Stator assembly and winding method thereof, and dual-rotor motor

Abstract

The present application provides a stator assembly and a winding method thereof, and a dual-rotor motor. The stator assembly comprises a stator core (1) and a stator winding, wherein the stator core (1) comprises an inner stator slot (2), an inner stator tooth (3), a stator yoke (4), an outer stator slot (5) and an outer stator tooth (6), and the stator winding comprises an inner winding (7) embedded in the inner stator slot (2) and an outer winding (8) embedded in the outer stator slot (5). According to the stator assembly of the present application, the winding utilization rate can be improved, and the output torque and power density of the motor can be improved.

Description

Technical Field

[0001] The present application relates to the field of motor technology, and in particular to a stator assembly and a winding method thereof, and a dual-rotor motor. Background Art

[0002] As the country vigorously promotes industrial upgrading, the motor field will continue to develop towards high speed and miniaturization. As a result, the power density and loss density of the motor will continue to rise, and the heat generation of the motor winding, especially the end winding, will further increase.

[0003] The back-wound winding method can effectively reduce the size of the motor winding ends, especially the output end, and the end resistance becomes smaller, and its heat generation can be effectively reduced. However, under the same number of turns, the back-wound winding requires a larger stator slot space. In order to ensure that the motor magnetic field distribution is not over-saturated and the output torque remains unchanged at the same current, the motor stator core size will become larger and the motor power density will decrease. Summary of the invention

[0004] Therefore, the technical problem to be solved by the present application is to provide a stator assembly and a winding method thereof, and a dual-rotor motor, which can improve the winding utilization rate and increase the output torque and power density of the motor.

[0005] In order to solve the above problems, the present application provides a stator assembly, including a stator core and a stator winding, the stator core includes inner stator slots, inner stator teeth, a stator yoke, outer stator slots and outer stator teeth, the stator winding includes an inner winding embedded in the inner stator slots and an outer winding embedded in the outer stator slots.

[0006] Preferably, the inner diameter of the stator core is R2, the outer diameter is R1, the inner diameter of the stator yoke is R4, the outer diameter is R3, the inner slot width of the inner stator slot is L, the cross-sectional area of ​​a single inner stator slot is S, the inner diameter size coefficient of the stator yoke is λ1, and the outer diameter size coefficient of the stator yoke is λ2, wherein:

[0007]

[0008]

[0009] 1.7≤λ1≤2.2, 0.34≤λ2≤0.61.

[0010] Preferably, the radial depth of the inner stator slot is more than twice the radial depth of the outer stator slot.

[0011] Preferably, in a cross section perpendicular to the central axis of the stator core, a side edge of the outer stator slot is located on an extension line of a side edge of the inner stator slot on the side.

[0012] Preferably, the cross-sectional area of ​​a single inner stator slot is S, the cross-sectional area of ​​a single outer stator slot is S1, and S<S1.

[0013] Preferably, 0.7≤S / S1≤0.9.

[0014] According to one aspect of the present application, a dual-rotor motor is provided, including a stator assembly, which is the stator assembly described above.

[0015] Preferably, the dual-rotor motor further comprises a first rotor and a second rotor, the first rotor being located on the inner circumference side of the inner stator teeth, and the second rotor being located on the outer circumference side of the outer stator teeth.

[0016] Preferably, the first rotor is an embedded or surface-mounted magnetic steel structure, the first rotor outer sleeve is provided with a first sleeve, and the first sleeve is made of non-magnetic material; and / or, the second rotor is an embedded or surface-mounted magnetic steel structure, the second rotor inner sleeve is provided with a second sleeve, and the second sleeve is made of non-magnetic material.

[0017] According to one aspect of the present application, a winding method for the stator assembly is provided, comprising:

[0018] Winding the stator core so that a single coil is wound in radially corresponding inner and outer stator slots at the same time;

[0019] The coils are wound in phases to form inner windings embedded in the inner stator slots and outer windings embedded in the outer stator slots.

[0020] Preferably, the winding sequence of the coil winding by phase is A+→C-→B+→A-→C+→B-, first completing the winding of the A+ phase, then completing the winding of the C- phase, and so on.

[0021] Preferably, the winding process of the A+ phase is as follows:

[0022] One end of the winding is inserted into the front side of the No. 1 inner stator slot at the edge of the A+ phase, and after crossing the stator yoke, enters the No. 1 outer stator slot corresponding to the inner stator slot from the back side;

[0023] After completing the winding of the No. 1 inner stator slot and the No. 1 outer stator slot, the winding is made to obliquely cross the stator yoke and enter the No. 2 inner stator slot adjacent to the No. 1 inner stator slot from the front to wind the coils of the No. 2 inner stator slot and the No. 2 outer stator slot; thereafter, it enters the other stator slots in turn to complete the A+ phase winding offline.

[0024] The stator assembly provided in the present application includes a stator core and a stator winding, wherein the stator core includes an inner stator slot, an inner stator tooth, a stator yoke, an outer stator slot and an outer stator tooth, and the stator winding includes an inner winding embedded in the inner stator slot and an outer winding embedded in the outer stator slot. The stator winding of the stator assembly includes an inner winding embedded in the inner stator slot and an outer winding embedded in the outer stator slot, and the same coil is wound in the inner stator slot and the outer stator slot at the same time, so that the stator magnetic field formed by the inner winding located in the inner stator slot and the rotor magnetic field inside the inner stator slot can interact to generate electromagnetic torque, and at the same time, the stator magnetic field formed by the outer winding located in the outer stator slot and the rotor magnetic field outside the outer stator slot can interact to generate electromagnetic torque, so that both the inner winding and the outer winding can be fully utilized, the utilization rate of the stator winding can be improved, and the output torque, power and power density of the motor can be improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 This is a schematic diagram of the structure of a dual-rotor motor according to an embodiment of the present application;

[0026] Figure 2 This is a schematic structural diagram of a stator assembly of a dual-rotor motor according to an embodiment of the present application;

[0027] Figure 3 A schematic diagram of the winding structure of the stator core of a dual-rotor motor according to an embodiment of the present application;

[0028] Figure 4 This is a parallel magnetic circuit structure diagram of a dual-rotor motor according to an embodiment of the present application;

[0029] Figure 5 A comparison diagram of output torques of a single-rotor back-wound winding motor in the prior art and a dual-rotor back-wound winding motor of the present application;

[0030] Figure 6 A diagram showing the relationship between the dimensions of the stator core of a dual-rotor motor according to an embodiment of the present application;

[0031] Figure 7 This is a flow chart of a winding method for a stator assembly of a dual-rotor motor according to an embodiment of the present application.

[0032] The reference numerals are:

[0033] 1. Stator core; 2. Inner stator slots; 3. Inner stator teeth; 4. Stator yoke; 5. Outer stator slots; 6. Outer stator teeth; 7. Inner winding; 8. Outer winding; 9. First rotor; 10. Second rotor; 11. First sheath; 12. Second sheath. DETAILED DESCRIPTION

[0034] See also Figures 1 to 6 As shown, according to an embodiment of the present application, the stator assembly includes a stator core 1 and a stator winding, the stator core 1 includes an inner stator slot 2, an inner stator tooth 3, a stator yoke 4, an outer stator slot 5 and an outer stator tooth 6, and the stator winding includes an inner winding 7 embedded in the inner stator slot 2 and an outer winding 8 embedded in the outer stator slot 5.

[0035] The stator winding of the stator assembly includes an inner winding 7 embedded in the inner stator slot 2 and an outer winding 8 embedded in the outer stator slot 5, and the same coil is wound in the inner stator slot 2 and the outer stator slot 5 at the same time, and the inner stator slot 2 is formed between two adjacent inner stator teeth 3, and the outer stator slot 5 is formed between two adjacent outer stator teeth 6. Therefore, the stator magnetic field formed by the inner winding 7 located in the inner stator slot 2 can interact with the rotor magnetic field inside the inner stator slot 2 to generate electromagnetic torque, and at the same time, the stator magnetic field formed by the outer winding 8 located in the outer stator slot 5 can interact with the rotor magnetic field outside the outer stator slot 5 to generate electromagnetic torque, so that both the inner winding 7 and the outer winding 8 can be fully utilized, which can improve the utilization rate of the stator winding, thereby improving the output torque, power and power density of the motor, and can also effectively reduce the end temperature of the motor winding.

[0036] In one embodiment, the inner diameter of the stator core 1 is R2, the outer diameter is R1, the inner diameter of the stator yoke 4 is R4, the outer diameter is R3, the inner slot width of the inner stator slot 2 is L, the cross-sectional area of ​​a single inner stator slot 2 is S, the inner diameter size coefficient of the stator yoke 4 is λ1, and the outer diameter size coefficient of the stator yoke 4 is λ2, wherein:

[0037]

[0038]

[0039] 1.7≤λ1≤2.2, 0.34≤λ2≤0.61.

[0040] In this embodiment, after R1 and R2 are determined, the inner diameter R4 and the outer diameter R3 of the stator yoke 4 can be determined by the inner slot width of the inner stator slot 2. Therefore, in the design process of the stator core 1, the inner slot width L can be associated with the inner diameter R4 and the outer diameter R3 of the stator yoke 4. When the cross-sectional area S of a single inner stator slot 2 is constant, by adjusting the inner slot width L of the inner stator slot 2, the values ​​of R3 and R4 can be adjusted accordingly, so that the inner stator slot 2 has a good slot fill rate, and at the same time, the area of ​​the stator yoke can be guaranteed, so that the inner winding 7 and the outer winding 8 can have sufficient magnetic line flow area to avoid the magnetic circuit oversaturation phenomenon, and at the same time, it can also effectively improve the power density and the output torque of the motor.

[0041] In one embodiment, the radial depth of the inner stator slot 2 is more than twice the radial depth of the outer stator slot 5, which can increase the depth of the inner stator slot 2 and reduce the inner slot width L, thereby further improving the slot fill rate and improving the copper wire utilization rate.

[0042] In one embodiment, on a cross section perpendicular to the central axis of the stator core 1, the side of the outer stator slot 5 is located on the extension line of the side of the inner stator slot 2 on that side, so that there is a better structural correspondence between the inner stator slot 2 and the outer stator slot 5, which can reduce the design difficulty of the inner stator slot 2 and the outer stator slot 5, and it is easier to determine the structural dimensions of the outer stator slot 5 according to the structural dimensions of the inner stator slot 2, thereby improving the design efficiency.

[0043] In one embodiment, the cross-sectional area of ​​a single inner stator slot 2 is S, and the cross-sectional area of ​​a single outer stator slot 5 is S1, where S<S1.

[0044] In one embodiment, 0.7≤S / S1≤0.9.

[0045] The stator core is made of magnetic conductive material, such as silicon steel sheet, amorphous alloy or soft magnetic material.

[0046] See also Figures 1 to 5 As shown, according to an embodiment of the present application, the dual-rotor motor includes a stator assembly, which is the stator assembly mentioned above.

[0047] The dual-rotor motor further includes a first rotor 9 and a second rotor 10 . The first rotor 9 is located on the inner circumference side of the inner stator teeth 3 , and the second rotor 10 is located on the outer circumference side of the outer stator teeth 6 .

[0048] The first rotor 9 is an embedded or surface mounted magnetic steel structure, specifically a solid structure or an annular structure, and a first sheath 11 is disposed outside the first rotor 9, and the first sheath 11 is made of a non-magnetic material. The first rotor 9 can be an axial segmented structure or a circumferential block structure, and the first sheath 11 is, for example, stainless steel or a high-strength alloy material or carbon fiber.

[0049] The second rotor 10 is an embedded or surface mounted magnetic steel structure, specifically a solid structure or an annular structure, and a second sheath 12 is provided inside the second rotor 10, and the second sheath 12 is made of a non-magnetic material. The second rotor 10 can be an axial segmented structure or a circumferential block structure, and the second sheath 12 is, for example, stainless steel or a high-strength alloy material or carbon fiber.

[0050] The first rotor 9 and the first sleeve 11 are interference fit, and the specific interference amount is determined by the motor speed. The second rotor 10 and the second sleeve 12 are also interference fit, and the interference amount is determined by the motor speed.

[0051] See also Figure 4 As shown, in the embodiment of the present application, the dual-rotor motor adopts a back-wound winding structure, so that the inner winding 7 can cooperate with the first rotor 9 to form a magnetic circuit structure, so that the stator magnetic field generated by the inner winding 7 interacts with the rotor magnetic field generated by the first rotor 9 to generate an electromagnetic torque, and the outer winding 8 can cooperate with the second rotor 10 to form a magnetic circuit structure, so that the stator magnetic field generated by the outer winding 8 interacts with the rotor magnetic field generated by the second rotor 10 to generate an electromagnetic torque, so that the inner winding 7 and the outer winding 8 of the back-wound winding can be fully utilized, thereby improving the output torque, power and power density of the motor.

[0052] See also Figure 5 As shown in FIG. 1 , the output torque of the single inner rotor back-wound winding motor in the prior art and the double rotor back-wound winding motor in the embodiment of the present application under the same current is given. Figure 5 It can be clearly seen that after adopting the dual-rotor motor of the embodiment of the present application, the output torque is increased by 208% compared with the single-rotor motor in the prior art, and the motor power density is also increased by 208% at the same speed, which is a huge improvement in the motor power density.

[0053] See also Figure 7 As shown, according to an embodiment of the present application, the winding method of the above-mentioned stator assembly includes: winding the stator core 1 so that a single coil is simultaneously wound in the radially corresponding inner stator slots 2 and outer stator slots 5; winding the coils according to phases to form an inner winding 7 embedded in the inner stator slots 2 and an outer winding 8 embedded in the outer stator slots 5.

[0054] The winding sequence of the coil by phase is A+→C-→B+→A-→C+→B-. The winding of the A+ phase is completed first, and then the winding of the C- phase is completed, and so on.

[0055] See also Figure 3 As shown, the winding process of the A+ phase is as follows: one end of the winding is embedded from the front of the No. 1 inner stator slot ① on the edge of one side of the A+ phase, and enters the No. 1 outer stator slot ② corresponding to the inner stator slot from the back after crossing the stator yoke; after completing the winding of the No. 1 inner stator slot ① and the No. 1 outer stator slot ②, the winding is made to cross the stator yoke 4 obliquely, and then enter the No. 2 inner stator slot ③ adjacent to the No. 1 inner stator slot ① from the front, and the coils of the No. 2 inner stator slot ③ and the No. 2 outer stator slot ④ are wound; thereafter, it enters the stator slots ⑤, ⑥, ⑦, and ⑧ in sequence to complete the winding of the A+ phase. The winding method of the other phase windings is consistent with that of the A+ phase, thus completing the winding of the back-wound winding.

[0056] The front face here refers to the end face of the winding entry side of the No. 1 inner stator slot, and the oblique crossing from the No. 1 stator slot to the No. 2 stator slot refers to crossing the end face of the stator yoke 4 from the front face of the No. 1 outer stator slot, and entering the No. 2 inner stator slot from the front face for winding.

[0057] The stator assembly winding method of the present application adopts a single set of windings to simultaneously wind the inner winding 7 and the outer winding 8, thereby realizing the winding of the back-wound winding, which has a simple structure and is convenient to wind, and can improve the winding efficiency. At the same time, it can effectively reduce the winding waste and improve the winding utilization rate.

[0058] It is easy for those skilled in the art to understand that, under the premise of no conflict, the above-mentioned advantageous methods can be freely combined and superimposed.

[0059] The above are only preferred embodiments of the present application and are not intended to limit the present application. Any modifications, equivalent replacements and improvements made within the spirit and principles of the present application shall be included in the protection scope of the present application. The above are only preferred implementations of the present application. It should be pointed out that for ordinary technicians in this technical field, several improvements and variations can be made without departing from the technical principles of the present application, and these improvements and variations should also be regarded as the protection scope of the present application.

Claims

1. A stator assembly, characterized in that it comprises a stator core (1) and a stator winding, wherein the stator core (1) comprises inner stator slots (2), inner stator teeth (3), a stator yoke (4), outer stator slots (5) and outer stator teeth (6), and the stator winding comprises an inner winding (7) embedded in the inner stator slots (2) and an outer winding (8) embedded in the outer stator slots (5); The inner diameter of the stator core (1) is R2, and the outer diameter is R1; the inner diameter of the stator yoke (4) is R4, and the outer diameter is R3; the inner slot width of the inner stator slot (2) is L; the cross-sectional area of ​​a single inner stator slot (2) is S; the inner diameter dimension coefficient of the stator yoke (4) is λ1; and the outer diameter dimension coefficient of the stator yoke (4) is λ2, wherein: 1.7≤λ1≤2.2, 0.34≤λ2≤0.

61.

2. The stator assembly according to claim 1, characterized in that: The radial depth of the inner stator slot (2) is more than twice the radial depth of the outer stator slot (5).

3. The stator assembly according to claim 1, characterized in that: In a cross section perpendicular to the central axis of the stator core (1), the side edge of the outer stator slot (5) is located on an extension line of the side edge of the inner stator slot (2) on that side.

4. The stator assembly according to claim 1, characterized in that: The cross-sectional area of ​​a single inner stator slot (2) is S, and the cross-sectional area of ​​a single outer stator slot (5) is S1, where S<S1.

5. The stator assembly according to claim 4, characterized in that 0.7≤S / S1≤0.

9.

6. A dual-rotor motor, comprising a stator assembly, characterized in that: The stator assembly is the stator assembly according to any one of claims 1 to 5.

7. The dual-rotor motor according to claim 6, characterized in that: The dual-rotor motor further comprises a first rotor (9) and a second rotor (10), wherein the first rotor (9) is located on the inner circumference side of the inner stator teeth (3), and the second rotor (10) is located on the outer circumference side of the outer stator teeth (6).

8. The dual-rotor motor according to claim 7, characterized in that: The first rotor (9) is an embedded or surface-mounted magnetic steel structure, the first rotor (9) is provided with a first sleeve (11) on its outer shell, and the first sleeve (11) is made of a non-magnetic material; and / or the second rotor (10) is an embedded or surface-mounted magnetic steel structure, the second rotor (10) is provided with a second sleeve (12) on its inner shell, and the second sleeve (12) is made of a non-magnetic material.

9. A winding method for a stator assembly according to any one of claims 1 to 5, characterized in that: include: Winding the stator core (1) so that a single coil is simultaneously wound in the inner stator slot (2) and the outer stator slot (5) corresponding to each other in the radial direction; The coils are wound in phases to form inner layer windings (7) embedded in the inner stator slots (2) and outer layer windings (8) embedded in the outer stator slots (5).

10. The winding method according to claim 9, characterized in that: The winding sequence of the coil by phase is A+→C-→B+→A-→C+→B-. The winding of the A+ phase is completed first, and then the winding of the C- phase is completed, and so on.

11. The winding method according to claim 10, characterized in that: The winding process of A+ phase is as follows: One end of the winding is inserted into the front side of the No. 1 inner stator slot at the edge of the A+ phase, and after crossing the stator yoke, enters the No. 1 outer stator slot corresponding to the inner stator slot from the back side; After completing the winding of the No. 1 inner stator slot and the No. 1 outer stator slot, the winding is made to obliquely cross the stator yoke and enter the No. 2 inner stator slot adjacent to the No. 1 inner stator slot from the front to wind the coils of the No. 2 inner stator slot and the No. 2 outer stator slot; thereafter, it enters the other stator slots in turn to complete the A+ phase winding offline.

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