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

Abstract

The present invention provides a stator assembly and an electric machine 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, and the stator winding includes a plurality of outer-layer conductors, a plurality of middle-layer conductors, a plurality of inner-layer conductors, and a plurality of lead conductors; in each branch of each phase winding, under each magnetic pole of one branch, a straight-segment portion of a first type of middle-layer conductor and a straight-segment portion of a second type of middle-layer conductor are circumferentially different by one stator slot and radially different by two slot layers, and another straight-segment portion of the first type of middle-layer conductor and another straight-segment portion of the second type of middle-layer conductor are circumferentially different by one stator slot and radially different by two slot layers. In the present invention, the voltage difference between conductors in different slot layers within the same stator slot is relatively low, reducing the voltage difference between conductors in different slot layers within the same slot, reducing the risk of breakdown of conductor insulation, and improving the reliability of the electric machine.

Description

Technical Field

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

[0002] In the prior art, the flat wire winding often adopts the wave winding Hairpin structure scheme. The wave winding winds multiple turns on the circumference of the iron core, and connects the coils under the same pole in a certain order. Analyzing from the electrical connection, in the same stator slot of the wave winding, the voltage difference between the conductors in different slot layers is relatively high, which is prone to interlayer breakdown, resulting in short circuit and causing the motor to fail. Moreover, pinholes may occur during the production of enameled flat wires, and the insulation may be damaged during the forming and laying processes of the hairpin coils. With the increase in the voltage of the electric drive assembly, it has become increasingly difficult to meet the actual use requirements only relying on the withstand voltage level of the enameled flat wires. Summary of the Invention

[0003] The present invention provides a stator assembly and a motor using the same, which solves the problem of easy interlayer breakdown of the coils caused by the increase in the voltage of the electric drive assembly, and provides the following technical solutions.

[0004] The present invention provides a stator assembly, comprising:

[0005] A stator core having stator slots, and the stator slots include a plurality of slot layers; and

[0006] A stator winding inserted into the stator slots, and the stator winding includes a plurality of outer layer conductors, a plurality of middle layer conductors, a plurality of inner layer conductors and a plurality of lead conductors;

[0007] 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 middle layer conductor includes a middle layer type I conductor and a middle layer type II conductor. Under each pole of a branch, a straight segment of the middle layer type I conductor and a straight segment of the middle layer type II conductor are circumferentially offset by one stator slot and radially offset by two slot layers;

[0008] Another straight segment of the middle layer type I conductor and another straight segment of the middle layer type II conductor are circumferentially offset by one stator slot and radially offset by two slot layers. The middle layer type I conductor is radially offset by one slot layer, the middle layer type II conductor is radially offset by one slot layer, and the middle layer type I conductor and the middle layer type II conductor occupy four slot layers;

[0009] The pitches of the first - type conductors and the second - type conductors in the middle layer are y2 and y3 respectively. The pole pitch of the stator winding is τ. The number of stator slots between two circumferentially adjacent first - type conductors in the same slot layer is L2, and the number of stator slots between two circumferentially adjacent second - type conductors in the same slot layer is L3, satisfying: y2 = τ + 1, y3 = τ - 1, L2 = L3 = 2τ.

[0010] In an embodiment of the present invention, in each branch of each phase winding, between the first - type conductors and the second - type conductors in the same circumferential slot layer under adjacent magnetic poles in one branch, the inner - layer conductor or the outer - layer conductor is connected.

[0011] In an embodiment of the present invention, in each branch of each phase winding, under one magnetic pole in one branch, the first - type conductor is connected to the inner - layer conductor, and the second - type conductor is connected to the outer - layer conductor, or the first - type conductor is connected to the outer - layer conductor, and the second - type conductor is connected to the inner - layer conductor.

[0012] In an embodiment of the present invention, one straight - line segment part of the outer - layer conductor and one straight - line segment part of the inner - layer conductor are circumferentially different by one stator slot, and the other straight - line segment part of the outer - layer conductor and the other straight - line segment part of the inner - layer conductor are circumferentially different by one stator slot;

[0013] The pitches of the inner - layer conductor and the outer - layer conductor are y1 and y4 respectively. The number of stator slots between two circumferentially adjacent inner - layer conductors is L1, and the number of stator slots between two circumferentially adjacent outer - layer conductors is L4, satisfying: y1 = τ - 1, y4 = τ + 1, L1 = τ + 1, L4 = τ - 1, or y1 = τ + 1, y4 = τ - 1, L1 = τ - 1, L4 = τ + 1.

[0014] In an embodiment of the present invention, in one branch of each phase winding, the number of lead - out conductors is two. The lead - out conductors include a straight - line segment part. The number of outer - layer conductors is one less than the number of inner - layer conductors. Under one magnetic pole in one branch, the two lead - out conductors are connected to the middle - layer conductor, and under the remaining magnetic poles in one branch, the outer - layer conductor is connected to the middle - layer conductor.

[0015] In an embodiment of the present invention, under one magnetic pole of a branch winding, the two lead - out conductors and one inner - layer conductor are circumferentially different by one stator slot. Under the remaining magnetic poles of a branch winding, one straight - line segment part of the outer - layer conductor and one straight - line segment part of the inner - layer conductor are circumferentially different by one stator slot, and the other straight - line segment part of the outer - layer conductor and the other straight - line segment part of the inner - layer conductor are circumferentially different by one stator slot.

[0016] In an embodiment of the present invention, each phase includes at least two branch windings, and the two branch windings are connected in series or in parallel.

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

[0018] In an embodiment of the present invention, under the same magnetic pole of the same-phase winding, the middle-layer conductors in one branch are circumferentially offset by one stator slot from the middle-layer conductors in 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. In the same stator slot, the voltage difference between conductors in different slot layers is low, and it is not easy to cause breakdown of the inter-layer conductors, which can better meet the requirements of high-voltage drive. Reducing the voltage difference between conductors in different slot layers in the same stator slot reduces the risk of breakdown of conductor insulation and improves the reliability of the motor. BRIEF DESCRIPTION OF THE DRAWINGS

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

[0022] Figure 2 is a schematic structural diagram of one phase winding of the stator winding in a stator assembly according to the present invention.

[0023] Figure 3 For the present invention Figure 2 is an enlarged schematic diagram at A.

[0024] Figure 4 is a schematic diagram of the inner-layer conductors of the first coil group in a stator assembly according to the present invention.

[0025] Figure 5 is a schematic structural diagram of the middle-layer conductors of the second coil group in a stator assembly according to the present invention.

[0026] Figure 6 is a schematic diagram of the middle-layer type-I conductors of the second coil group in a stator assembly according to the present invention.

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

[0028] Figure 8 is a schematic diagram of the outer-layer conductors of the third coil group in a stator assembly according to the present invention.

[0029] Figure 9 is a schematic diagram of the lead conductors of the fourth coil group in a stator assembly according to the present invention.

[0030] Figure 10 This is a wiring diagram of a phase winding of the stator winding in a stator assembly of the present invention.

[0031] Figure 11 This is a developed view of a phase winding of the stator winding in a stator assembly of the present invention.

[0032] Figure 12 This is a wiring diagram showing the first connection rule in a stator assembly of the present invention.

[0033] Figure 13 This is a wiring diagram showing the second connection rule in a stator assembly of the present invention.

[0034] Figure 14 This is a schematic diagram of the star connection of two parallel branches of the stator winding in a stator assembly of the present invention.

[0035] In the figure: 100, stator winding; 1001, hairpin end; 1002, welding end;

[0036] 110, inner layer conductor;

[0037] 120, middle layer conductor; 121, middle layer first type conductor; 122, middle layer second type conductor;

[0038] 130, outer layer conductor;

[0039] 140, lead-out conductor;

[0040] 101, head; 102, first straight section; 103, second straight section; 104, first bending section; 105, second bending section;

[0041] 200, stator core. Detailed implementation manners

[0042] The following uses specific specific examples to illustrate the implementation manners 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 manners. 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.

[0043] 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 in actual implementation. The types, quantities, and proportions of the components in actual implementation can be arbitrarily changed, and the component layout type may also be more complex.

[0044] Please refer toFigures 1 to 14 , the present invention provides 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 solve the problem that the voltage difference between conductors of different layers is relatively high, which is prone to interlayer breakdown and cause motor short circuit. The present invention will be described in detail through specific embodiments below.

[0045] Please refer to Figure 1 , the present invention provides a stator assembly. In some embodiments, the stator assembly may include a stator winding 100 and a stator core 200. 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 at a predetermined stator slot interval on the stator core 200. 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, and 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.

[0046] Please refer to Figure 1 As shown, in some embodiments, a plurality of stator slots in the circumferential direction of the stator core 200 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... For example, the stator core 200 may be provided with 48 stator slots along the circumferential direction. Among them, each stator slot may be provided with a plurality of slot layers. In some embodiments, 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 sequentially 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 from the inner side to the outer side 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 label of the slot layer of each stator slot is not limited. In the embodiments of the present invention, the arrangement is carried out in the order of 1-6 from the inside to the outside. In some other embodiments, it may also be arranged in the order of 1-6 from the outside to the inside.

[0047] Please refer to Figures 2 to 9As shown, in some embodiments, the stator winding 100 may include a plurality of outer layer conductors 130, a plurality of middle layer conductors 120, a plurality of inner layer conductors 110, and a plurality of lead conductors 140. Along the radial direction from the stator slot opening to the stator slot bottom, the inner layer conductors 110, middle layer conductors 120, and outer layer conductors 130 may be arranged. Among them, the plurality of inner layer conductors 110 may form a first coil group, the first coil group may be located in the stator slots of the stator core 200, and the first coil group may be located on the side close to the stator slot opening. The plurality of middle layer conductors 120 may form a second coil group, the second coil group may be located in the stator slots of the stator core 200, and the second coil group may be located between the first coil group and the third coil group. The plurality of outer layer conductors 130 may form a third coil group, the third coil group may be located in the stator slots of the stator core 200, and the third coil group may be located on the side close to the stator slot bottom. The plurality of lead conductors 140 may form a fourth coil group, the fourth coil group may be located in the stator slots of the stator core 200, and the fourth coil group may be located on the side close to the stator slot bottom.

[0048] Please refer to Figures 4 to 8 As shown, in some embodiments, the inner layer conductors 110, middle layer conductors 120, and outer layer conductors 130 may include a head, two straight section parts, and two bending parts. Among them, one end of each of the two ends of the head is connected to a straight section part. After the two straight section parts pass through the stator slots of the stator core 200, they are twisted at the welding end 1002 to form two bending parts. Among the inner layer conductors 110, middle layer conductors 120, and outer layer conductors 130, the bending parts of different conductors may be connected by welding, so as to form a complete branch. The two bending parts of the inner layer conductors 110, middle layer conductors 120, and outer layer conductors 130 extend the same distance along one side of the welding end 1002 of the stator core 200, and may be half of the pole pitch. For example, the inner layer conductors 110, middle layer conductors 120, and outer layer conductors 130 may include a head 101, a first straight section part 102, a second straight section part 103, a first bending part 104, and a second bending part 105. Among them, the first straight section part 102 and the second straight section part 103 may be used to be inserted into the stator slots, and the first straight section part 102 and the second straight section part 103 may be inserted into different stator slots. One end of the first straight section part 102 may be connected to the first bending part 104, and one end of the second straight section part 103 may be connected to the second bending part 105. The other end of the first straight section part 102 and the other end of the second straight section part 103 may be connected to the head 101. The two straight section parts of the middle layer conductor 120 may be radially different by one slot layer. The two straight section parts of the inner layer conductor 110 may be located in the same slot layer. The two straight section parts of the outer layer conductor 130 may be located in the same slot layer. The first coil group and the third coil group may be wave windings.

[0049] Please refer to Figures 5 to 7As shown, in some embodiments, the number of radial slot layers of the third coil group in the stator core 200 is not limited, and the number of radial slot layers of the third coil group in the stator core 200 can be an even number. For example, the number of radial slot layers of the third coil group in the stator core 200 can be four layers, that is, the third coil group can be composed of two middle-layer conductors 120. The symmetry axes of the two middle-layer conductors 120 can be the same, and the two middle-layer conductors 120 can form an overlapping coil group. The specific structure of the two middle-layer conductors 120 is not limited. In other embodiments, the pitches of the two middle-layer conductors 120 can be different, and the pitch of the two middle-layer conductors 120 can differ from the pole pitch by one stator slot. For example, when the pole pitch is equal to 6 stator slots, the pitch of one of the middle-layer conductors 120 is 5 stator slots, and the pitch of the other middle-layer conductor 120 is 7 stator slots. For example, the middle-layer conductor 120 with a pitch larger than the pole pitch by one stator slot can be defined as the middle-layer type-1 conductor 121, and the middle-layer conductor 120 with a pitch smaller than the pole pitch by one stator slot can be defined as the middle-layer type-2 conductor 122. The symmetry axes of the middle-layer type-1 conductor 121 and the middle-layer type-2 conductor 122 can be the same, and the circumferences of the stator slots occupied by the middle-layer type-1 conductor 121 and the middle-layer type-2 conductor 122 can differ by one stator slot.

[0050] Please refer to Figures 4 to 8 As shown, in some embodiments, the first bending portions 104 and the second bending portions 105 in the inner-layer conductor 110 can extend in the same direction. For example, the extending directions of the multiple first bending portions 104 and the multiple second bending portions 105 can be along the clockwise direction or the counterclockwise direction. The first bending portions 104 and the second bending portions 105 in the middle-layer conductor 120 can be close to each other, and the first bending portions 104 and the second bending portions 105 in the middle-layer conductor 120 can extend in opposite directions. For example, the extending direction of the multiple first bending portions 104 can be along the clockwise direction or the counterclockwise direction, and the extending direction of the multiple second bending portions 105 can be opposite. The first bending portions 104 and the second bending portions 105 in the outer-layer conductor 130 can extend in the same direction. For example, the extending directions of the multiple first bending portions 104 and the multiple second bending portions 105 can be along the clockwise direction or the counterclockwise direction. Among them, the extending directions of the two bending portions of the inner-layer conductor 110, the middle-layer conductor 120, and the outer-layer conductor 130 are not specifically limited and must satisfy as Figures 10 to 11 the wiring circuit diagram.

[0051] Please refer to Figure 9As shown, in some embodiments, the lead conductor 140 may include a head, a straight segment portion, and a bent portion. For example, the lead conductor 140 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 140 may extend in the same direction, for example, may be in the clockwise direction or the counterclockwise direction. In some embodiments, each phase winding may include two branches. In one branch winding, the number of lead conductors 140 may be two, and the circumferential spacing between two circumferentially adjacent lead conductors 140 may be L4, L4 = τ + 1 or L4 = τ - 1, where τ is the pole pitch of the stator winding 100. The lead conductor 140 may be used as the lead end and the outgoing end of each branch. The stator slot where the bent portion of the lead conductor 140 extends along the welding end 1002 side of the stator core 200 may be half of the pole pitch.

[0052] Please refer to Figures 1 to 11 As shown, in some embodiments, under each magnetic pole of one branch winding, the first straight segment portion 102 of the middle-layer type-1 conductor 121 and the first straight segment portion 102 of the middle-layer type-2 conductor 122 may be circumferentially different by one stator slot, and at this time, the first straight segment portion 102 of the middle-layer type-1 conductor 121 and the first straight segment portion 102 of the middle-layer type-2 conductor 122 may be radially different by two slot layers. The second straight segment portion 103 of the middle-layer type-1 conductor 121 and the second straight segment portion 103 of the middle-layer type-2 conductor 122 may be circumferentially different by one stator slot, and at this time, the second straight segment portion 103 of the middle-layer type-1 conductor 121 and the second straight segment portion 103 of the middle-layer type-2 conductor 122 may be radially different by two slot layers. In the middle-layer type-1 conductor 121, there is a difference of one slot layer radially, and in the middle-layer type-2 conductor 122, there is also a difference of one slot layer radially. For example, the middle-layer type-1 conductor 121 may occupy two slot layers, and the middle-layer type-2 conductor 122 may occupy two slot layers. The middle-layer type-1 conductor 121 and the middle-layer type-2 conductor 122 may occupy four consecutive slot layers.

[0053] Please refer to Figures 1 to 11As shown, in some embodiments, in each branch of each phase winding, under a magnetic pole of a branch, one lead conductor 140 and a straight segment portion of the first-type middle-layer conductor 121 are located in the same stator slot, and another lead conductor 140 and another straight segment portion of the first-type middle-layer conductor 121 are located in the same stator slot. Or under a magnetic pole of a branch winding, one lead conductor 140 and a straight segment portion of the second-type middle-layer conductor 122 are located in the same stator slot, and another lead conductor 140 and another straight segment portion of the second-type middle-layer conductor 122 are located in the same stator slot. In each branch of each phase winding, under a magnetic pole of a branch, the first straight segment portion 102 of the outer-layer conductor 130 and the first straight segment portion 102 of the inner-layer conductor 110 can be circumferentially offset by one stator slot, and the second straight segment portion 103 of the outer-layer conductor 130 and the second straight segment portion 103 of the inner-layer conductor 110 can be circumferentially offset by one stator slot.

[0054] Please refer to Figures 12 to 13 As shown, in some embodiments, in each branch of each phase winding, under a magnetic pole of a branch, a lead conductor 140 and a straight segment portion of the first-type middle-layer conductor 121 are located in the same stator slot, and the lead conductor 140 and a straight segment portion of the second-type middle-layer conductor 122 are located in the same stator slot. For example, in adjacent two slot layers, the first-type middle-layer conductor 121 and the second-type middle-layer conductor 122 can be simultaneously located in the same stator slot, and at this time, the first-type middle-layer conductor 121 and the second-type middle-layer conductor 122 are radially offset by one slot layer.

[0055] Please refer to Figure 12 As shown, in some embodiments, in each branch of each phase winding, under a magnetic pole of a branch, in adjacent two slot layers near the outermost slot layer, an outer-layer conductor 130 can be connected between the first-type middle-layer conductor 121 and the second-type middle-layer conductor 122, that is, the middle-layer conductor 120 is distributed between the outer-layer conductors 130. For example, the first bent portion 104 of the outer-layer conductor 130 can be connected to the first bent portion 104 of the first-type middle-layer conductor 121, and the second bent portion 105 of the outer-layer conductor 130 can be connected to the first bent portion 104 of the second-type middle-layer conductor 122. In adjacent two slot layers near the innermost slot layer, an inner-layer conductor 110 can be connected between the first-type middle-layer conductor 121 and the second-type middle-layer conductor 122, that is, the middle-layer conductor 120 is distributed between the inner-layer conductors 110. For example, the first bent portion 104 of the inner-layer conductor 110 can be connected to the first bent portion 104 of the first-type middle-layer conductor 121, and the second bent portion 105 of the inner-layer conductor 110 can be connected to the first bent portion 104 of the second-type middle-layer conductor 122.

[0056] Please refer to Figure 13As shown, in some embodiments, in each branch of each phase winding, under each pole of one branch winding, the symmetry axes of the middle-layer type-1 conductors 121 and the middle-layer type-2 conductors 122 can be the same, the stator slots occupied by the middle-layer type-1 conductors 121 and the middle-layer type-2 conductors 122 can be adjacent, and the middle-layer type-1 conductors 121 and the middle-layer type-2 conductors 122 can form a lap-wound coil group. The two ends of the lap-wound coil group can be respectively connected to the inner-layer conductors 110 and the outer-layer conductors 130.

[0057] Please refer to Figures 11 to 13 As shown, in some embodiments, in each branch of each phase winding, under one pole of one branch, the pitches of the inner-layer conductors 130, the middle-layer type-1 conductors 121, the middle-layer type-2 conductors 122, and the outer-layer conductors 110 can be y1, y2, y3, and y4 in sequence. The pole pitch of the stator winding 100 can be τ. The number of stator slots that the circumferentially adjacent two inner-layer conductors 130 differ by circumferentially is L1, the number of stator slots that the circumferentially adjacent two middle-layer type-1 conductors 121 in the same slot layer differ by circumferentially is L2, the number of stator slots that the circumferentially adjacent two middle-layer type-2 conductors 122 in the same slot layer differ by circumferentially is L3, and the number of stator slots that the circumferentially adjacent two outer-layer conductors 110 differ by circumferentially is L4. The following conditions can be satisfied: y2 = τ + 1, y3 = τ - 1, y4 = τ + 1, y1 = τ - 1, L2 = L3 = 2τ, L4 = τ - 1, L1 = τ + 1. At this time, the number of stator slots that the circumferentially adjacent two lead conductors 140 differ by circumferentially can be L4, and L4 = τ + 1. Or the following conditions can be satisfied: y2 = τ + 1, y3 = τ - 1, y4 = τ - 1, y1 = τ + 1, L2 = L3 = 2τ, L4 = τ + 1, L1 = τ - 1. At this time, the number of stator slots that the circumferentially adjacent two lead conductors 140 differ by circumferentially can be L4, and L4 = τ - 1.

[0058] Please refer to Figures 1 to 11 As shown, in some embodiments, the heads 101 of the inner-layer conductors 110, the heads 101 of the middle-layer conductors 120, and the heads 101 of the outer-layer conductors 130 are located on the same side, and one end of the stator winding 100 where the heads 101 are located can be the hairpin end 1001. One end of the stator winding 100 away from the heads 101 can be the welding end 1002. The number of stator slots of the stator core 200 can be, for example, 48. The stator winding 100 can include a plurality of phase windings, and the plurality of phase windings are different from each other in electrical phase. For example, the stator winding 100 can include three phase windings. Please refer to Figure 11 As shown, in some embodiments, each phase winding can include two branch windings, and the two branch windings can be connected in series or in parallel.

[0059] Please refer to Figure 11As shown, in some embodiments, in one branch of each phase winding, the pitches of the outer conductor 130, the first type of middle-layer conductor 121, the second type of middle-layer conductor 122, and the inner conductor 110 may be 5, 7, 5, and 7 stator slots respectively. The pole pitch of the stator winding 100 may be equal to 6 stator slots. The circumferential difference between two circumferentially adjacent outer conductors 130 is 7 stator slots, the circumferential difference between two circumferentially adjacent first type of middle-layer conductors 121 in the same slot layer is 12 stator slots, the circumferential difference between two circumferentially adjacent second type of middle-layer conductors 122 in the same slot layer is 12 stator slots, and the circumferential difference between two circumferentially adjacent inner conductors 110 is 5 stator slots.

[0060] Please refer to Figure 11 As shown, in some embodiments, in the other branch of each phase winding, the pitches of the outer conductor 130, the first type of middle-layer conductor 121, the second type of middle-layer conductor 122, and the inner conductor 110 may be 7, 7, 5, and 5 stator slots respectively. The pole pitch of the stator winding 100 may be equal to 6 stator slots. The circumferential difference between two circumferentially adjacent outer conductors 130 is 5 stator slots, the circumferential difference between two circumferentially adjacent first type of middle-layer conductors 121 in the same slot layer is 12 stator slots, the circumferential difference between two circumferentially adjacent second type of middle-layer conductors 122 in the same slot layer is 12 stator slots, and the circumferential spacing between two circumferentially adjacent inner conductors 110 is 7 stator slots.

[0061] Please refer to Figures 1 to 11 As shown, 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 branch windings in the stator slots adjacent to the hairpin end 1001 can facilitate the welding of the inlet ends of the two branch windings. Similarly, the outlet ends of the two branch windings are located at the hairpin end 1001, which is convenient for welding.

[0062] Please refer to Figure 11 As shown, in some embodiments, the stator winding 100 may include three-phase windings, and each phase winding may include two branches. The following refers to Figure 11 to describe the specific embodiments of the present invention in detail. For example, each branch winding may include 8 magnetic poles, 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 winding of phase A, the developed diagrams of the first branch and the second branch are as Figure 11As shown in the figure. A1X1 is the first branch of the A-phase winding, 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. 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. 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.

[0063] Please refer to Figure 11 As shown in the figure, in some embodiments, the specific winding method of the first parallel branch A1X1 of the A-phase winding is as follows. For example, 27(6) represents the 6th layer of the 27th stator slot.

[0064] A1 -> 27(6) -> 33(5) -> 28(4) -> 34(3) -> 27(2) -> 33(1) -> 40(1) -> 34(2) -> 39(3) -> 33(4) -> 40(5) -> 34(6) -> 39(6) -> 45(5) -> 40(4) -> 46(3) -> 39(2) -> 45(1) -> 4(1) -> 46(2) -> 3(3) -> 45(4) -> 4(5) -> 46(6) -> 3(6) -> 9(5) -> 4(4) -> 10(3) -> 3(2) -> 9(1) -> 16(1) -> 10(2) -> 15(3) -> 9(4) -> 16(5) -> 10(6) -> 15(6) -> 21(5) -> 16(4) -> 22(3) -> 15(2) -> 21(1) -> 28(1) -> 22(2) -> 27(3) -> 21(4) -> 28(5) -> 22(6) -> X1.

[0065] Please refer to Figure 11 As shown in the figure, in some embodiments, the specific winding method of the second parallel branch A2X2 of the A-phase winding is as follows. For example, 28(6) represents the 6th layer of the 28th stator slot.

[0066] A2 -> 28(6) -> 34(5) -> 27(4) -> 33(3) -> 28(2) -> 34(1) -> 39(1) -> 33(2) -> 40(3) -> 34(4) -> 39(5) -> 33(6) -> 40(6) -> 46(5) -> 39(4) -> 45(3) -> 40(2) -> 46(1) -> 3(1) -> 45(2) -> 4(3) -> 46(4) -> 3(5) -> 45(6) -> 4(6) -> 10(5) -> 3(4) -> 9(3) -> 4(2) -> 10(1) -> 15(1) -> 9(2) -> 16(3) -> 10(4) -> 15(5) -> 9(6) -> 16(6) -> 22(5) -> 15(4) -> 21(3) -> 16(2) -> 22(1) -> 27(1) -> 21(2) -> 28(3) -> 22(4) -> 27(5) -> 21(6) -> X2。

[0067] Please refer to Figure 11 As shown, from the above winding method, it can be seen that the lead ends and outlet ends of the first parallel branch A1X1 and the second parallel branch A2X2 are located in the outermost wire layer. 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. The lead end A1 and the outlet end X1 of the first branch are 5 stator slots apart in the circumferential direction. The lead end A2 and the outlet end X2 of the second branch are 7 stator slots apart in the circumferential direction; the lead ends and outlet ends of the first branch and the second branch are located in the outermost wire layer. It should be noted that "apart" refers to the difference between two slot numbers. 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.

[0068] Please refer to Figures 2 to 3 and Figures 9 to 11 As shown, in some embodiments, Figure 2 is a three-dimensional schematic diagram of phase A. Each phase winding includes a first coil group, a second coil group, a third coil group, and a fourth coil group. The partial enlarged view of its end is as shown in Figure 3 As shown. The first coil group contains a plurality of lead conductors 140 and is distributed in the outermost slot layer of the stator slots. The lead conductor 140 is as shown in Figure 9As shown, its head 101 serves as the lead end or outgoing end of each branch. After the first straight segment 102 passes through the outermost slot layer of the stator slot, its end extends beyond the stator core 200 and turns at the welding end 1002 to form the first bending portion 104. This first bending portion 104 is connected to the second coil group by welding. For example, the first bending portion 104 of the lead conductor 140 is connected to the first bending portion 104 of the middle-layer type-one conductor 121. Or the first bending portion 104 of the lead conductor 140 is connected to the first bending portion 104 of the middle-layer type-two conductor 122.

[0069] Please refer to Figure 11 and Figure 14 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 14 shown, the two branches of the A-phase winding can be connected in parallel to form two parallel branches. The figure shows that the star connection method is adopted between the three-phase windings =. When the first branch and the second branch are connected in parallel, the incoming line ends A1 and A2 are connected, and the outgoing line ends X1 and X2 are connected, so that the first branch and the second branch are connected in parallel with each other.

[0070] The two parallel branches of the present invention are completely symmetric in the magnetic circuit, and are completely equal in electrical parameters such as resistance and inductance. There is no circulating current between the branches after parallel connection, thereby improving the efficiency of the motor, 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 filling rate of the winding stator slot, and further improving the motor efficiency.

[0071] Please refer to Figures 1 to 14 As shown, in some embodiments, the present invention also proposes a motor, including the stator assembly described above.

[0072] In summary, the present invention proposes a stator assembly and a motor using the same. In the same stator slot of the present invention, the voltage difference between the conductors in different slot layers is relatively low, and it is not easy to cause breakdown of the interlayer conductors, which can better meet the requirements of high-voltage drive. Reducing the voltage difference between the conductors in different slot layers in the same stator slot reduces the risk of breakdown of the conductor insulation and improves the reliability of the motor. The manufacturing process of the present invention is simple, with high efficiency, few coil forms, and low production cost.

[0073] The present document has generally described systems and methods 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.

[0074] 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. Thus, 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, it 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, and the stator winding includes a plurality of outer-layer conductors, a plurality of middle-layer conductors, a plurality of inner-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 middle-layer conductor includes a middle-layer type-one conductor and a middle-layer type-two conductor. Under each pole of a branch, a straight-line segment portion of the middle-layer type-one conductor and a straight-line segment portion of the middle-layer type-two conductor are circumferentially different by one stator slot and radially different by two slot layers; another straight-line segment portion of the middle-layer type-one conductor and another straight-line segment portion of the middle-layer type-two conductor are circumferentially different by one stator slot and radially different by two slot layers. The middle-layer type-one conductor is radially different by one slot layer, the middle-layer type-two conductor is radially different by one slot layer, and the middle-layer type-one conductor and the middle-layer type-two conductor occupy four slot layers; the pitches of the middle-layer type-one conductor and the middle-layer type-two conductor are y2 and y3 in sequence, the pole pitch of the stator winding is τ, the stator slots that are circumferentially adjacent to two middle-layer type-one conductors in the same slot layer are different by L2, and the stator slots that are circumferentially adjacent to two middle-layer type-two conductors in the same slot layer are different by L3, satisfying: y2 = τ + 1, y3 = τ - 1, L2 = L3 = 2τ; a straight-line segment portion of the outer-layer conductor and a straight-line segment portion of the inner-layer conductor are circumferentially different by one stator slot, and another straight-line segment portion of the outer-layer conductor and another straight-line segment portion of the inner-layer conductor are circumferentially different by one stator slot; the pitches of the inner-layer conductor and the outer-layer conductor are y1 and y4 in sequence, the stator slots that are circumferentially adjacent to two inner-layer conductors are different by L1, and the stator slots that are circumferentially adjacent to two outer-layer conductors are different by L4, satisfying: y1 = τ - 1, y4 = τ + 1, L1 = τ + 1, L4 = τ - 1, or y1 = τ + 1, y4 = τ - 1, L1 = τ - 1, L4 = τ + 1.

2. The stator assembly according to claim 1, characterized in that, in each branch of each phase winding, under adjacent poles of a branch, the inner-layer conductor or the outer-layer conductor is connected between the middle-layer type-one conductor and the middle-layer type-two conductor in the same circumferential slot layer.

3. The stator assembly according to claim 1, characterized in that, in each branch of each phase winding, under a pole of a branch, the middle-layer type-one conductor is connected to the inner-layer conductor, the middle-layer type-two conductor is connected to the outer-layer conductor, or the middle-layer type-one conductor is connected to the outer-layer conductor, and the middle-layer type-two conductor is connected to the inner-layer conductor.

4. The stator assembly according to claim 1, characterized in that, In one branch of each phase winding, the number of the lead conductors is two. The lead conductors include a straight segment portion. The number of the outer conductors is one less than the number of the inner conductors. Under one magnetic pole of one branch, the two lead conductors are connected to the middle conductor. Under the remaining magnetic poles of one branch, the outer conductor is connected to the middle conductor.

5. The stator assembly according to claim 4, wherein, under one magnetic pole of one branch winding, the two lead conductors are circumferentially offset from one inner conductor by one stator slot. Under the remaining magnetic poles of one branch winding, one straight segment portion of the outer conductor is circumferentially offset from one straight segment portion of the inner conductor by one stator slot, and the other straight segment portion of the outer conductor is circumferentially offset from the other straight segment portion of the inner conductor by one stator slot.

6. The stator assembly according to claim 1, wherein, each phase includes at least two branch windings, and the two branch windings are connected in series or in parallel.

7. The stator assembly according to claim 6, wherein, under the same magnetic pole of the same phase winding, the inner conductors in one branch are circumferentially offset from the inner conductors in the other branch by one stator slot.

8. The stator assembly according to claim 6, wherein, under the same magnetic pole of the same phase winding, the middle conductors in one branch are circumferentially offset from the middle conductors in the other branch by one stator slot.

9. An electric machine, wherein, it includes the stator assembly according to any one of claims 1 to 8.

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