An equal-height lead-out three-branch stacked stator assembly and motor

Abstract

The present invention discloses an equal-height lead-out type three-branch lapped winding stator assembly and a motor, comprising a stator core, 72 stator slots are distributed along the circumferential direction on the inner side of the stator core, a stator winding formed by connecting a plurality of conductor segments to each other is arranged in the stator slot, 6 layers of conductor segments are arranged radially in each stator slot, each conductor segment comprises a middle part, and the two ends of the middle part are respectively provided with a hairpin end and a welding end extending to the outer side of the stator slot, the welding end comprises a twist welding end and a lead-out wire welding end, wherein the lead-out wire welding end comprises a star point lead-out wire welding end and a three-phase lead-out wire welding end, the three-phase lead-out wire welding end is located at the outermost layer of the stator core and is connected to a three-phase copper bar, the star point lead-out wire welding end is located at the second outer layer of the stator core and is connected to a center line; the top heights of the star point lead-out wire welding end and the three-phase lead-out wire welding end are the same as the height of the twist welding end. The present invention has the characteristics of simple winding structure, convenient processing and small space occupation.

Description

Technical Field

[0001] The invention relates to a stator assembly and a motor, in particular to an equal-height lead-out three-branch stacked stator assembly and a motor. Background Art

[0002] There are two existing methods for wiring the lead wires of the stator assembly. One is to connect the two connection parts of the center line of each branch with two U-shaped wires, but this structure will cause the middle welding part to be thick, occupy a large space, and the welding performance is difficult to guarantee. Another method is to connect the center line to the three-phase star point lead wires at the same time through multiple welding feet, but because the span of the star point lead wires of each phase in the circumferential direction of the stator core is large, and the welding ends of the star point lead wires and the three-phase lead wires will also be cross-distributed due to the same lead wire structure, the center line and the three-phase copper busbar connected to it also need to form a corresponding cross-distribution structure, resulting in a complex structure of the center line and the three-phase copper busbar, and difficult welding positioning.

[0003] In addition, due to the wiring structure characteristics of the flat copper wire motor, its winding conductor needs to be connected through the twisted welding end across the stator slot, so that the lead wire welding end not only needs to be twisted together with the twisted welding end to reach the welding position, but also its welding part needs to extend above the twisted welding end to achieve a stable connection with the center line or three-phase copper busbar; thus, the overall height of the motor is lengthened, which is difficult to be applied to a small-volume motor structure. On the other hand, when arranging the center line and the three-phase copper busbar, it is necessary to coordinate the circumferential position of the lead wire welding end and avoid mutual interference between the two when connected, resulting in the need for the center line and the three-phase copper busbar to be arranged in a mutually staggered structure in the circumferential direction; thus, the volume of the motor in the radial direction is enlarged, further reducing the applicability of the motor. Therefore, the existing electronic components have the problems of complex winding structure, difficult processing and large space occupation. Summary of the invention

[0004] The object of the present invention is to provide a stator assembly and a motor with three branches of equal height lead-out, which have the characteristics of simple winding structure, convenient processing and small space occupation.

[0005] The technical solution of the present invention is as follows: an equal-height lead-out type three-branch stacked stator assembly, comprising a stator core, 72 stator slots are distributed along the circumferential direction on the inner side of the stator core, a stator winding formed by a plurality of conductor segments connected to each other is arranged in the stator slot, 6 layers of conductor segments are arranged in each stator slot along the radial direction of the stator core, each conductor segment comprises a middle portion located in the stator slot, two ends of the middle portion are respectively provided with a hairpin end and a welding end extending to the outer side of the stator slot, the welding end comprises a twist welding end and a lead-out wire welding end, wherein the lead-out wire welding end comprises a star point lead-out wire welding end and a three-phase lead-out wire welding end, the three-phase lead-out wire welding end is located at the outermost layer of the stator core and is connected to a three-phase copper bar, the star point lead-out wire welding end is located at the second outer layer of the stator core and is connected to a center line; the top heights of the star point lead-out wire welding end and the three-phase lead-out wire welding end are the same as the height of the twist welding end.

[0006] In the aforementioned equal-height lead-out three-branch stacked stator assembly, the center line and the three-phase copper bar are circumferentially arranged on the outside of the stator winding and are respectively connected to the star point lead-out wire welding end and the three-phase lead-out wire welding end, and the center line is radially arranged on the inside of the three-phase copper bar and is staggered with the center line along the circumferential direction.

[0007] In the aforementioned equal-height lead-out three-branch stacked stator assembly, a bending foot is provided at the connection between the three-phase lead wire welding end and the three-phase copper busbar. The bending foot extends radially outward along the stator core, and the end of the bending foot extends from below the center line to the outside and connects to the three-phase copper busbar.

[0008] In the aforementioned equal-height lead-out three-branch stacked stator assembly, the conductor segment is a U-shaped conductor segment, and the U-shaped conductor segment forms two welding ends on the side away from the hairpin end, one of the welding ends of the U-shaped conductor segment is a twisted head welding end, and the other welding end of the U-shaped conductor segment is a twisted head welding end or a lead wire welding end.

[0009] In the aforementioned equal-height lead-out three-branch stacked-wound stator assembly, the stator winding is composed of a three-phase winding structure, and each phase winding structure is composed of three winding branches.

[0010] In the aforementioned equal-height lead-out three-branch stacked winding stator assembly, the starting and ending points of the three winding branches during winding are arranged in three consecutive adjacent stator slots.

[0011] In the aforementioned equal-height lead-out three-branch stacked stator assembly, the shape of the center line is arc-shaped, the middle width of the center line is greater than the width at both ends, and the center line is provided with multiple welding feet that cooperate with the star point lead-out wire welding ends. The circumferential span of the center line on the stator core is the maximum circumferential span of each star point lead-out wire welding end on the stator core.

[0012] A motor comprises an equal-height lead-out three-branch stacked stator assembly as described in any one of the above.

[0013] Compared with the prior art, the present invention has the following characteristics:

[0014] (1) The present invention enables the hairpin end and the welding end to be located at the upper and lower sides of the stator slot respectively, so that each welding end can be welded once after clamping and directly coated with insulation, which effectively reduces the processing difficulty of the present invention. At the same time, the structure can also reduce the electrical clearance of the hairpin end of the stator winding, thereby reducing the axial space occupied by the hairpin end;

[0015] (2) The present invention locates the star point lead wire welding end and the three-phase lead wire welding end in the second outer layer and the outermost layer of the stator core respectively, so that the center line and the three-phase copper bar can be arranged side by side in the radial direction of the stator core when connected, and staggered and partially overlapped in the circumferential direction of the stator core, thereby effectively reducing the span of the center line and the three-phase copper bar in the circumferential direction and reducing the space occupied by the motor in the radial direction;

[0016] (3) By optimizing the distribution structure and appearance of the twist welding end and the lead wire welding end, the three-phase lead wire welding end does not need to be twisted together with other twist welding ends when arranged. On the one hand, it can promote the circumferential dislocation structure of the center line and the three-phase copper bar. On the other hand, the bending foot can form a placement space that matches the center line, thereby avoiding mutual interference between the center line and the three-phase lead wire welding end, so that the center line is welded in the same way as the outermost welding end during welding, and the placement position can be at the same height as the three-phase copper bar; at the same time, under the above-mentioned coordination, the present invention can make the placement position of the center line at the outermost layer of the stator slot, and the placement position of the three-phase copper bar at the outer side of the stator slot, and the two will not interfere with each other with the adjacent twist welding end, so that their welding position can maintain the same height as the welding position of the twist welding end, avoiding the extension of the lead wire welding end in the height direction, so that the shell height of the motor can be shortened by 15 to 30 mm compared with the existing structure, greatly improving the applicability of the motor and reducing its structural cost;

[0017] (4) By placing the center line at the outermost layer of the stator slot, the radial length increase caused by the center line and the three-phase copper bar being superimposed can be avoided. That is, the center line makes full use of the gap formed by the welding end of the three-phase lead wire and the welding end of the adjacent twist head after radial bending. That is, it does not occupy the height space of the stator assembly, nor does it occupy the radial space of the stator assembly, and gives up the corresponding welding space, further reducing the occupied space and processing difficulty of the present invention;

[0018] (5) The present invention can realize the wiring of the stator winding through the U-shaped conductor segment, while reducing the number of line types and processing difficulty of the U-shaped conductor segment, thereby reducing the winding complexity and processing and assembly difficulty of the stator winding;

[0019] Therefore, the present invention has the characteristics of simple winding structure, convenient processing and small occupied space. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 It is a schematic diagram of the structure of the present invention;

[0021] Figure 2 is a schematic diagram of the distribution of conductor segments in the stator slots;

[0022] Figure 3 It is a connection diagram of the welding end of the star point lead wire and the center line;

[0023] Figure 4 This is a connection diagram of the three-phase lead-out wire welding end and the three-phase copper busbar;

[0024] Figure 5 It is the distribution structure diagram of three-phase copper busbar and center line;

[0025] Figure 6 is an outline diagram of a conductor segment with three-phase lead wire welding ends located in the first layer of stator slots in an embodiment;

[0026] Figure 7 is an outline diagram of other conductor segments located in the first layer of stator slots in the embodiment;

[0027] Figure 8 is an outline diagram of the conductor segments located at the second to fifth layers of the stator slots in the embodiment;

[0028] Fig. 9 is an outline diagram of a conductor segment located at the sixth layer of stator slots in the embodiment;

[0029] Fig.10 A schematic diagram of the development of a three-phase stator winding in an embodiment;

[0030] Fig.11 1 is a schematic diagram of the connection of the first branch winding of the V phase in the embodiment;

[0031] Fig.12 is a schematic diagram of the connection of the second branch winding of the V phase in the embodiment;

[0032] Fig.13 Schematic diagram of the connection of the third branch winding of the V phase in the embodiment.

[0033] The markings in the attached figure are: 1- stator core, 2- stator slot, 3- conductor segment, 4- hairpin end, 5- twist welding end, 6- star point lead wire welding end, 7- three-phase lead wire welding end, 8- three-phase copper busbar, 9- center line, 10- bending foot. DETAILED DESCRIPTION

[0034] The present invention is further described below in conjunction with the accompanying drawings and embodiments, but they are not intended to limit the present invention.

[0035] Embodiment. A three-branch stacked stator assembly with equal height lead-out structure is as follows Figure 1-5 As shown, it includes a stator core 1, 72 stator slots 2 are distributed along the circumferential direction on the inner side of the stator core 1, the depth direction of the stator slot 2 is consistent with the radial direction of the stator core 1, and a stator winding composed of a plurality of conductor segments 3 connected to each other is arranged in the stator slot 2, and 6 layers of conductor segments 3 are arranged from the outside to the inside along the radial direction of the stator core 1 in each stator slot 2 (wherein the first layer of conductor segments 3 is located at the outermost side of the stator core 1), and each conductor segment 3 includes a middle portion located in the stator slot 2, and two ends of the middle portion are respectively provided with a conductor segment extending to the outside of the stator slot 2. The hairpin end 4 and the welding end on the side, the welding end includes a twist head welding end 5 and a lead wire welding end, wherein the lead wire welding end includes a star point lead wire welding end 6 and a three-phase lead wire welding end 7, the three-phase lead wire welding end 7 is located at the outermost layer (first layer) of the stator core 1 and is connected to a three-phase copper bus 8, the star point lead wire welding end 6 is located at the sub-outer layer (second layer) of the stator core 1 and is connected to a center line 9; the top heights of the star point lead wire welding end 6 and the three-phase lead wire welding end 7 are the same as the height of the twist head welding end 5.

[0036] The center line 9 and the three-phase copper bar 8 are circumferentially arranged on the outside of the stator winding and are respectively connected to the star point lead wire welding end 6 and the three-phase lead wire welding end 7. The center line 9 is radially arranged on the inside of the three-phase copper bar 8 and is staggered and partially overlapped with the center line 9 along the circumferential direction.

[0037] The three-phase lead wire welding end 7 is provided with a bending foot 10 at the connection with the three-phase copper busbar 8. The bending foot 10 is L-shaped. The bending foot 10 extends outward along the radial direction of the stator core 1. The end of the bending foot 10 extends from below the center line 9 to the outside and connects to the three-phase copper busbar 8.

[0038] The conductor segment 3 is a U-shaped conductor segment, and the cross-sectional shape of the U-shaped conductor segment is a rectangle. The U-shaped conductor segment forms two relatively independent welding ends on the side away from the hairpin end 4. One of the welding ends of the U-shaped conductor segment is a twist welding end 5, and the other welding end of the U-shaped conductor segment is a twist welding end 5 or a lead wire welding end.

[0039] The U-shaped conductor segments in the stator winding are formed according to the different number of layers in the stator slots. Figure 6-9As shown, it is divided into U-shaped first layer, U-shaped second and third layers spanning 10 slots, U-shaped fourth and fifth layers spanning 10 slots, and U-shaped sixth layer spanning 10 slots. Among them, the U-shaped first layer is further divided into U-shaped first layer spanning 8 slots, U-shaped first layer spanning 9 slots, U-shaped first layer spanning 10 slots, U-shaped first layer spanning 11 slots, and U-shaped first layer spanning 12 slots.

[0040] The stator winding is composed of a three-phase winding structure, each phase winding structure is composed of three winding branches, and the number of poles of the stator winding is 8.

[0041] The starting and ending points of the three winding branches during winding are arranged in three consecutive adjacent stator slots 2 .

[0042] The center line 9 is arc-shaped, the width of the middle part of the center line 9 is greater than the width of the two ends, and a plurality of welding feet are provided on the center line 9 to cooperate with the star point lead wire welding end 6. The circumferential span of the center line 9 on the stator core 1 is the maximum circumferential span of each star point lead wire welding end 6 on the stator core 1.

[0043] The connection diagram of the winding structure of this embodiment is as follows: Fig.10 As shown, taking the V-phase stacked winding as an example (U and W phases are similar to V phase and will not be repeated here):

[0044] Each branch winding of the V phase includes a winding branch formed by 24 conductor segment windings connected in series. The numbers in the brackets represent the number of layers of the conductor segment in the stator slot, and the numbers outside the brackets represent the sequence number of the stator slot where the conductor segment is located. For example: 13(2) represents the position of the 2nd layer conductor in the 13th slot.

[0045] The first branch, from Fig.11 The first branch is connected in series through the following slot numbers: 64(1)→3(1)→12(2)→3(3)→12(4)→3(5)→12(6)→21(6)→12(5)→21(4)→12(3)→21(2)→12(1)→21(1)→30(2)→21(3)→30(4)→21(5)→30(6)→39(6)→30(5)→39(4)→30(3 )→39(2)→30(1)→37(1)→46(2)→37(3)→46(4)→37(5)→46(6)→55(6)→46(5)→55(4)→46(3)→55(2)→46(1)→55(1)→64(2)→55(3)→64(4)→55(5)→64(6)→1(6)→64(5)→1(4)→64(3)→1(2).

[0046] The second branch line from Fig.12The second branch is connected in series through the following slot numbers: 65(1)→2(1)→11(2)→2(3)→11(4)→2(5)→11(6)→20(6)→11(5)→20(4)→11(3)→20(2)→11(1)→19(1)→28(2)→19(3)→28(4)→19(5)→28(6)→37(6)→28(5)→37(4)→28(3 )→37(2)→28(1)→39(1)→48(2)→39(3)→48(4)→39(5)→48(6)→57(6)→48(5)→57(4)→48(3)→57(2)→48(1)→56(1)→65(2)→56(3)→65(4)→56(5)→65(6)→2(6)→65(5)→2(4)→65(3)→2(2).

[0047] The third branch line Fig.13 The third branch is connected in series through the following slot numbers: 66(1)→1(1)→10(2)→1(3)→10(4)→1(5)→10(6)→19(6)→10(5)→19(4)→10(3)→19(2)→10(1)→20(1)→29(2)→20(3)→29(4)→20(5)→29(6)→38(6)→29(5)→38(4)→29(3 )→38(2)→29(1)→38(1)→47(2)→38(3)→47(4)→38(5)→47(6)→56(6)→47(5)→56(4)→47(3)→56(2)→47(1)→57(1)→66(2)→57(3)→66(4)→57(5)→66(6)→3(6)→66(5)→3(4)→66(3)→3(2).

[0048] The starting and ending slot numbers corresponding to the three branches are distributed as follows: V1 corresponds to 64 (1), Y1 corresponds to 1 (2); V2 corresponds to 65 (1), Y2 corresponds to 2 (2); V3 corresponds to 66 (1), Y3 corresponds to 3 (2); V1, V2 and V3 are connected in parallel, Y1, Y2 and Y3 are connected in parallel, and finally connected through a common busbar to form a complete V-phase winding.

[0049] The remaining U and W phase windings are symmetrically and evenly distributed on the circumference and are not explained here.

[0050] A motor comprises an equal-height lead-out three-branch stacked stator assembly as described in any one of the above.

[0051] Working principle of the present invention: When the stator winding of the present invention is wound, its star point lead wire welding end 6 and the three-phase lead wire welding end 7 are respectively located at the sub-outer layer and the outermost layer of the stator slot 2, and the two are arranged in a mutually staggered manner in the circumferential direction, so that the center line 9 and the three-phase copper bar 8 can be arranged side by side in the outermost layer and the outer side of the stator slot 2 after being connected, effectively reducing the space occupied by the stator assembly in the radial direction. When welding, the three-phase lead wire welding end 7 can form a spacing space for placing the center line 9 between it and the twist welding end 5 of the conductor segments 3 on both sides through the radially outward bending feet 10, so that the height of the welding position of the center line 9 after placement can be the same as the welding height of the twist welding end 5, effectively shortening the overall height of the stator assembly, improving the applicability of the motor and reducing its production cost.

[0052] On the basis of the above features, the present invention further optimizes the shape and routing structure of the conductor segment 3, so that the conductor segments 3 in the stator winding can all be connected by U-shaped conductor segments, and the number of linear types of the U-shaped conductor segments and the corresponding processing difficulty are reduced, thereby further facilitating the manufacturer's processing and wiring.

Claims

1. An equal-height lead-out three-branch stacked stator assembly, characterized in that: The invention comprises a stator core (1), wherein 72 stator slots (2) are distributed along the circumferential direction on the inner side of the stator core (1), and a stator winding formed by a plurality of conductor segments (3) connected to each other is arranged in the stator slot (2), and six layers of conductor segments (3) are arranged in the radial direction of the stator core (1) in each stator slot (2), and each conductor segment (3) comprises a middle portion located in the stator slot (2), and two ends of the middle portion are respectively provided with a hairpin end (4) extending to the outer side of the stator slot (2) and a welding end, and the welding end comprises a twist welding end. The lead wire welding end (5) and the lead wire welding end, wherein the lead wire welding end includes a star point lead wire welding end (6) and a three-phase lead wire welding end (7), the three-phase lead wire welding end (7) is located at the outermost layer of the stator core (1) and is connected to a three-phase copper bar (8), and the star point lead wire welding end (6) is located at the second outer layer of the stator core (1) and is connected to a center line (9); the top heights of the star point lead wire welding end (6) and the three-phase lead wire welding end (7) are the same as the height of the twist head welding end (5); The center line (9) and the three-phase copper bar (8) are arranged circumferentially on the outside of the stator winding and are respectively connected to the star point lead wire welding end (6) and the three-phase lead wire welding end (7); the center line (9) is arranged radially on the inside of the three-phase copper bar (8) and is arranged circumferentially in an alternating manner with the center line (9); The stator winding is composed of a three-phase winding structure, and each phase winding structure is composed of three winding branches; The starting and ending points of the three winding branches during winding are arranged in three consecutive adjacent stator slots (2).

2. According to claim 1, a three-branch stacked stator assembly with equal height lead-out is characterized in that: The three-phase lead wire welding end (7) is provided with a bending foot (10) at the connection with the three-phase copper bar (8), the bending foot (10) extending outwardly in the radial direction of the stator core (1), and the end of the bending foot (10) extends from below the center line (9) to the outside and is connected to the three-phase copper bar (8).

3. The equal-height lead-out three-branch stacked stator assembly according to claim 1, characterized in that: The conductor segment (3) is a U-shaped conductor segment, and the U-shaped conductor segment forms two welding ends on a side away from the hairpin end (4), one welding end of the U-shaped conductor segment is a twist welding end (5), and the other welding end of the U-shaped conductor segment is a twist welding end (5) or a lead wire welding end.

4. The equal-height lead-out three-branch stacked stator assembly according to claim 1, characterized in that: The center line (9) has an arc shape, the width of the center line (9) in the middle is greater than the width of the two ends, a plurality of welding feet are provided on the center line (9) for cooperating with the star point lead wire welding ends (6), and the circumferential span of the center line (9) on the stator core (1) is the maximum circumferential span of each star point lead wire welding end (6) on the stator core (1).

5. A motor, characterized in that: The motor comprises an equal-height lead-out three-branch stacked stator assembly as described in claim 1, 2, 3 or 4.

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