A stator assembly and an electric machine to which it is applied

Abstract

The present invention provides a stator assembly and a motor to which the same is applied. The stator assembly includes: a stator core having stator slots, and the stator slots include a plurality of slot layers; and a stator winding inserted into the stator slots, the stator winding including a plurality of inner-layer conductors, a plurality of middle-layer conductors, a plurality of outer-layer conductors, and a plurality of lead conductors; wherein, under one magnetic pole of a branch winding, two lead conductors are circumferentially different from an inner-layer conductor by one stator slot, and under the remaining magnetic poles of a branch winding, a straight segment portion of an outer-layer conductor is circumferentially different from a straight segment portion of an inner-layer conductor by one stator slot, and another straight segment portion of the outer-layer conductor is circumferentially different from another straight segment portion of the inner-layer conductor by one stator slot. In the present invention, there are no axially nested coils in the innermost and outermost coil groups of the winding, the manufacturing process is simple, the efficiency is high, the coil forms are few, and the production cost is low.

Description

Technical Field

[0001] The present invention relates to the field of motors, and particularly to a stator assembly and a motor to which the stator assembly is applied. Background Art

[0002] The drive motors of new energy vehicles adopting flat wire windings have the advantages of light weight, high power density, and high efficiency. Flat wire windings have gradually become the development direction of drive motors. In the prior art, the main forms of flat wire windings include Hairpin (hairpin) structure, I-pin (wire segment) structure, and continuous wave winding structure, among which Hairpin is the most common and mature structure. Hairpin often adopts wave winding and stacked winding methods. Compared with the wave winding method, the flat wire winding in the stacked winding method has a lower voltage difference between different layers in the same stator slot, is not easy to generate interlayer breakdown, and can better meet the requirements of high-voltage drive.

[0003] However, in the flat wire winding in the stacked winding method in the prior art, there are one or more axially nested coils in the same layer in the innermost or outermost coil, resulting in problems such as complex manufacturing process, low manufacturing efficiency, multiple coil forms, and high production cost of the flat wire winding. Summary of the Invention

[0004] The present invention provides a stator assembly and a motor to which the stator assembly is applied, which solve the technical problem that there are one or more axially nested coils in the same layer in the innermost or outermost coil in the prior art, and the following technical solutions are proposed.

[0005] The present invention provides a stator assembly, comprising:

[0006] A stator core having stator slots, and the stator slots include a plurality of slot layers; and

[0007] A stator winding inserted into the stator slots, and the stator winding includes a plurality of inner layer conductors, a plurality of middle layer conductors, a plurality of outer layer conductors, and a plurality of lead conductors;

[0008] In each branch of each phase winding, the inner layer conductor is connected to the middle layer conductor, the middle layer conductor is connected to the outer layer conductor, or the middle layer conductor is connected to the lead conductor. Wherein, the number of the lead conductors is two, the lead conductors include a straight segment portion, and the number of the outer layer conductors is one less than the number of the inner layer conductors; under one magnetic pole of a branch, the two lead conductors and one inner layer conductor are circumferentially different by one stator slot, and under the remaining magnetic poles of a branch, a straight segment portion of the outer layer conductor and a straight segment portion of the inner layer conductor are circumferentially different by one stator slot, and another straight segment portion of the outer layer conductor and another straight segment portion of the inner layer conductor are circumferentially different by one stator slot;

[0009] In each branch of each phase winding, the pitches of the inner conductor and the outer conductor are y1 and y3 respectively, the number of stator slots by which two circumferentially adjacent lead conductors differ circumferentially is y4, the pole pitch of the stator winding is τ, the number of stator slots by which two circumferentially adjacent inner conductors differ circumferentially is L1, the number of stator slots by which two circumferentially adjacent outer conductors differ circumferentially is L3, and the number of stator slots by which the lead conductor and the straight segment part of the outer conductor differ circumferentially is L4, satisfying: y1 = y4 = τ + 1, y3 = τ - 1, L1 = L4 = τ - 1, L3 = τ + 1, or y1 = y4 = τ - 1, y3 = τ + 1, L1 = L4 = τ + 1, L3 = τ - 1.

[0010] In an embodiment of the present invention, in each branch of each phase winding, the two straight segment parts of the middle conductor differ radially by one slot layer. Under each magnetic pole of one branch, one straight segment part of the middle conductor and one straight segment part of the inner conductor are located in the same stator slot, and the other straight segment part of the middle conductor and the other straight segment part of the inner conductor differ circumferentially by one stator slot. The pitch of the middle conductor is y2, and the number of stator slots by which two circumferentially adjacent middle conductors in the same slot layer differ circumferentially is L2, satisfying: y2 = τ, L2 = τ - 1 or L2 = τ + 1.

[0011] In an embodiment of the present invention, in each branch of each phase winding, the middle conductor occupies at least two radially slot layers. Under each magnetic pole of one branch, the middle conductors in different slot layers are located in the same stator slot circumferentially, and the radially slot layers occupied by the middle conductors located in the same stator slot circumferentially do not intersect.

[0012] In an embodiment of the present invention, in each branch of each phase winding, the straight segment parts of the middle conductors that are radially adjacent and located in the same stator slot differ radially by two slot layers.

[0013] In an embodiment of the present invention, the lead conductor and the outer conductor are located in the same circumferential slot layer.

[0014] In an embodiment of the present invention, each phase winding includes at least two branches. The winding directions of the two branches of the same phase winding are opposite, and the two branch windings are connected in series or in parallel.

[0015] In an embodiment of the present invention, the lead ends of the two branch windings of the same phase winding differ circumferentially by one stator slot. When y1 = y4 = τ + 1, y3 = τ - 1, L1 = L4 = τ - 1, L3 = τ + 1, the outlet ends of the two branch windings differ circumferentially by 2τ - 1 stator slots.

[0016] Alternatively, when y1 = y4 = τ - 1, y3 = τ + 1, L1 = L4 = τ + 1, and L3 = τ - 1, the outgoing ends of the two branch windings are circumferentially different by 2τ + 1 stator slots.

[0017] In an embodiment of the present invention, under the same magnetic pole of the same-phase winding, the inner-layer conductors of one branch are circumferentially different by one stator slot from the inner-layer conductors of the other branch.

[0018] In an embodiment of the present invention, under the same magnetic pole of the same-phase winding, the outer-layer conductors of one branch are circumferentially different by one stator slot from the outer-layer conductors of the other branch.

[0019] The present invention also provides a motor including the stator assembly described in any one of the above.

[0020] The present invention provides a stator assembly and a motor using the same. There are no axially nested coils in the innermost and outermost coil groups of the winding, the manufacturing process is simple, the efficiency is high, the coil form is few, and the production cost is low. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 It is a schematic structural diagram of a stator assembly of the present invention.

[0022] Figure 2 It is a three-dimensional schematic diagram of a phase winding in a stator assembly of the present invention.

[0023] Figure 3 For the present invention Figure 2 The enlarged view at A.

[0024] Figure 4 It is a schematic diagram of the first coil group in a stator assembly of the present invention.

[0025] Figure 5 It is a schematic diagram of the inner-layer conductors of the first coil group in a stator assembly of the present invention.

[0026] Figure 6 It is a schematic diagram of the second coil group in a stator assembly of the present invention.

[0027] Figure 7 It is a schematic diagram of the first type of middle-layer conductors of the second coil group in a stator assembly of the present invention.

[0028] Figure 8 It is a schematic diagram of the second type of middle-layer conductors of the second coil group in a stator assembly of the present invention.

[0029] Figure 9 It is a schematic diagram of the third coil group in a stator assembly of the present invention.

[0030] Figure 10Schematic diagram of the outer conductor of the third coil group in a stator assembly of the present invention.

[0031] Figure 11 Schematic diagram of the fourth coil group in a stator assembly of the present invention.

[0032] Figure 12 Schematic diagram of the lead conductor of the fourth coil group in a stator assembly of the present invention.

[0033] Figure 13 Expanded view of a branch of a phase winding in an embodiment of a stator assembly of the present invention.

[0034] Figure 14 Expanded view of another branch of a phase winding in an embodiment of a stator assembly of the present invention.

[0035] Figure 15 Wiring diagram of a branch of a phase winding in an embodiment of a stator assembly of the present invention.

[0036] Figure 16 Wiring diagram of another branch of a phase winding in an embodiment of a stator assembly of the present invention.

[0037] Figure 17 Expanded view of a branch of a phase winding in another embodiment of a stator assembly of the present invention.

[0038] Figure 18 Expanded view of another branch of a phase winding in another embodiment of a stator assembly of the present invention.

[0039] Figure 19 Wiring diagram of a branch of a phase winding in another embodiment of a stator assembly of the present invention.

[0040] Figure 20 Wiring diagram of another branch of a phase winding in another embodiment of a stator assembly of the present invention.

[0041] Figure 21 Schematic diagram of the star connection of a parallel branch of a stator winding in a stator assembly of the present invention.

[0042] Figure 22 Schematic diagram of the star connection of two parallel branches of a stator winding in a stator assembly of the present invention.

[0043] In the figure: 100, stator winding; 1001, hairpin end; 1002, welding end;

[0044] 110, first coil group; 111, inner conductor;

[0045] 120, second coil group; 121, first type of middle layer conductor; 122, second type of middle layer conductor;

[0046] 130. Third coil group; 131. Outer conductor;

[0047] 140. Fourth coil group; 141. Lead-out conductor;

[0048] 101. Head; 102. First straight section; 103. Second straight section; 104. First bending section; 105. Second bending section;

[0049] 200. Stator core. Detailed implementation mode

[0050] The following uses specific specific examples to illustrate the implementation mode of the present invention. Those skilled in the art can easily understand other advantages and functions of the present invention from the content disclosed in this specification. The present invention can also be implemented or applied through other different specific implementation modes. Various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of the present invention.

[0051] It should be noted that the drawings provided in this embodiment only illustrate the basic concept of the present invention in a schematic manner. Therefore, only the components related to the present invention are shown in the drawings, rather than being drawn according to the number, shape, and size of the components during actual implementation. The type, quantity, and ratio of each component during actual implementation can be arbitrarily changed, and the component layout type may also be more complex.

[0052] Please refer to Figures 1 - 22 , the present invention proposes a stator assembly and a motor to which it is applied, which can be applied to the fields of electric servo drive, transportation, etc. For example, the stator assembly and the motor to which it is applied in this application can be applied to electric vehicles. The invention of this application can avoid stator winding circulating current, reduce losses, solve the problem of nesting of numerous coils in the stator winding, and improve the efficiency of the motor. The following describes the present invention in detail through specific embodiments.

[0053] Embodiment 1

[0054] Please refer to Figures 1 - 16As shown, the present invention provides a stator assembly, which may include a stator winding 100 and a stator core 200. The stator winding 100 may include a plurality of phase windings that are electrically different from each other in electrical phase. For example, the stator winding 100 may include three phase windings. Each phase winding may include two branches, and the two branches may be connected in series or in parallel. The stator core 200 may be provided with a plurality of stator slots, and the stator slots may be formed on the inner wall of the stator core 200. The stator slots may be arranged along the circumferential direction of the inner wall of the stator core 200, and the stator slots may be spaced apart from each other on the stator core 200 at a predetermined stator slot interval. The upper and lower end faces of the stator core 200 may be respectively defined as a hairpin end 1001 and a welding end 1002. The stator winding 100 may be inserted into the stator core 200 from the side of the hairpin end 1001, and the stator winding 100 may be welded at the welding end 1002.

[0055] Please refer to Figure 1 As shown, in the circumferential direction of the stator core 200, the plurality of stator slots may be respectively defined as the No. 1 stator slot, the No. 2 stator slot, the No. 3 stator slot, the No. 4 stator slot, and so on. For example, 48 stator slots may be arranged along the circumferential direction of the stator core 200. Among them, each stator slot may be provided with a plurality of slot layers, and each stator slot may be provided with an even number of slot layers. For example, each stator slot may be provided with 6 slot layers. For example, the 6 slot layers may be successively the first layer slot layer, the second layer slot layer, the third layer slot layer, the fourth layer slot layer, the fifth layer slot layer, and the sixth layer slot layer in the direction from the inside to the outside along the radial direction of the stator core 200, that is, the first layer slot layer may be located on the side close to the stator slot opening, and the sixth layer slot layer may be located on the side close to the stator slot bottom. In addition, the specific numbering of the slot layers of each stator slot is not limited. In the embodiments of the present invention, the slot layers are arranged in the order of 1 to 6 from the inside to the outside. In some other embodiments, they may also be arranged in the order of 1 to 6 from the outside to the inside.

[0056] Please refer to Figures 2 - 12As shown, the stator winding 100 may include a plurality of inner-layer conductors 111, a plurality of middle-layer conductors, a plurality of outer-layer conductors 131, and a plurality of lead conductors 141. Along the radial direction from the stator slot opening to the stator slot bottom, the inner-layer conductors 111, the middle-layer conductors, and the outer-layer conductors 131 may be arranged. Among them, the plurality of inner-layer conductors 111 may form a first coil group 110, and the first coil group 110 may be located in the stator slot of the stator core 200, and the first coil group 110 may be located on the side close to the stator slot opening. The plurality of middle-layer conductors may form a second coil group 120, and the second coil group 120 may be located in the stator slot of the stator core 200, and the second coil group 120 may be located between the first coil group 110 and the third coil group 130. The plurality of outer-layer conductors 131 may form a third coil group 130, and the third coil group 130 may be located in the stator slot of the stator core 200, and the third coil group 130 may be located on the side close to the stator slot bottom. The plurality of lead conductors 141 may form a fourth coil group 140, and the fourth coil group 140 may be located in the stator slot of the stator core 200, and the fourth coil group 140 may be located on the side close to the stator slot bottom.

[0057] Please refer to Figures 4 - 10 As shown, the inner-layer conductor 111, the middle-layer conductor, and the outer-layer conductor 131 may include a head, two straight-segment parts, and two bent parts. Among them, one end of each of the two straight-segment parts is connected to the head. After the two straight-segment parts pass through the stator slot of the stator core 200, they turn their heads at the welding end 1002 to form two bent parts. Among the inner-layer conductor 111, the middle-layer conductor, and the outer-layer conductor 131, the bent parts of different conductors may be connected by welding, so as to form a complete branch. The two bent parts of the inner-layer conductor 111, the middle-layer conductor, and the outer-layer conductor 131 extend the same distance along one side of the welding end 1002 of the stator core 200, and may be equal to half of the pole pitch. For example, the inner-layer conductor 111, the middle-layer conductor, and the outer-layer conductor 131 may include a head 101, a first straight-segment part 102, a second straight-segment part 103, a first bent part 104, and a second bent part 105. Among them, the first straight-segment part 102 and the second straight-segment part 103 may be used to be inserted into the stator slot, and the first straight-segment part 102 and the second straight-segment part 103 may be inserted into different stator slots. One end of the first straight-segment part 102 may be connected to the first bent part 104, and one end of the second straight-segment part 103 may be connected to the second bent part 105. The other end of the first straight-segment part 102 and the other end of the second straight-segment part 103 may be connected to the head 101. In each branch of each phase winding, the two straight-segment parts of the middle-layer conductor may be radially different by one layer of slot layers. In each branch of each phase winding, the two straight-segment parts of the inner-layer conductor 111 may be located in the same circumferential slot layer. In each branch of each phase winding, the two straight-segment parts of the outer-layer conductor 131 may be located in the same circumferential slot layer. Among them, the first coil group 110 and the third coil group 130 may be wave windings.

[0058] Please refer to Figures 6 - 8 As shown, the number of radial slot layers of the third coil group 130 occupying the stator core 200 is not limited, and the number of radial slot layers of the third coil group 130 occupying the stator core 200 can be an even number of layers. For example, the number of radial slot layers of the third coil group 130 occupying the stator core 200 can be four layers, that is, the third coil group 130 can be composed of two middle-layer conductors. Since the stator core 200 is in the shape of a hollow circular cylinder, for the middle-layer conductors with the same pitch, the size of the middle-layer conductor near the center of the circle is smaller, and the size of the middle-layer conductor far from the center of the circle is larger. The middle-layer conductor near the center of the circle can be defined as the middle-layer first-class conductor 121, and the middle-layer conductor far from the center of the circle can be defined as the middle-layer second-class conductor 122. The pitches of the middle-layer first-class conductor 121 and the middle-layer second-class conductor 122 can be the same. In each branch of each phase winding, the circumferential stator slots occupied by the middle-layer first-class conductor 121 and the middle-layer second-class conductor 122 can be the same, that is, the first straight section 102 of the middle-layer first-class conductor 121 and the first straight section 102 of the middle-layer second-class conductor 122 are located in the same circumferential stator slot, and the second straight section 103 of the middle-layer first-class conductor 121 and the second straight section 103 of the middle-layer second-class conductor 122 are located in the same circumferential stator slot. Among them, the symmetry axes of the middle-layer first-class conductor 121 and the middle-layer second-class conductor 122 can be the same, that is, the third coil group 130 can be an overlapping coil group.

[0059] Please refer to Figures 4 - 10 As shown, the first bending part 104 and the second bending part 105 in the inner conductor 111 can extend in the same direction. For example, the extending directions of the plurality of first bending parts 104 and the plurality of second bending parts 105 can be along the clockwise direction or the counterclockwise direction. The first bending part 104 and the second bending part 105 in the middle-layer conductor can be close to each other, and the first bending part 104 and the second bending part 105 in the middle-layer conductor can extend in opposite directions. For example, the extending direction of the plurality of first bending parts 104 can be along the clockwise direction or the counterclockwise direction, and the extending directions of the plurality of second bending parts 105 are opposite. The first bending part 104 and the second bending part 105 in the outer conductor 131 can extend in the same direction. For example, the extending directions of the plurality of first bending parts 104 and the plurality of second bending parts 105 can be along the clockwise direction or the counterclockwise direction. Among them, the extending directions of the two bending parts of the inner conductor 111, the middle-layer conductor, and the outer conductor 131 are not specifically limited and must satisfy as Figures 12 - 16 the wiring circuit diagram shown.

[0060] Please refer to Figures 11 - 12As shown, the lead conductor 141 may include a head, a straight segment portion, and a bent portion. For example, the lead conductor 141 may include a head 101, a first straight segment portion 102, and a first bent portion 104. Among them, the first straight segment portion 102 may be used to insert into the stator slot. One end of the first straight segment portion 102 may be connected to the first bent portion 104, and the other end of the first straight segment portion 102 may be connected to the head 101. The first bent portions 104 of multiple lead conductors 141 may extend in the same direction, for example, along the clockwise direction or the counterclockwise direction. Each phase winding may include two branches. In each branch of each phase winding, the number of lead conductors 141 may be two. The stator slots between two circumferentially adjacent lead conductors 141 may be y4, y4 = τ + 1. The stator slots between a circumferentially adjacent lead conductor 141 and the straight segment portion of the outer conductor 131 may be L4, L4 = τ - 1, where τ is the pole pitch of the stator winding 100. The two lead conductors 141 may be used as the lead end and the outgoing end of each branch respectively. The stator slots where the bent portion of the lead conductor 141 extends along the side of the welding end 1002 of the stator core 200 may be equal to half of the pole pitch.

[0061] Please refer to Figures 13 - 16 As shown, in each branch of each phase winding, the number of outer conductors 131 is one less than the number of inner conductors 111. Under one pole of a branch, the first straight segment portion 102 of the inner conductor 111 and a lead conductor 141 are circumferentially different by one stator slot, and the second straight segment portion 103 of the inner conductor 111 and another lead conductor 141 are circumferentially different by one stator slot. Under the remaining poles of a branch, the first straight segment portion 102 of the outer conductor 131 may be circumferentially different by one stator slot from the first straight segment portion 102 of the inner conductor 111, and the second straight segment portion 103 of the outer conductor 131 may be circumferentially different by one stator slot from the second straight segment portion 103 of the inner conductor 111. In each branch of each phase winding, the two straight segment portions of multiple middle conductors may be located in two slot layers with a radial difference. For example, the first straight segment portion 102 and the second straight segment portion 103 of the middle conductor may have a radial difference of one slot layer. Under each pole of a branch, one straight segment portion of the middle conductor and the first straight segment portion 102 of the inner conductor 111 may be located in the same stator slot, and the other straight segment portion of the middle conductor and the second straight segment portion 103 of the inner conductor 111 are circumferentially different by one stator slot.

[0062] Please refer to Figures 13 - 16As shown, in each branch of each phase, the pitch of the inner conductor 111 is y1, the pitch of the middle conductor is y2, and the pitch of the outer conductor 131 is y3. The circumferential difference in stator slots between two adjacent inner conductors 111 in the circumferential direction is L1, the circumferential difference in stator slots between two adjacent middle conductors in the same slot layer in the circumferential direction is L2, and the circumferential difference in stator slots between two adjacent outer conductors 131 in the circumferential direction is L3, satisfying the following conditions: y1 = τ - 1, y2 = τ, y3 = τ + 1, L1 = τ + 1, L3 = τ - 1, L2 = τ - 1 or L2 = τ + 1.

[0063] Please refer to Figures 1 - 16 As shown, the heads 101 of the inner conductors 111, the heads 101 of the middle conductors, and the heads 101 of the outer conductors 131 are on the same side. One end of the stator winding 100 located at the head 101 can be the hairpin end 1001. One end of the stator winding 100 located away from the head 101 can be the welding end 1002.

[0064] Please refer to Figures 13 - 16 As shown, the pitch of the outer conductor 131 can be 7 stator slots, the pitch of the middle conductor can be 6 stator slots, the pitch of the inner conductor 111 can be 5 stator slots, and the pole pitch τ of the stator winding 100 can be 6 stator slots. In one branch of each phase, the circumferential difference between two adjacent outer conductors 131 is 5 stator slots, the circumferential difference between two adjacent middle conductors in the same slot layer is 5 stator slots or 7 stator slots, and the circumferential difference between two adjacent inner conductors 111 is 7 stator slots. The circumferential difference between two adjacent lead conductors 141 is 7 stator slots, and the circumferential difference between the adjacent lead conductor 141 and the outer conductor 131 is 5 stator slots.

[0065] Please refer to Figures 1 - 16 , by winding in this winding method, the winding structure of each phase winding of the stator winding 100 can be optimized. This winding method can arrange the inlet end and the outlet end of each branch on the same side of the stator winding 100, and can make full use of the height of the hairpin end 1001. Placing the inlet ends of the two branches in the stator slots adjacent to the hairpin end 1001 can facilitate the welding of the inlet ends of the two branches. Similarly, the outlet ends of the two branches are located at the hairpin end 1001, which is convenient for welding. At this time, it belongs to the parallel connection of the two branches. In some embodiments, the two branches can also be connected in series. For example, the outlet end of one branch can be connected to the inlet end of the other branch through a wire. Connecting the two branches into a phase winding can adjust the number of paths, is not likely to generate unbalanced current, and can prevent the generation of circulating current phenomenon, thereby preventing the motor from failing.

[0066] Please refer to Figures 1 - 16, To more clearly illustrate the wiring structure of the present invention, the winding expansion diagram describes the A-phase coil group as an example. Only the winding of the A-phase coil group is shown in the winding expansion diagram, which does not involve the B-phase and C-phase coil groups. The winding methods of the B-phase and C-phase coil groups are the same as that of the A-phase coil group, and the only difference lies in the slot numbers of the stator slots where the incoming and outgoing ends are located. For example, the incoming ends of the A-phase winding are the 27th and 28th stator slots respectively, the incoming ends of the B-phase winding can be the 31st and 32nd stator slots, and the incoming ends of the C-phase winding can be the 35th and 36th stator slots.

[0067] Please refer to Figures 1 - 16 As shown, the stator winding 100 may include three-phase windings, and each phase winding may include two branches. The following will refer to Figures 13 - 16 to describe the specific embodiments of the present invention in detail. For example, the number of stator slots of the stator core 200 may be 48, for example. Each branch may include 8 magnetic poles, and the pole pitch of the stator winding 100 may be 6 stator slots, that is, τ = 6. The number of slots per pole per phase is 2, and the number of slot layers L of the stator winding 100 is 6. Among them, for the A-phase winding, the expansion diagrams of the first branch and the second branch are respectively as Figure 15 and Figure 16 shown. Figure 15 In Figure 16 , A1X1 is the first branch of the A-phase winding. Figure 15 In Figure 16 , A2X2 is the second branch of the A-phase winding. A1 and A2 are the incoming ends of the winding, and X1 and X2 are the outgoing ends of the winding. In each stator slot of the winding expansion diagram, from left to right, there are 6 layers, 5 layers, 4 layers, 3 layers, 2 layers, and 1 layer in sequence.

[0068] Please refer to Figure 13 and Figure 15 shown. The specific winding method of the first branch A1X1 of the A-phase winding is as follows. For example, 27(6) represents the 6th layer of the 27th stator slot.

[0069] A1 -> 27(6) -> 33(5) -> 27(4) -> 33(3) -> 27(2) -> 33(1) -> 28(1) -> 22(2) -> 28(3) -> 22(4) -> 28(5) -> 22(6) -> 15(6) -> 21(5) -> 15(4) -> 21(3) -> 15(2) -> 21(1) -> 16(1) -> 10(2) -> 16(3) -> 10(4) -> 16(5) -> 10(6) -> 3(6) -> 9(5) -> 3(4) -> 9(3) -> 3(2) -> 9(1) -> 4(1) -> 46(2) -> 4(3) -> 46(4) -> 4(5) -> 46(6) -> 39(6) -> 45(5) -> 39(4) -> 45(3) -> 39(2) -> 45(1) -> 40(1) -> 34(2) -> 40(3) -> 34(4) -> 40(5) -> 34(6) -> X1。

[0070] Please refer to Figure 14 and Figure 16 as shown, the specific winding method of the second branch A2X2 of the A-phase winding is as follows. For example, 28(6) represents the 6th layer of the 28th stator slot.

[0071] A2 -> 28(6) -> 34(5) -> 28(4) -> 34(3) -> 28(2) -> 34(1) -> 39(1) -> 33(2) -> 39(3) -> 33(4) -> 39(5) -> 33(6) -> 40(6) -> 46(5) -> 40(4) -> 46(3) -> 40(2) -> 46(1) -> 3(1) -> 45(2) -> 3(3) -> 45(4) -> 3(5) -> 45(6) -> 4(6) -> 10(5) -> 4(4) -> 10(3) -> 4(2) -> 10(1) -> 15(1) -> 9(2) -> 15(3) -> 9(4) -> 15(5) -> 9(6) -> 16(6) -> 22(5) -> 16(4) -> 22(3) -> 16(2) -> 22(1) -> 27(1) -> 21(2) -> 27(3) -> 21(4) -> 27(5) -> 21(6) -> X2。

[0072] Please refer to Figures 12 - 16As shown, from the above winding method, it can be seen that the lead ends A1 and A2 of the first branch A1X1 and the second branch A2X2 are 1 stator slot apart in the circumferential direction. In one branch of each phase, when: y1 = τ - 1, y2 = τ, y3 = τ + 1, L1 = τ + 1, L3 = τ - 1, L2 = τ - 1 or L2 = τ + 1, and when y4 = τ + 1, L4 = τ - 1, the outgoing ends of the two branch windings are 2τ + 1 stator slots apart in the circumferential direction. That is, when y1 = 5, y2 = 6, y3 = 7, L1 = 7, L3 = 5, L2 = 5 or L2 = 7, and when y4 = 7, L4 = 5, the outgoing ends of the two branch windings are 13 stator slots apart in the circumferential direction. The lead end A1 and the outgoing end X1 of the first branch are 7 stator slots apart in the circumferential direction. The lead end A2 and the outgoing end X2 of the second branch are 7 stator slots apart in the circumferential direction; the lead ends and the outgoing ends of the first branch and the second branch are located in the outermost layer. It should be noted that "apart" can refer to the difference in the number of stator slots between two stator slots, for example, there are 6 stator slots between the 3rd stator slot and the 9th stator slot. In addition, "apart" can also refer to the difference between two slot layers, for example, there are 3 slot layers between the 1st slot layer and the 4th slot layer.

[0073] Embodiment 2

[0074] Please refer to Figures 1 - 12 and Figures 17 - 20 As shown, in another embodiment of the present invention, in each branch winding of each phase, the pitch of the inner layer conductor 131 is y1, the pitch of the middle layer conductor is y2, the pitch of the outer layer conductor 111 is y3, the pole pitch of the stator winding 100 is τ, the circumferential difference between two adjacent inner layer conductors 111 in the circumferential direction is the stator slot L1, the circumferential difference between two adjacent middle layer conductors in the same slot layer in the circumferential direction is the stator slot L2, the circumferential difference between two adjacent outer layer conductors 131 in the circumferential direction is the stator slot L3, and the following conditions are satisfied: y1 = τ + 1, y2 = τ, y3 = τ - 1, L1 = τ - 1, L3 = τ + 1, L2 = τ - 1 or L2 = τ + 1. And, the circumferential difference between two adjacent lead conductors 141 can be the stator slot y4, y4 = τ - 1, and the circumferential difference between the adjacent lead conductor 141 and the straight section of the outer layer conductor 131 can be the stator slot L4, L4 = τ + 1.

[0075] Please refer to Figures 1 - 12 and Figures 17 - 20As shown, for example, the number of stator slots of the stator core 200 may be, for example, 48, each branch may include 8 magnetic poles, the pole pitch of the stator winding 100 may be 6 stator slots, and the number of slots per pole per phase is 2. At this time, in one branch of each phase, the pitch of the outer conductor 131 is 5 stator slots, the pitch of the middle conductor is 6 stator slots, the pitch of the inner conductor 111 is 7 stator slots, the circumferential difference between two adjacent outer conductors 131 is 7 stator slots, the circumferential difference between two adjacent middle conductors in the same slot layer is 5 stator slots or 7 stator slots, and the circumferential difference between two adjacent inner conductors 111 is 5 stator slots. The circumferential difference between two adjacent lead conductors 141 is 5 stator slots, and the circumferential difference between the adjacent lead conductor 141 and the outer conductor 131 is 7 stator slots.

[0076] Please refer to Figures 17 - 20 As shown, in some embodiments, the specific implementation manners of the present invention are described in detail. Taking the winding method of a three-phase 8-pole 48-stator-slot motor with 6 wires in each stator slot as an example for illustration. The developed views of the first branch and the second branch of the winding of phase A are respectively as Figure 19 and Figure 20 shown. Figure 19 In , A1X1 is the first branch of the winding of phase A, Figure 20 in , A2X2 is the second branch of the winding of phase A, A1 and A2 are the incoming ends of the winding, and X1 and X2 are the outgoing ends of the winding. In each stator slot of the developed view of the winding, from left to right, there are 6 layers, 5 layers, 4 layers, 3 layers, 2 layers and 1 layer in sequence. Figure 19 In , the first branch A1X1 is wound in the positive direction, Figure 20 in , the second branch A2X2 is wound in the reverse direction.

[0077] Please refer to Figure 17 and Figure 19 As shown, in some embodiments, the specific winding method of the first branch A1X1 of the winding of phase A is as follows:

[0078] A1 -> 27(6) -> 33(5) -> 27(4) -> 33(3) -> 27(2) -> 33(1) -> 40(1) -> 34(2) -> 40(3) -> 34(4) -> 40(5) -> 34(6) -> 39(6) -> 45(5) -> 39(4) -> 45(3) -> 39(2) -> 45(1) -> 4(1) -> 46(2) -> 4(3) -> 46(4) -> 4(5) -> 46(6) -> 3(6) -> 9(5) -> 3(4) -> 9(3) -> 3(2) -> 9(1) -> 16(1) -> 10(2) -> 16(3) -> 10(4) -> 16(5) -> 10(6) -> 15(6) -> 21(5) -> 15(4) -> 21(3) -> 15(2) -> 21(1) -> 28(1) -> 22(2) -> 28(3) -> 22(4) -> 28(5) -> 22(6) -> X1。

[0079] Please refer to Figure 18 and Figure 20 as shown, in some embodiments, the specific winding method of the second branch A2X2 of the A-phase winding is as follows:

[0080] A2 -> 28(6) -> 34(5) -> 28(4) -> 34(3) -> 28(2) -> 34(1) -> 27(1) -> 21(2) -> 27(3) -> 21(4) -> 27(5) -> 21(6) -> 16(6) -> 22(5) -> 16(4) -> 22(3) -> 16(2) -> 22(1) -> 15(1) -> 9(2) -> 15(3) -> 9(4) -> 15(5) -> 9(6) -> 4(6) -> 10(5) -> 4(4) -> 10(3) -> 4(2) -> 10(1) -> 3(1) -> 45(2) -> 3(3) -> 45(4) -> 3(5) -> 45(6) -> 40(6) -> 46(5) -> 40(4) -> 46(3) -> 40(2) -> 46(1) -> 39(1) -> 33(2) -> 39(3) -> 33(4) -> 33(5) -> 33(6) -> X2。

[0081] As can be seen from the above winding method, the lead ends A1 and A2 of the first branch A1X1 and the second branch A2X2 are 1 stator slot apart in the circumferential direction. When y1 = τ + 1, y2 = τ, y3 = τ - 1, L1 = τ - 1, L3 = τ + 1, L2 = τ - 1 or L2 = τ + 1, and when y4 = τ - 1, L4 = τ + 1, the outgoing ends of the two branch windings are 2τ - 1 stator slots apart in the circumferential direction. That is, when y1 = 7, y2 = 6, y3 = 5, L1 = 5, L3 = 7, L2 = 5 or L2 = 7, and when y4 = 5, L4 = 7, the outgoing ends of the two branch windings are 11 stator slots apart in the circumferential direction. The lead end A1 and the outgoing end X1 of the first branch are 5 stator slots apart in the circumferential direction, and the lead end A2 and the outgoing end X2 of the second branch are 5 stator slots apart in the circumferential direction; the lead ends and the outgoing ends of the first branch and the second branch are located in the outermost line layer.

[0082] Please refer to Figures 21 - 22 As shown, in some embodiments, after the bending portions of each coil group are welded to each other at the welding end 1002, the A-phase winding is formed. As Figure 21 shown, the two branches of the A-phase winding can be connected in series to form a parallel branch. As Figure 22 shown, the two branches of the A-phase winding can be connected in parallel to form two parallel branches. The figure shows a star connection method between the three-phase windings. When the first branch and the second branch are connected in parallel, the incoming end A1 and the incoming end A2 are connected, and the outgoing end X1 and the outgoing end X2 are connected, so that the first branch and the second branch are connected in parallel with each other.

[0083] The present invention solves the problem of numerous coil nesting in the stator winding 100. Through the above winding arrangement, there are no axially nested coils in the innermost and outermost coil groups of the winding. The manufacturing process is simple, the efficiency is high, the coil form is few, and the production cost is low. In addition, the two parallel branches are completely symmetrical in the magnetic circuit, and their electrical parameters such as resistance and inductance are exactly equal. There is no circulating current between the branches after parallel connection, thereby improving the efficiency of the motor and reducing the vibration and noise of the motor. And the conductor of each stator slot belongs to the conductor of a certain phase, eliminating the interlayer insulating paper, increasing the slot fill factor of the winding stator slot, and further improving the efficiency of the motor.

[0084] Please refer to Figures 1 - 22 As shown, in an embodiment, the present invention also proposes a motor, which may include the stator assembly described above.

[0085] In summary, the present invention proposes a stator assembly and a motor using the same. The present invention solves the problem of numerous coil nesting in the stator winding. Through the above winding arrangement, there are no axially nested coils in the innermost and outermost coil groups of the winding. The manufacturing process is simple, the efficiency is high, the coil form is few, and the production cost is low.

[0086] The present disclosure has described systems and methods in general terms to facilitate an understanding of the details of the present invention. In addition, various specific details have been given to provide a general understanding of embodiments of the present invention. However, those skilled in the relevant art will recognize that embodiments of the present invention may be practiced without one or more of the specific details, or with other devices, systems, components, methods, assemblies, materials, parts, etc. In other instances, well-known structures, materials, and / or operations have not been shown or described in detail to avoid obscuring aspects of the embodiments of the present invention.

[0087] Accordingly, while the present invention has been described herein with reference to its specific embodiments, modifications, various changes, and substitutions are intended within the above disclosure, and it should be understood that in some instances, some features of the present invention will be employed without corresponding use of other features without departing from the scope and spirit of the claimed invention. Accordingly, many modifications may be made to adapt a particular environment or material to the essential scope and spirit of the present invention. The present invention is not intended to be limited to the specific terms and / or specific embodiments disclosed as the best mode contemplated for carrying out the present invention, but the present invention will include any and all embodiments and equivalents falling within the scope of the appended claims. Accordingly, the scope of the present invention will be determined only by the appended claims.

Claims

1. A stator assembly, characterized in that, comprising: a stator core having stator slots, and the stator slots include a plurality of slot layers; and a stator winding inserted into the stator slots, and the stator winding includes a plurality of inner-layer conductors, a plurality of middle-layer conductors, a plurality of outer-layer conductors, and a plurality of lead conductors; wherein, in each branch of each phase winding, the inner-layer conductor is connected to the middle-layer conductor, the middle-layer conductor is connected to the outer-layer conductor, or the middle-layer conductor is connected to the lead conductor, the number of the lead conductors is two, the lead conductors include a straight-segment portion, and the number of the outer-layer conductors is one less than the number of the inner-layer conductors; under one magnetic pole of a branch, the two lead conductors and one inner-layer conductor are circumferentially different by one stator slot, under the remaining magnetic poles of a branch, a straight-segment portion of the outer-layer conductor and a straight-segment portion of the inner-layer conductor are circumferentially different by one stator slot, and another straight-segment portion of the outer-layer conductor and another straight-segment portion of the inner-layer conductor are circumferentially different by one stator slot; in each branch of each phase winding, the pitches of the inner-layer conductor and the outer-layer conductor are y1 and y3 in sequence, the stator slots by which two circumferentially adjacent lead conductors are circumferentially different is y4, the pole pitch of the stator winding is τ, the stator slots by which two circumferentially adjacent inner-layer conductors are circumferentially different is L1, the stator slots by which two circumferentially adjacent outer-layer conductors are circumferentially different is L3, and the stator slots by which a circumferentially adjacent lead conductor and a straight-segment portion of the outer-layer conductor are circumferentially different is L4, satisfying: y1 = y4 = τ + 1, y3 = τ - 1, L1 = L4 = τ - 1, L3 = τ + 1, or y1 = y4 = τ - 1, y3 = τ + 1, L1 = L4 = τ + 1, L3 = τ - 1; in each branch of each phase winding, the two straight-segment portions of the middle-layer conductor are radially different by one slot layer, under each magnetic pole of a branch, a straight-segment portion of the middle-layer conductor and a straight-segment portion of the inner-layer conductor are located in the same stator slot, another straight-segment portion of the middle-layer conductor and another straight-segment portion of the inner-layer conductor are circumferentially different by one stator slot, the pitch of the middle-layer conductor is y2, and the stator slots by which two circumferentially adjacent middle-layer conductors in the same slot layer are circumferentially different is L2, satisfying: y2 = τ, L2 = τ - 1 or L2 = τ + 1.

2. The stator assembly according to claim 1, characterized in that, in each branch of each phase winding, the middle-layer conductor occupies at least two radially slot layers, under each magnetic pole of a branch, the middle-layer conductors in different slot layers are located in the same circumferential stator slot, and the radially slot layers occupied by the middle-layer conductors located in the same circumferential stator slot do not intersect.

3. The stator assembly according to claim 2, characterized in that, in each branch of each phase winding, in the same stator slot, the straight-segment portions of the radially adjacent middle-layer conductors are radially different by two slot layers.

4. The stator assembly according to claim 1, characterized in that, the lead conductor and the outer-layer conductor are located in the same circumferential slot layer.

5. The stator assembly according to claim 1, wherein, each phase winding includes at least two branches, the winding directions of the two branches of the same phase winding are opposite, and the two branch windings are connected in series or in parallel.

6. The stator assembly according to claim 5, wherein, the lead ends of the two branch windings of the same phase winding are circumferentially different by one stator slot. When y1 = y4 = τ + 1, y3 = τ - 1, L1 = L4 = τ - 1, L3 = τ + 1, the outgoing ends of the two branch windings are circumferentially different by 2τ - 1 stator slots, or when y1 = y4 = τ - 1, y3 = τ + 1, L1 = L4 = τ + 1, L3 = τ - 1, the outgoing ends of the two branch windings are circumferentially different by 2τ + 1 stator slots.

7. The stator assembly according to claim 5, wherein, under the same magnetic pole of the same phase winding, the inner conductors of one branch are circumferentially different by one stator slot from the inner conductors of the other branch.

8. The stator assembly according to claim 5, wherein, under the same magnetic pole of the same phase winding, the outer conductors of one branch are circumferentially different by one stator slot from the outer conductors of the other branch.

9. A motor, wherein, it includes the stator assembly according to any one of claims 1 to 8.

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