figure 7 This is a three-phase winding installation method provided by the present invention;

[0055] Figure 8 It is a structural schematic diagram of a tooling used for manufacturing a flat wire stator provided by the present invention;

[0056] Fig. 9 It is a combination diagram of a tool and a flat wire stator in a process of manufacturing a flat wire stator provided by the present invention;

[0057] Fig.10 This is another combination diagram of a tool and a flat wire stator in a process of manufacturing a flat wire stator provided by the present invention;

[0058] Fig.11 It is a flow chart of a method for manufacturing a flat wire stator provided by the present invention;

[0059] Fig.12 This is a flow chart of another method for manufacturing a flat wire stator provided by the present invention. DETAILED DESCRIPTION

[0060] Various exemplary embodiments of the present invention will now be described in detail with reference to the accompanying drawings. It should be noted that the relative arrangement of components and steps, numerical expressions and numerical values ​​set forth in these embodiments do not limit the scope of the present invention unless otherwise specifically stated.

[0061] The following description of at least one exemplary embodiment is merely illustrative in nature and is in no way intended to limit the invention, its application, or uses.

[0062] Technologies, methods, and equipment known to ordinary technicians in the relevant art may not be discussed in detail, but where appropriate, the technologies, methods, and equipment should be considered as part of the specification.

[0063] In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not limiting. Therefore, other examples of the exemplary embodiments may have different values.

[0064] It should be noted that like reference numerals and letters refer to similar items in the following figures, and therefore, once an item is defined in one figure, it need not be further discussed in subsequent figures.

[0065] Example 1

[0066] Combination Figures 1 to 3 The present invention provides a flat wire stator 100, including a stator winding 200 and a block-type stator core 300.

[0067] Reference Figure 1 and Figure 2 The stator winding 200 is integrally formed, and includes N sets of vertical winding coil groups 1. The outer side of each set of vertical winding coil groups 1 is wrapped with an insulating layer 20. Each set of vertical winding coil groups 1 includes M coils 2 along the radial direction D of the stator winding 200;

[0068] Reference Figure 3 The stator core 300 includes N stator core sub-blocks 3. The N stator core sub-blocks 3 are assembled to form the stator core 300. Two adjacent stator core sub-blocks 3 are assembled to form a stator slot 4 along the axial direction on one side close to the inner wall. The stator slot 4 includes K installation slots along the radial direction D (not shown in the figure). The stator core sub-block 3 is inserted between two adjacent vertical winding coil groups 1 along the radial direction D, so that the vertical winding coil group 1 is located in the stator slot 4, and the M coils 2 correspond to the installation slots one by one.

[0069] N, M and K are all positive integers.

[0070] Specifically, the stator winding 200 in the present invention is a stator winding of continuous wave winding. The stator winding 200 includes N groups of vertical winding coil groups 1. The outer side of each group of vertical winding coil groups 1 is wrapped with an insulating layer 20 to prevent short circuit. The insulating layer 20 can be insulating paper to insulate the vertical winding coil groups 1. The insulating paper can be made of high-temperature insulating materials such as polyimide film or polyimide fiber, which can withstand high temperature and high voltage, and has good corrosion resistance and mechanical strength. Along the radial direction D of the stator winding 200, each group of vertical winding coil groups 1 includes M coils 2, and the two ends of each coil 2 are connected to adjacent commutator segments to form a continuous "wave" shape. The material of the coil 2 can be copper or copper alloy. Copper has excellent electrical conductivity and thermal conductivity, can withstand high current, and is not easily damaged by high temperature.

[0071] Reference Figure 6 and Figure 7 For the integrally formed stator winding 200, this embodiment takes a motor with 54 slots, 6 poles, 6 layers, a total of three-phase windings, Y-type connection, and 6 branches in parallel for each phase as an example for schematic description. From left to right, they are 1# to 54# stator slots (refer to Fig.10 The numbers in the figure are as follows: L1 to L6 installation slots along the radial direction D, specifically:

[0072] Branch 1: Passing through 1#L1-10#L2-19#L1-28#L2-37#L1-46#L2-1#L3-10#L4-19#L3-28#L4-37#L3-46#L4-1#L5-10#L6-19#L5-28#L6-37#L5-46#L6 in sequence;

[0073] The second branch: passes through 2#L1-11#L2-20#L1-29#L2-38#L1-47#L2-2#L3-11#L4-20#L3-29#L4-38#L3-47#L4-2#L5-11#L6-20#L5-29#L6-38#L5-47#L6 in sequence;

[0074] The third branch: passes through 3#L1-12#L2-21#L1-30#L2-39#L1-48#L2-3#L3-12#L4-21#L3-30#L4-39#L3-48#L4-3#L5-12#L6-21#L5-30#L6-39#L5-48#L6 in sequence;

[0075] The 4th branch: passes through 19#L6-10#L5-1#L6-46#L5-37#L6-28#L5-19#L4-110#L3-1#L4-46#L3-37#L4-28#L3-19#L2-10#L1-1#L2-46#L1-37#L2-28#L1 in sequence;

[0076] The 5th branch: passes through 20#L6-11#L5-2#L6-47#L5-38#L6-29#L5-20#L4-111#L3-2#L4-47#L3-38#L4-29#L3-20#L2-11#L1-2#L2-47#L1-38#L2-29#L1;

[0077] Branch No. 6: Passes through 21#L6-12#L5-3#L6-48#L5-39#L6-30#L5-21#L4-112#L3-3#L4-48#L3-39#L4-30#L3-21#L2-12#L1-3#L2-48#L1-39#L2-30#L1 in sequence.

[0078] The stator winding 200 of the present invention is integrally formed, which speeds up the direct forming of the stator winding 200 and can reduce 95% of the winding welding process. There is no need to use a twisting tool for twisting, no need to paint hundreds of flat wires, and the gluing process is also omitted. Of course, the motor will not have the problem of debonding and causing insulation failure during long-term use, thereby improving the reliability of the motor.

[0079] Optionally, 2≤N≤120. The number of poles refers to the number of magnetic poles or windings uniformly distributed in the stator circumference of each phase coil 2. The magnetic poles appear in pairs, and the back and forth of the vertical winding coil group 1 forms a loop. The more poles there are, the faster the motor speed is, and the fewer poles there are, the higher the motor speed is. For example, two poles, four poles, six poles, or greater than eight poles, two poles are high-speed motors, four poles are medium-speed motors, six poles are low-speed motors, and greater than eight poles are ultra-low-speed motors. The flat wire stator 100 of this embodiment, 2≤N≤120, can meet both multi-pole electrodes and small-pole electrodes, and is more widely applicable. In the prior art, the method for making a flat wire stator needs to force the winding to be reduced and then stuffed into the stator slot, so the number N of the vertical winding coil group cannot be made very large, which limits the number of poles of the motor. It can be understood that the more poles there are, the smaller the torque fluctuation, vibration and noise, so the present invention can simplify the production process of multi-pole electrodes.

[0080] The stator core in the prior art is made by laminating multiple layers of annular steel sheets with stator slots, and the stator slots need to be punched out of the steel sheets. In this embodiment, the stator core sub-block 3 is used, and the stator slots do not need to be cut, which can simplify the manufacturing process.

[0081] The present invention inserts the stator core block 3 between two adjacent vertical winding coil groups 1 to form a stator core 300. There is no need to forcibly shrink the stator winding 200, and there is no wear on the stator winding 200, which improves the qualified rate of the flat wire stator 100, and is more convenient to install, thereby improving work efficiency.

[0082] It should be noted that the outer diameters of both ends of the continuously wave wound stator can be directly formed into the optimal spacing between the flat wires (coil 2) and the flat wires (coil 2). The outer diameter of the ends of the stator will not be reduced due to the new process of the present invention, but the height of the ends will be shortened.

[0083] In some optional embodiments, P stator core sub-blocks 3 form an integrated structure, and Q integrated structures are assembled to form the stator core 300, where N = P × Q;

[0084] P and Q are both positive integers.

[0085] Specifically, several stator core sub-blocks 3 are manufactured into an integrated structure during manufacturing, and a plurality of integrated structures are assembled to form the stator core 300 , which can speed up the installation process of the flat wire stator 100 and improve work efficiency.

[0086] In some optional embodiments, continue to refer to Figure 3 The width m1 of the stator core block 3 close to the outer wall along the circumferential direction C is greater than the width m2 of the stator core block 3 close to the inner wall along the circumferential direction C. After two adjacent stator core blocks 3 are bonded together, a stator slot 4 is formed along the axial direction on the side close to the inner wall.

[0087] It is understandable that the stator core in the prior art is made by stacking multiple layers of annular steel sheets with stator slots, and the stator slots need to be cut from the steel sheets. In this embodiment, a stator core sub-block 3 is used. It is only necessary to make the width of the stator core sub-block 3 close to the outer wall along the circumferential direction C greater than the width of the stator core sub-block 3 close to the inner wall along the circumferential direction C during manufacturing. After two adjacent stator core sub-blocks 3 are fitted together, the stator slots 4 can be formed along the axial direction on the side close to the inner wall. There is no need to cut the stator slots, which simplifies the manufacturing process. Example 2:

[0088] Reference Figure 1 , Figure 2 , Figure 4 and Figure 5 This embodiment provides a flat wire stator 100 including a stator winding 200 and a stator core 300 .

[0089] Please refer to Figure 1 and Figure 2 The stator winding 200 is integrally formed, and includes N sets of vertical winding coil groups 1. The outer side of each set of vertical winding coil groups 1 is wrapped with an insulating layer 20. Each set of vertical winding coil groups 1 includes M coils 2 along the radial direction D of the stator winding 200;

[0090] Please refer to Figure 4 and Figure 5 The stator core 300 includes a spirally wound main body 7, one side of the main body 7 includes a stator slot 4, the stator slot 4 corresponds to the position of the vertically wound coil group 1, and along the axial direction A, the main body 7 is spirally wound from one end of the vertically wound coil group 1 to the other end of the vertically wound coil group 1 to form the stator core 300.

[0091] Specifically, the stator winding 200 in the present invention is a continuous wave wound stator winding, and the stator winding 200 includes N groups of vertical winding coil groups 1. The outside of each group of vertical winding coil groups 1 is wrapped with an insulating layer 20 to prevent short circuit. The insulating layer 20 can be insulating paper to insulate the vertical winding coil groups 1. The insulating paper can be made of high-temperature insulating materials such as polyimide film or polyimide fiber, which can withstand high temperature and high voltage, and has good corrosion resistance and mechanical strength. Figure 1 The number of neutral winding coil groups 1 is only for illustrative purposes and is not intended to limit the actual product. Each neutral winding coil group 1 includes M coils 2 along the radial direction D of the stator winding 200. Of course, Figure 1The number of coils 2 in each vertical winding coil group 1 is only for schematic illustration and is not intended to limit the actual product. When forming the winding, the two ends of each coil 2 are connected to the adjacent commutator segments to form a continuous "wave" shape. The material of the coil 2 can be copper or copper alloy. Copper has excellent electrical and thermal conductivity, can withstand high current, and is not easily damaged by high temperature.

[0092] The spirally wound main body 7 has a plurality of stator slots 4 , and there is a certain interval between the stator slots 4 . The spacing between the stator slots 4 is equal to the spacing between adjacent vertically wound coil groups 1 , ensuring that the positions of the stator slots 4 and the vertically wound coil groups 1 correspond to each other after winding, so that the vertically wound coil groups 1 are located in the stator slots 4 .

[0093] Reference Figure 6 and Figure 7 For the integrally formed stator winding 200, this embodiment takes a motor with 54 slots, 6 poles, 6 layers, a total of three-phase windings, Y-type connection, and 6 branches in parallel per phase as an example for schematic description. From left to right, they are 1# to 54# stator slots, and along the radial direction D, they are L1 to L6 installation slots, specifically:

[0094] Branch 1: Passing through 1#L1-10#L2-19#L1-28#L2-37#L1-46#L2-1#L3-10#L4-19#L3-28#L4-37#L3-46#L4-1#L5-10#L6-19#L5-28#L6-37#L5-46#L6 in sequence;

[0095] The second branch: passes through 2#L1-11#L2-20#L1-29#L2-38#L1-47#L2-2#L3-11#L4-20#L3-29#L4-38#L3-47#L4-2#L5-11#L6-20#L5-29#L6-38#L5-47#L6 in sequence;

[0096] The third branch: passes through 3#L1-12#L2-21#L1-30#L2-39#L1-48#L2-3#L3-12#L4-21#L3-30#L4-39#L3-48#L4-3#L5-12#L6-21#L5-30#L6-39#L5-48#L6 in sequence;

[0097] The 4th branch: passes through 19#L6-10#L5-1#L6-46#L5-37#L6-28#L5-19#L4-110#L3-1#L4-46#L3-37#L4-28#L3-19#L2-10#L1-1#L2-46#L1-37#L2-28#L1 in sequence;

[0098] The 5th branch: passes through 20#L6-11#L5-2#L6-47#L5-38#L6-29#L5-20#L4-111#L3-2#L4-47#L3-38#L4-29#L3-20#L2-11#L1-2#L2-47#L1-38#L2-29#L1;

[0099] Branch No. 6: Passes through 21#L6-12#L5-3#L6-48#L5-39#L6-30#L5-21#L4-112#L3-3#L4-48#L3-39#L4-30#L3-21#L2-12#L1-3#L2-48#L1-39#L2-30#L1 in sequence.

[0100] The stator winding 200 of the present invention is integrally formed, which speeds up the direct forming of the stator winding 200 and can reduce 95% of the winding welding process. There is no need to use a twisting tool for twisting, no need to paint hundreds of flat wires, and the gluing process is also omitted. Of course, the motor will not have the problem of debonding and causing insulation failure during long-term use, thereby improving the reliability of the motor.

[0101] In this embodiment, the spirally wound main body 7 is spirally wound from one end of the vertically wound coil group 1 to the other end of the vertically wound coil group 1 to form the stator core 300. There is no need to forcibly shrink the stator winding 200, and there is no wear on the stator winding 200, which improves the qualified rate of the flat wire stator 100, and the installation is more convenient, thereby improving work efficiency.

[0102] It should be noted that the outer diameters of both ends of the continuously wave wound stator can be directly formed into the optimal spacing between the flat wires (coil 2) and the flat wires (coil 2). The outer diameter of the ends of the stator will not be reduced due to the new process of the present invention, but the height of the ends will be shortened.

[0103] In the prior art, the spirally wound main body is pre-wound, and then the stator winding is forcibly reduced and stuffed into the stator slot. Since the spirally wound main body is unstable, there is a problem of poor precision during the installation of the stator winding. However, the present invention winds the spirally wound main body 7 on the stator winding 200, and there is no problem of poor precision.

[0104] It should be noted that, on the opposite side of the stator slot 4 , an open oil groove is punched out on the main body 7 to facilitate smooth winding of the main body 7 .

[0105] Optionally, when the stator core 300 includes a spirally wound main body 7, 2≤N≤54.

[0106] It should be noted that the stator core 300 of the present embodiment is formed by spirally winding the main body 7 along the axial direction A from one end of the vertical winding coil group 1 to the other end of the vertical winding coil group 1. During the winding process, the stator slot 4 on the main body 7 needs to be matched with the vertical winding coil group 1 so that the vertical winding coil group 1 is inserted into the stator slot 4. Therefore, if N is too large, the difficulty of winding the main body 7 will increase. In the present embodiment, 2≤N≤54 can ensure the feasibility of winding the main body 7.

[0107] In some optional embodiments, when the stator core 300 includes a spirally wound main body 7, the height of the vertically wound coil group 1 along the axial direction A is H, the thickness of the spirally wound main body 7 along the axial direction A is d, and the number of spirals of the spirally wound main body 7 is k, H=d×k,

[0108] H, d, and k are all positive numbers.

[0109] When the stator core 300 includes a spirally wound main body 7, the spirally wound main body 7 along the axial direction A is spirally wound from one end of the vertically wound coil group 1 to the other end of the vertically wound coil group 1 to form the stator core 300. During the winding process, the main bodies 7 of adjacent layers need to be tightly fitted. It can be understood that if the main bodies 7 are not tightly wound, the gaps between the main bodies 7 will increase, and the magnetic flux distribution will be uneven, thereby affecting the performance of the generator, such as causing power loss and reduced motor efficiency. In this embodiment, along the axial direction A, the product of the thickness d of the spirally wound main body 7 and the number k of spirals of the spirally wound main body 7 is equal to the height H of the vertically wound coil group 1, reducing the gaps between the main bodies 7 of adjacent layers to ensure the performance of the motor.

[0110] Example 3

[0111] This embodiment provides a tool 400 for manufacturing a flat wire stator 100, referring to Figure 8 The tooling 400 includes a rotating platform 8, a central axis 9 and a supporting assembly 10, wherein:

[0112] The central shaft 9 is connected to one end of the rotating platform 8;

[0113] The support assembly 10 is evenly distributed around the central axis 9 along the circumferential direction C. The support assembly 10 includes a support arm 11 extending along the axial direction A. The support arm 11 includes a support groove 12. The number of the support grooves 12 is N.

[0114] The tool 400 includes a first state and a second state, wherein:

[0115] In the first state, the support assembly 10 moves along the first direction F1, and the outer diameter of the support assembly 10 increases. In the second state, the support assembly 10 moves along the second direction F2, and the outer diameter of the support assembly 10 decreases.

[0116] The first direction F1 and the second direction F2 are both radial directions D, and the first direction F1 and the second direction F2 are in opposite directions.

[0117] Specifically, the rotating platform 8 can be driven to rotate by a motor. Figure 8 and Fig. 9 The figure only shows that the rotating platform 8 is in a cubic shape. Optionally, the rotating platform 8 may be in a cylindrical shape, which is not specifically limited here.

[0118] The central shaft 9 is cylindrical and is fixedly connected to one end of the rotating platform 8 . When the rotating platform 8 rotates, the central shaft 9 can be driven to rotate.

[0119] The support assembly 10 is evenly distributed around the central axis 9 along the circumferential direction C. It should be noted that each support assembly 10 may have a plurality of support arms 11, that is, the number of support assemblies 10 and the number of vertical winding coil groups 1 do not necessarily correspond one to one, so that the number of support assemblies 10 can be reduced, thereby reducing the number of welding points connected to the central axis 9. The support assembly 10 includes a support arm 11 extending along the axial direction A. The outer side of each support arm 11 has a support slot 12 extending along the axial direction A. The number of support slots 12 is N. The number of support slots 12 is equal to the number of vertical winding coil groups 1 in the stator winding 200. The position of each support slot 12 corresponds to the position of the vertical winding coil group 1. Optionally, a fixing structure is provided on the central axis 9, each fixing structure is used to fix the support assembly 10. After the support assembly 10 is fixed, the support slot 12 corresponds to the position of the vertical winding coil group 1. During installation, the inner coil 2 of the vertical winding coil group 1 is fixed in the support slot 12 to support and fix the stator winding 200.

[0120] In the first state, the support assembly 10 moves along the first direction F1, and the outer diameter of the support assembly 10 becomes larger, so that the stator winding 200 can be supported. In the second state, the support assembly 10 moves along the second direction F2, and the outer diameter of the support assembly 10 decreases, so that the tooling 400 can be placed inside the stator winding 200, and the tooling 400 can be pulled out of the stator winding 200 after assembly is completed.

[0121] It should be noted that there are not only one first direction F1 and second direction F2 here, the extension direction of the central axis 9 is the axial direction CA, and there are multiple first directions F1 and second directions F2 in a plane perpendicular to the central axis 9 .

[0122] In the tooling 400 of this embodiment, the support assembly 10 moves along the first direction F1 to increase the outer diameter of the support assembly 10, and the tooling 400 is stretched out so that each vertically wound coil 2 is at least partially located in the support groove 12. The tooling 400 is in the second state, and the support assembly 10 moves along the second direction F2 to reduce the outer diameter of the support assembly 10, and the tooling 400 is contracted and taken out from the inside of the stator winding 200. The tooling 400 has a more reasonable structure and is easy to use, ensuring that the stator winding 200 will not be deformed during the installation process, facilitating the installation of the stator core block 3 or the spirally wound main body 7, thereby improving the work efficiency and the qualified rate of the flat wire stator 100.

[0123] In some optional embodiments, continue to refer to Figure 8 The side of the central axis 9 close to the rotating platform 8 includes a first fixing component 13, the first fixing component 13 is sleeved on the outside of the central axis 9, and the side of the central axis 9 away from the rotating platform 8 is fixedly connected with a second fixing component 14;

[0124] The support assembly 10 is I-shaped and further includes two cross arms 15 extending radially, wherein one cross arm 15 is rotatably connected to the first fixing assembly 13 , and the other cross arm 15 is rotatably connected to the second fixing assembly 14 . The two cross arms 15 are rotatably connected to the support arms 11 , respectively.

[0125] It can be understood that the first fixing assembly 13 and the second fixing assembly 14 are respectively located at the two ends of the central shaft 9, and a spring 19 is further included between the first fixing assembly 13 and the second fixing assembly 14. The first fixing assembly 13 and the second fixing assembly 14 are both sleeved on the outside of the central shaft 9. The first fixing assembly 13 and the central shaft 9 are movably connected, and the second fixing assembly 14 and the central shaft 9 can be movably connected or fixedly connected. When the second fixing assembly 14 and the central shaft 9 are movably connected, a second stopper 17 needs to be provided at the end of the central shaft 9 (refer to Fig.10) to limit the second fixing component 14. The center axis 9 has an external thread; the support assembly 10 is I-shaped and also includes two cross arms 15 extending radially, one of which is rotatably connected to the first fixed assembly 13, and the other cross arm 15 is rotatably connected to the second fixed assembly 14, and the two cross arms 15 are rotatably connected to the support arm 11 respectively. When the first fixed assembly 13 moves axially, it drives the cross arm 15 to move radially toward the side away from the center axis 9, thereby driving the support arm 11 to move radially toward the side away from the center axis 9, and the distance between the support arm 11 and the center axis 9 becomes larger, thereby increasing the outer diameter of the support assembly 10, and the vertical winding coil group 1 can be supported; similarly, when the first fixed assembly 13 moves axially, it drives the cross arm 15 to move radially toward the side close to the center axis 9, thereby driving the support arm 11 to move radially toward the side close to the center axis 9, and the distance between the support arm 11 and the center axis 9 becomes smaller, thereby reducing the outer diameter of the support assembly 10, and the tooling 400 can be pulled out of the stator winding 200.

[0126] The structure of this embodiment makes the operation simple, and can realize the support of the stator winding 200, ensuring that the stator winding 200 will not be deformed during the installation process, facilitating the installation of the stator core block 3 or the spirally wound main body 7, thereby improving the work efficiency and the qualified rate of the flat wire stator 100.

[0127] In some optional embodiments, continue to refer to Figure 8 , and reference Fig. 9 and Fig.10 The central shaft 9 is also sleeved with a first stopper 16 and a second stopper 17. The first stopper 16 is located on a side of the first fixing assembly 13 close to the rotating platform 8, and the second stopper 17 is located on a side of the second fixing assembly 14 away from the rotating platform 8. The second stopper 17 is fixedly connected to the central shaft 9;

[0128] In the first state, the distance between the first limiting member 16 and the second limiting member 17 is smaller than the distance between the first limiting member 16 and the second limiting member 17 in the second state.

[0129] It is understandable that a first stopper 16 can be provided on the side of the first fixing component 13 close to the rotating platform 8. When the first fixing component 13 moves along the first direction F1 so that the outer diameter of the supporting component 10 is the largest, the first stopper 16 can be used to fix the first fixing component 13 to prevent the first fixing component 13 from returning to its original position. The second stopper 17 in this embodiment is located at the end of the central axis 9. The second stopper 17 and the central axis 9 can be fixedly connected to prevent the second fixing component from falling off the central axis 9 and to limit the second fixing component. Specifically, the first stopper 16 can be a screw, which cooperates with the external thread of the central axis 9. The first stopper 16 can be rotated toward the side away from the rotating platform 8 to limit the first fixing component 13. At this time, the distance between the first stopper 16 and the second stopper 17 is reduced. When the flat wire stator 100 is installed, the first stopper 16 is rotated toward the malicious side close to the rotating platform 8. At this time, the distance between the first stopper 16 and the second stopper 17 is increased.

[0130] Optionally, a buffer gasket 18 can be provided between the first limiter 16 and the first fixing member, so that the tooling 400 is evenly stressed, that is, each supporting assembly 10 is evenly stressed, and different vertical winding coil groups 1 are subjected to the same supporting force, thereby ensuring that the stator winding 200 is not deformed.

[0131] Example 4

[0132] Based on the above embodiments, this embodiment provides a method for manufacturing a flat wire stator 100. Fig.11 , combined Figure 1 , Figure 2 , Figure 3 and Figure 8 The manufacturing method of this embodiment uses the tooling 400 of embodiment 3 to manufacture the flat wire stator 100 of embodiment 1, and includes the following steps:

[0133] S401, obtaining a stator winding 200, wherein the stator winding 200 is integrally formed and comprises N sets of vertical winding coil groups 1, each set of vertical winding coil groups 1 is wrapped with an insulating layer 20 on the outside, and each set of vertical winding coil groups 1 comprises M coils 2 along a radial direction D of the stator winding 200;

[0134] The structure of the stator winding 200 may refer to Embodiment 1 and will not be described in detail here.

[0135] S402, obtaining a tool 400, and placing a supporting device of the tool 400 inside the stator winding 200, with the rotating platform 8 exposed to the stator winding 200;

[0136] In step S402 , the tooling 400 is in the second state. At this time, the outer diameter of the support assembly 10 is small, and it is easy to place the support device of the tooling 400 inside the stator winding 200 .

[0137] S403, the tooling 400 is in the first state, the support assembly 10 is moved along the first direction F1 to increase the outer diameter of the support assembly 10, and the tooling 400 is opened so that each vertical winding coil assembly 1 is at least partially located in the support groove 12;

[0138] Specifically, after the support component 10 is placed inside the stator winding 200, the support component 10 is moved along the radial direction D, and the outer diameter of the support component 10 gradually increases until the outer diameter of the support component 10 is maximized for positioning, and the tooling 400 is then opened. At this time, at least a portion of each vertical winding coil group 1 needs to be located in the support groove 12. The portion here refers to the first or the first to third coil 2 of the vertical winding coil group 1, that is, the first or the first to third coil 2 is located in the support groove 12, which is convenient for the subsequent removal of the tooling 400.

[0139] S404, rotating the rotating platform 8, and inserting each stator core sub-block 3 between two adjacent vertical winding coil groups 1 in sequence, until N stator core sub-blocks 3 are assembled to form a stator core 300;

[0140] By rotating the rotating platform 8 , each stator core sub-block 3 can be sequentially inserted between two adjacent vertical winding coil groups 1 at a fixed position. After all the stator core sub-blocks 3 are inserted, the assembly is completed to form a complete stator core 300 .

[0141] S405 , the tooling 400 is in the second state, the support assembly 10 moves along the second direction F2 to reduce the outer diameter of the support assembly 10 , shrinks the tooling 400 , and removes the tooling 400 from the inside of the stator winding 200 .

[0142] In this embodiment, the present invention places the tooling 400 inside the stator winding 200, stretches out the tooling 400 to support the stator winding 200, and then inserts the stator core block 3 between two adjacent vertical winding coil groups 1 to form a stator core 300. This flat wire stator 100 and its manufacturing method do not require forced contraction of the stator winding 200, and there is no wear on the stator winding 200, thereby improving the qualified rate of the flat wire stator 100, and the installation is more convenient, thereby improving work efficiency.

[0143] Example 5

[0144] This embodiment provides a method for manufacturing a flat wire stator 100, referring to Fig.12 , combined Figure 1 , Figure 2 , Figure 4 , Figure 8 , Fig. 9 and Fig.10The manufacturing method of this embodiment uses the tooling 400 in Embodiment 3 to manufacture the flat wire stator 100 in Embodiment 2, including:

[0145] S501, obtaining a stator winding 200, wherein the stator winding 200 is integrally formed and comprises N sets of vertical winding coil groups 1, each set of vertical winding coil groups 1 is wrapped with an insulating layer 20 on the outside, and each set of vertical winding coil groups 1 comprises M coils 2 along a radial direction D of the stator winding 200;

[0146] The structure of the stator winding 200 may refer to Embodiment 1 and will not be described in detail here.

[0147] S502, obtaining a tool 400, and placing a supporting device of the tool 400 inside the stator winding 200, with the rotating platform 8 exposed to the stator winding 200;

[0148] In step S502 , the tooling 400 is in the second state. At this time, the outer diameter of the support assembly 10 is small, and it is easy to place the support device of the tooling 400 inside the stator winding 200 .

[0149] S503, the tooling 400 is in the first state, the support assembly 10 moves along the first direction F1 to increase the outer diameter of the support assembly 10, and the tooling 400 is opened so that each vertically wound coil 2 is at least partially located in the support groove 12;

[0150] Specifically, after the support component 10 is placed inside the stator winding 200, the support component 10 is moved along the radial direction D, and the outer diameter of the support component 10 gradually increases until the outer diameter of the support component 10 is maximized for positioning, and the tooling 400 is then opened. At this time, at least a portion of each vertical winding coil group 1 needs to be located in the support groove 12. The portion here refers to the first or the first to third coil 2 of the vertical winding coil group 1, that is, the first or the first to third coil 2 is located in the support groove 12, which is convenient for the subsequent removal of the tooling 400.

[0151] S504, rotating the rotating platform 8, and sequentially spirally winding the spirally wound main body 7 from one end of the vertically wound coil group 1 to the other end of the vertically wound coil group 1, and inserting the vertically wound coil group 1 into the stator slot 4 of the spirally wound main body 7 to form the stator core 300;

[0152] The purpose of rotating the rotating platform 8 is to spirally wind the main body 7 from one end of the vertical winding coil group 1 to the other end of the vertical winding coil group 1 in sequence at a fixed position, and to insert the vertical winding coil group 1 into the stator slot 4 of the spirally wound main body 7 to form a complete stator core 300.

[0153] S505 , the tooling 400 is in the second state, the support assembly 10 moves along the second direction F2 to reduce the outer diameter of the support assembly 10 , shrinks the tooling 400 , and takes the tooling 400 out of the stator winding 200 .

[0154] In this embodiment, the present invention places the tooling 400 inside the stator winding 200, stretches out the tooling 400, supports the stator winding 200, and then spirally winds the spirally wound main body 7 from one end of the vertical winding coil group 1 to the other end of the vertical winding coil group 1 to form the stator core 300. This method for making the flat wire stator 100 does not require forced contraction of the stator winding 200, and there is no wear on the stator winding 200, thereby improving the qualified rate of the flat wire stator 100, and the installation is more convenient, thereby improving work efficiency.

[0155] Although some specific embodiments of the present invention have been described in detail by way of example, it will be appreciated by those skilled in the art that the above examples are for illustration only and are not intended to limit the scope of the present invention. It will be appreciated by those skilled in the art that the above embodiments may be modified without departing from the scope and spirit of the present invention. The scope of the present invention is defined by the appended claims.

Claims

1. A flat wire stator, characterized in that: include: The stator winding is integrally formed, and comprises N groups of vertical winding coil groups, each group of the vertical winding coil groups is wrapped with an insulating layer on the outside, and each group of the vertical winding coil groups comprises M coils along the radial direction of the stator winding; A stator core, wherein the stator core comprises N stator core sub-blocks, wherein the stator core is formed by splicing the N stator core sub-blocks, wherein two adjacent stator core sub-blocks are bonded together to form a stator slot along the axial direction on one side close to the inner wall, wherein the stator slot comprises K installation slots along the radial direction, wherein the stator core sub-block is inserted between two adjacent vertical winding coil groups along the radial direction, so that the vertical winding coil group is located in the stator slot, and the M coils correspond to the installation slots one by one; N, M and K are all positive integers.

2. The flat wire stator according to claim 1, characterized in that: P of the stator core sub-blocks form an integrated structure, and Q of the integrated structures are assembled to form the stator core, N = P × Q; P and Q are both positive integers.

3. The flat wire stator according to claim 1, characterized in that: The width of the stator core sub-block close to the outer wall along the circumferential direction is greater than the width of the stator core sub-block close to the inner wall along the circumferential direction. After two adjacent stator core sub-blocks are bonded together, the side close to the inner wall forms a stator slot along the axial direction.

4. A flat wire stator, characterized in that: include: The stator winding is integrally formed, and comprises N groups of vertical winding coil groups, each group of the vertical winding coil groups is wrapped with an insulating layer on the outside, and each group of the vertical winding coil groups comprises M coils along the radial direction of the stator winding; The stator core comprises a spirally wound main body, one side of the main body comprises stator slots, the stator slots correspond to the positions of the vertically wound coil groups, and along the axial direction, the main body is spirally wound from one end of the vertically wound coil group to the other end of the vertically wound coil group to form the stator core.

5. The flat wire stator according to claim 4, characterized in that: When the stator core includes a spirally wound main body, the height of the vertically wound coil group in the axial direction is H, the thickness of the spirally wound main body in the axial direction is d, the number of spirals of the spirally wound main body is k, and H=d×k. H, d, and k are all positive numbers.

6. A tool for making a flat wire stator, characterized in that: It includes a rotating platform, a central axis and a supporting assembly, wherein: The central axis is connected to one end of the rotating platform; The support assembly is evenly distributed around the central axis along the circumferential direction, the support assembly includes a support arm extending along the axial direction, the support arm includes a support groove, and the number of the support grooves is N; The tooling includes a first state and a second state, wherein: In the first state, the support assembly moves along the first direction, and the outer diameter of the support assembly increases; in the second state, the support assembly moves along the second direction, and the outer diameter of the support assembly decreases; The first direction and the second direction are both radial directions, and the first direction and the second direction are in opposite directions.

7. The tooling according to claim 6, characterized in that: The side of the central axis close to the rotating platform includes a first fixing component, the first fixing component is sleeved on the outside of the central axis, and the side of the central axis away from the rotating platform is fixedly connected with a second fixing component; The support assembly is I-shaped and also includes two cross arms extending radially, one of which is rotatably connected to the first fixed assembly, the other cross arm is rotatably connected to the second fixed assembly, and the two cross arms are rotatably connected to the support arms respectively.

8. The tooling according to claim 7, characterized in that: The central shaft is also sleeved with a first limiting member and a second limiting member, the first limiting member is located on a side of the first fixing component close to the rotating platform, the second limiting member is located on a side of the second fixing component away from the rotating platform, and the second limiting member is fixedly connected to the central shaft; In the first state, a distance between the first position-limiting member and the second position-limiting member is smaller than a distance between the first position-limiting member and the second position-limiting member in the second state.

9. A method for manufacturing a flat wire stator, characterized in that: The flat wire stator according to any one of claims 1 to 3 is manufactured by using the tooling according to claims 6 to 8, characterized in that it comprises: Obtaining the stator winding, wherein the stator winding is integrally formed, and the stator winding comprises N groups of vertical winding coil groups, each group of the vertical winding coil groups is wrapped with an insulating layer on the outside, and each group of the vertical winding coil groups comprises M coils along the radial direction of the stator winding; Obtaining the tooling, and placing the supporting device of the tooling inside the stator winding, with the rotating platform exposed to the stator winding; The tooling is in a first state, the support assembly moves along a first direction to increase the outer diameter of the support assembly, and the tooling is opened so that each of the vertical winding coils is at least partially located in the support groove; Rotating the rotating platform, and inserting each of the stator core sub-blocks into between two adjacent vertical winding coil groups in sequence, until N stator core sub-blocks are assembled to form the stator core; The tool is in a second state, and the support assembly moves along a second direction to reduce the outer diameter of the support assembly, thereby contracting the tool and taking the tool out from the interior of the stator winding.

10. A method for manufacturing a flat wire stator, characterized in that: The flat wire stator according to claim 4 or 5 is manufactured by using the tooling according to claim 6 to 8, characterized in that it comprises: Obtaining the stator winding, wherein the stator winding is integrally formed, and the stator winding comprises N groups of vertical winding coil groups, each group of the vertical winding coil groups is wrapped with an insulating layer on the outside, and each group of the vertical winding coil groups comprises M coils along the radial direction of the stator winding; Obtaining the tooling, and placing the supporting device of the tooling inside the stator winding, with the rotating platform exposed to the stator winding; The tooling is in a first state, the support assembly moves along a first direction to increase the outer diameter of the support assembly, and the tooling is opened so that each of the vertical winding coils is at least partially located in the support groove; Rotating the rotating platform, and sequentially spirally winding the spirally wound body from one end of the vertically wound coil group to the other end of the vertically wound coil group, and inserting the vertically wound coil group into the stator slot of the spirally wound body to form the stator core; The tool is in a second state, and the support assembly moves along a second direction to reduce the outer diameter of the support assembly, thereby contracting the tool and taking the tool out from the interior of the stator winding.

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