A stator assembly and motor using the same

Abstract

The present invention proposes a stator assembly, comprising: a stator core having stator slots, wherein the stator slots include 2N slot layers; and a stator winding inserted into the stator slots, wherein the stator winding includes a plurality of adjacent layer coils and a plurality of cross-layer coils; wherein N-1 adjacent layer coils are connected to form an adjacent layer coil group, the cross-layer coils differ radially by 2N-1 slot layers, and the cross-layer coils include full-pitch cross-layer coils, long-pitch cross-layer coils, and short-pitch cross-layer coils; a full-pitch cross-layer coil and an adjacent layer coil group are connected to form a first connecting section, a long-pitch cross-layer coil and another adjacent layer coil group are connected to form a second connecting section, and a short-pitch cross-layer coil and another adjacent layer coil group are connected to form a third connecting section; 2N first connecting sections, a second connecting section, and a third connecting section are connected to form a complete branch. The present invention can avoid circulating current, reduce losses, and improve motor efficiency. It is applicable to even-numbered winding layers and can be designed for motors with specific power and torque requirements.

Description

Technical Field

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

[0002] Existing flat-wire motors typically use short-pitch windings to reduce winding magnetic potential harmonics. For example, short-pitch windings are used in Chinese patent CN2015202654363. In CN2020101934004, the flat-wire continuous-wave winding employs full-pitch windings. However, due to the staggered winding structure, it is equivalent to a double-layer short-pitch winding. Consequently, the flat-wire coils within a stator slot belong to different phase windings. To ensure insulation reliability, additional interlayer insulating paper is required, which reduces the stator slot fill rate and reduces motor efficiency. Summary of the Invention

[0003] The present invention provides a stator assembly and a motor using the same, which are used to solve the problem of low insulation reliability caused by flat wire coils in a stator slot belonging to different phase windings, and provides the following technical solutions.

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

[0005] A stator core having stator slots, wherein the stator slots include 2N slot layers; and

[0006] A stator winding is inserted into the stator slot, wherein the stator winding includes a plurality of adjacent layer coils and a plurality of cross-layer coils;

[0007] Wherein, N-1 adjacent layer coils are connected to form an adjacent layer coil group, the radial difference between the cross-layer coils is 2N-1 slot layers, and the cross-layer coils include full-distance cross-layer coils, long-distance cross-layer coils and short-distance cross-layer coils;

[0008] One of the full-distance cross-layer coils and one of the adjacent layer coil groups are connected to form a first connection segment, one of the long-distance cross-layer coils and another of the adjacent layer coil groups are connected to form a second connection segment, and one of the short-distance cross-layer coils and another of the adjacent layer coil groups are connected to form a third connection segment; 2N first connection segments, one second connection segment and one third connection segment are connected to form a complete branch.

[0009] In one embodiment of the present invention, the adjacent layer coil includes:

[0010] two straight line segments; and

[0011] Connecting segment, connecting between two straight line segments;

[0012] Wherein, in the radial direction of the motor core, the two straight line segments located in a single adjacent layer of coils are separated by one slot layer.

[0013] In one embodiment of the present invention, the adjacent layer coil further includes:

[0014] A twisting section connected to the connecting section;

[0015] Wherein, the adjacent coils in adjacent layers are connected via a twist section, and the adjacent coils in adjacent layers are radially separated by one slot layer.

[0016] In one embodiment of the present invention, the span of the adjacent layer coils is y, where y represents the motor pole pitch, the span of the twisting section is y / 2, and the circumferential difference between the adjacent layer coils is y stator slots.

[0017] In one embodiment of the present invention, the span of the full-distance cross-layer coil is y, the span of the long-distance cross-layer coil is y+1, and the span of the short-distance cross-layer coil is y-1.

[0018] In one embodiment of the present invention, in each branch of each phase winding, the symmetry axis of the long-distance cross-layer coil and the symmetry axis of the short-distance cross-layer coil are the same.

[0019] In one embodiment of the present invention, the branches are connected in parallel, and the number of the branches is a positive integer greater than or equal to 2.

[0020] In one embodiment of the present invention, each phase winding includes two branches, and the output end of the first branch is circumferentially different from the output end of the second branch by one stator slot and radially different by one slot layer.

[0021] In one embodiment of the present invention, each phase winding includes two branches, and the incoming end of the first branch and the incoming end of the second branch are circumferentially spaced apart by 2y-1 stator slots and radially spaced apart by one slot layer.

[0022] The present invention may also provide a motor comprising any of the above-mentioned stator assemblies.

[0023] The present invention proposes a stator assembly and a motor using the same. The present invention can avoid circulating current, reduce losses, and improve motor efficiency. It is applicable to even-layer windings and can be designed for motors with specific power and torque requirements. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 This is a structural schematic diagram of a stator assembly of the present invention.

[0025] Figure 2 The present invention provides a wiring diagram of a single-phase winding of a stator winding in a stator assembly.

[0026] Figure 3 The present invention is a schematic structural diagram of adjacent layer coil groups in a stator winding in a stator assembly.

[0027] Figure 4 The figure is a schematic structural diagram of adjacent layer coils in a stator winding in a stator assembly of the present invention.

[0028] Figure 5 The present invention is a structural schematic diagram of a stator winding with full pitch and layer-spanning coils in a stator assembly.

[0029] Figure 6 The present invention is a schematic structural diagram of a long-distance cross-layer coil in a stator winding of a stator assembly.

[0030] Figure 7 The present invention is a schematic structural diagram of a short-spacing cross-layer coil in a stator winding in a stator assembly.

[0031] Figure 8 The figure is a schematic diagram of the coil distribution in the stator slot under a magnetic pole in a stator assembly of the present invention.

[0032] Figure 9 The figure is a schematic diagram of the star connection structure of a parallel branch in a stator assembly of the present invention.

[0033] Figure 10 The figure is a schematic diagram of the star connection structure of another parallel branch in a stator assembly of the present invention.

[0034] In the figure: 100, stator winding; 1001, hairpin end; 1002, welding end;

[0035] 110. Adjacent layer coil group; 111. Adjacent layer coil;

[0036] 121. Full-spacing cross-layer coil; 122. Long-spacing cross-layer coil; 123. Short-spacing cross-layer coil;

[0037] 101. Connecting segment; 102. Straight segment; 103. Turning segment;

[0038] 200. Stator core; 210. Stator slot. DETAILED DESCRIPTION

[0039] The following describes the embodiments of the present invention through specific examples. Those skilled in the art will readily understand the other advantages and benefits of the present invention from the disclosure herein. The present invention may also be implemented or applied through various other specific embodiments, and the details in this specification may be modified or altered based on different viewpoints and applications without departing from the spirit of the present invention.

[0040] It should be noted that the illustrations provided in this embodiment are only used to schematically illustrate the basic concept of the present invention. Therefore, the illustrations only show components related to the present invention and are not drawn according to the number, shape and size of components in actual implementation. In actual implementation, the type, quantity and proportion of each component can be changed at will, and the component layout type may also be more complicated.

[0041] See also Figures 1 to 10 The present invention provides a stator assembly and a motor using the same, which can be applied to fields such as electric servo drives and transportation. For example, the stator assembly and the motor used in the present application can be used in electric vehicles. In the stator core of the present invention, each branch coil within the stator slot is completely symmetrical, and all coils in the same stator slot belong to the same phase winding. The present invention is described in detail below using specific embodiments.

[0042] See also 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 210, which may be formed on the inner wall of the stator core 200. The stator slots 210 may be arranged along the circumferential direction of the inner wall of the stator core 200, and the stator slots 210 may be spaced apart at predetermined intervals on the stator core 200. The upper and lower end surfaces of the stator core 200 may be defined as a hairpin end 1001 and a welding end 1002, respectively. The stator winding 100 may be inserted into the interior of the stator core 200 from the hairpin end 1001, and the stator winding 100 may be welded at the welding end 1002.

[0043] See also Figure 1 As shown, in some embodiments, the plurality of stator slots 210 may be defined as stator slot 210 No. 1, stator slot 210 No. 2, stator slot 210 No. 3, stator slot 210 No. 4, and so on, along the circumferential direction of the stator core 200. For example, the stator core 200 may have 48 stator slots 210 arranged circumferentially. Each stator slot 210 may be arranged with multiple slot layers. In some embodiments, each stator slot 210 may be arranged with 2N slot layers, for example, each stator slot 210 may be arranged with six slot layers. For example, the six slot layers may be arranged from the inner side to the outer side of the radial direction of the stator core 200, respectively, as slot layer 1, slot layer 2, slot layer 3, slot layer 4, slot layer 5, and slot layer 6. That is, slot layer 1 may be located near the opening of the stator slot 210, and slot layer 6 may be located near the bottom of the stator slot 210. In addition, the specific numbering of the slot layers of each stator slot 210 is not limited. In the embodiment of the present invention, they are arranged in the order of 1 to 6 from the inside to the outside. In some other embodiments, they can also be arranged in the order of 1 to 6 from the outside to the inside.

[0044] See also Figures 2 to 7 As shown, in some embodiments, the stator winding 100 may include a plurality of adjacent layer coils 111 and a plurality of cross-layer coils. The two straight segments 102 of the adjacent layer coils 111 may differ radially by one slot layer, and the two adjacent adjacent layer coils 111 are connected. The two adjacent adjacent layer coils 111 may differ circumferentially by y stator slots 210, and the motor pole pitch is represented as y. N-1 adjacent layer coils 111 may constitute an adjacent layer coil group 110. The adjacent layer coil group 110 may be located in the stator slots 210 of the stator core 200. An adjacent layer coil group 110 may occupy consecutive slot layers from the 1st layer to the 2Nth layer. The cross-layer coils may differ by 2N-1 slot layers in the radial direction of the stator core 200. The cross-layer coils may include full-distance cross-layer coils 121, long-distance cross-layer coils 122, and short-distance cross-layer coils 123.

[0045] See also Figures 2-4 As shown, in some embodiments, the adjacent layer coil 111 may include a connecting segment 101, two straight segments 102, and two twisted segments 103. A connecting segment 101 may be connected to a straight segment 102 at each end. After passing through the stator slots 210 of the stator core 200, the two straight segments 102 are twisted at the welded end 1002 to form two twisted segments 103. The two twisted segments 103 of the adjacent layer coil 111 extend the same distance along one side of the welded end 1002 of the stator core 200, which may be equal to half the pole pitch.

[0046] See also Figures 2-4 As shown, in some embodiments, the pitch of the adjacent layer coil 111 is characterized as y1, for example, y1 = y. The two twist segments 103 of the adjacent layer coil 111 can be separated from each other, and the two twist segments 103 can extend in opposite directions. For example, the extension direction of one twist segment 103 can be in the clockwise direction or in the counterclockwise direction, while the extension direction of the other twist segment 103 is opposite.

[0047] See also Figures 5-7 As shown, in some embodiments, the full-pitch cross-layer coil 121, the long-pitch cross-layer coil 122, and the short-pitch cross-layer coil 123 may include a connecting segment 101, two straight segments 102, and two twisted segments 103. A connecting segment 101 may be connected to a straight segment 102 at each end. The two straight segments 102 pass through the stator slots 210 of the stator core 200 and then twist at the welding end 1002 to form two twisted segments 103. The two twisted segments 103 of the full-pitch cross-layer coil 121, the long-pitch cross-layer coil 122, and the short-pitch cross-layer coil 123 extend along one side of the welding end 1002 of the stator core 200 for the same distance, which may be equal to half the pole pitch.

[0048] See also Figures 5-7As shown, in some embodiments, the pitches of the full-spacing layer-crossing coil 121, the long-spacing layer-crossing coil 122, and the short-spacing layer-crossing coil 123 are represented as y2, y3, and y4, respectively, for example, y2=y, y3=y+1, and y4=y-1. The two twist segments 103 of the full-spacing layer-crossing coil 121, the long-spacing layer-crossing coil 122, and the short-spacing layer-crossing coil 123 can be separated from each other, and the two twist segments 103 can extend in opposite directions. For example, the extension direction of one twist segment 103 can be in the clockwise direction or in the counterclockwise direction, and the extension direction of the other twist segment 103 is the opposite.

[0049] See also Figure 2 As shown, in some embodiments, for example, the motor may include eight magnetic poles, and the stator winding 100 may include a three-phase winding, with each phase winding including two branches. The flat wire winding has six slot layers, L. In the winding expansion diagram for phase A, A1X1 represents the first branch, A2X2 represents the second branch, A1 and A2 represent the winding's incoming wire ends, and X1 and X2 represent the winding's outgoing wire ends. Welding terminals 1002 and hairpin terminals 1001 are located on either side of the winding. Within each stator slot 210, from left to right, the number of slot layers is, from left to right, 6, 5, 4, 3, 2, and 1.

[0050] The specific winding method of the first branch A1X1 of the A-phase winding is as follows, where 27(6) represents the 6th slot layer of the 27th stator slot 210.

[0051] A1->27(6)->33(1)->39(2)->45(3)->3(4)->9(5)->15(6)->22(1)->28(2)->34(3)->40(4)->46(5 )->4(6)->10(1)->16(2)->22(3)->28(4)->34(5)->40(6)->46(1)->4(2)->10(3)->16(4)->22(5)- >28(6)->34(1)->40(2)->46(3)->4(4)->10(5)->16(6)->21(1)->27(2)->33(3)->39(4)->45(5)- >3(6)->9(1)->15(2)->21(3)->27(4)->33(5)->39(6)->45(1)->3(2)->9(3)->15(4)->21(5)->X1.

[0052] The specific winding method of the second branch A2X2 of the A-phase winding is as follows:

[0053] A2->16(5)->10(4)->4(3)->46(2)->40(1)->34(6)->28(5)->22(4)->16(3)->10(2)->4(1)->46(6 )->40(5)->34(4)->28(3)->22(2)->16(1)->9(6)->3(5)->45(4)->39(3)->33(2)->27(1)->21(6)- >15(5)->9(4)->3(3)->45(2)->39(1)->33(6)->27(5)->21(4)->15(3)->9(2)->3(1)->45(6)->39 (5)->33(4)->27(3)->21(2)->15(1)->10(6)->4(5)->46(4)->40(3)->34(2)->28(1)->22(6)->X2.

[0054] See also Figure 2 As shown, in some embodiments, the outlet end X1 of the first branch and the outlet end X2 of the second branch differ by one stator slot 210 circumferentially and one slot layer radially, and are located near the mouth of the stator slot 210. The inlet end A1 of the first branch and the inlet end A2 of the second branch differ by 2y-1 stator slots 210 circumferentially and one slot layer radially, and are located near the bottom of the stator slot 210. It should be noted that "difference" can refer to the difference between the number of two slots, for example, there is a difference of 6 stator slots 210 between stator slot 210 No. 3 and stator slot 210 No. 9. In addition, "difference" can also refer to the difference between two slot layers, for example, there is a difference of 3 slot layers between the first slot layer and the fourth slot layer.

[0055] See also Figure 2 As shown, in some embodiments, a full-pitch cross-layer coil 121 is connected to an adjacent layer coil group 110, and is characterized as a first connection segment. Taking the first branch A1X1 of the A-phase winding as an example, "27(6)->33(1)->39(2)->45(3)->3(4)->9(5)" is a first connection segment. Among them, "27(6)->33(1)" is the full-pitch cross-layer coil 121, "39(2)->45(3)" and "3(4)->9(5)" are the adjacent layer coils 111, and "39(2)->45(3)->3(4)->9(5)" is the adjacent layer coil group 110. A full-pitch cross-layer coil 121 and an adjacent layer coil group 110 are distributed in different slot layers, that is, they occupy all slot layers in the radial direction.

[0056] See also Figure 2As shown, in some embodiments, a long-distance cross-layer coil 122 is connected to an adjacent layer coil group 110 and characterized as a second connection segment. Taking the first branch A1X1 of the A-phase winding as an example, "15(6)->22(1)->28(2)->34(3)->40(4)->46(5)" is a second connection segment. Among them, "15(6)->22(1)" is the long-distance cross-layer coil 122, "28(2)->34(3)" and "40(4)->46(5)" are the adjacent layer coils 111, and "28(2)->34(3)->40(4)->46(5)" is the adjacent layer coil group 110. A long-distance cross-layer coil 122 and an adjacent layer coil group 110 are distributed in different slot layers, that is, they occupy all slot layers in the radial direction.

[0057] See also Figure 2 As shown, in some embodiments, a short-distance cross-layer coil 123 is connected to an adjacent layer coil group 110 and characterized as a third connection segment. Taking the first branch A1X1 of the A-phase winding as an example, "16(6)->21(1)->27(2)->33(3)->39(4)->45(5)" is a second connection segment. Among them, "16(6)->21(1)" is the short-distance cross-layer coil 123, "27(2)->33(3)" and "39(4)->45(5)" are the adjacent layer coils 111, and "27(2)->33(3)->39(4)->45(5)" is the adjacent layer coil group 110. A short-distance cross-layer coil 123 and an adjacent layer coil group 110 are distributed in different slot layers, that is, they occupy all slot layers in the radial direction.

[0058] See also Figure 2 As shown, in some embodiments, in each branch of each phase winding, a complete branch can be formed by 2N first connecting segments, one second connecting segment, and one third connecting segment. In the first branch or the second branch, the axis of symmetry of the long-distance adjacent layer coil 131 and the axis of symmetry of the short-distance adjacent layer coil 132 can be the same. The first straight line segment 102 of the long-distance adjacent layer coil 131 and the first straight line segment 102 of the short-distance adjacent layer coil 132 can differ in circumferential direction by one stator slot 210, and the second straight line segment 102 of the long-distance adjacent layer coil 131 and the second straight line segment 102 of the short-distance adjacent layer coil 132 can differ in circumferential direction by one stator slot 210.

[0059] See also Figure 8 As shown, in some embodiments, the flat wire coils of each stator slot 210 belong to the same phase winding, the interlayer insulation paper is eliminated, the slot fill rate of the stator slot 210 in the stator winding 100 is improved, the resistance of the stator winding 100 is reduced, the copper loss of the motor is reduced, and the efficiency of the motor is improved.

[0060] See also Figure 8 As shown, in some embodiments, two branches of a phase winding can be connected in series to form a parallel branch. Figure 9 As shown, in some embodiments, two branches of a phase winding can also be connected in parallel to form two parallel branches. Figures 8-9 As shown, in this embodiment, the three-phase windings are connected in star. In other embodiments, a triangle connection can also be used.

[0061] In summary, the present invention provides a stator assembly and a motor using the same. The stator winding wiring of the present invention avoids circulating currents, reduces losses, and improves motor efficiency. It is applicable to even-numbered winding layers and can be designed for motors with specific power and torque requirements.

[0062] The above description is only a preferred embodiment of the present application and an explanation of the technical principles used. Those skilled in the art should understand that the scope of the invention involved in this application is not limited to the technical solutions formed by the specific combination of the above-mentioned technical features, but should also cover other technical solutions formed by any combination of the above-mentioned technical features or their equivalent features without departing from the inventive concept, such as the technical solutions formed by the mutual replacement of the above-mentioned features with (but not limited to) technical features with similar functions disclosed in this application.

[0063] Except for the technical features described in the specification, the remaining technical features are known technologies to those skilled in the art. In order to highlight the innovative features of the present invention, the remaining technical features will not be described here in detail.

Claims

1. A stator assembly, characterized in that: include: A stator core having stator slots, wherein the stator slots include 2N slot layers; as well as A stator winding is inserted into the stator slot, wherein the stator winding includes a plurality of adjacent layer coils and a plurality of cross-layer coils; Wherein, N-1 adjacent layer coils are connected to form an adjacent layer coil group, the radial difference between the cross-layer coils is 2N-1 slot layers, and the cross-layer coils include full-distance cross-layer coils, long-distance cross-layer coils and short-distance cross-layer coils; One of the full-distance cross-layer coils and one of the adjacent layer coil groups are connected to form a first connection segment, one of the long-distance cross-layer coils and another of the adjacent layer coil groups are connected to form a second connection segment, and one of the short-distance cross-layer coils and another of the adjacent layer coil groups are connected to form a third connection segment; 2N first connection segments, one second connection segment and one third connection segment are connected to form a complete branch.

2. The stator assembly according to claim 1, characterized in that The adjacent layer coil comprises: two straight line segments; and Connecting segment, connecting between two straight line segments; Wherein, in the radial direction of the motor core, the two straight line segments located in a single adjacent layer of coils are separated by one slot layer.

3. The stator assembly according to claim 2, characterized in that The adjacent layer coil further includes: a twisting segment connected to the straight segment; Wherein, the adjacent coils in adjacent layers are connected via a twist section, and the adjacent coils in adjacent layers are radially separated by one slot layer.

4. The stator assembly according to claim 3, characterized in that The span of the adjacent layer coils is y, where y represents the motor pole pitch. The span of the twisting section is y / 2, and the circumferential difference between the adjacent layer coils is y stator slots.

5. The stator assembly according to claim 1, characterized in that The span of the full-distance cross-layer coil is y, the span of the long-distance cross-layer coil is y+1, and the span of the short-distance cross-layer coil is y-1.

6. The stator assembly according to claim 1, wherein: In each branch of each phase winding, the symmetry axis of the long-distance cross-layer coil and the symmetry axis of the short-distance cross-layer coil are the same.

7. The stator assembly according to claim 1, characterized in that The branches are arranged in parallel, and the number of the branches is a positive integer greater than or equal to 2.

8. The stator assembly according to claim 1, wherein: Each phase winding includes two branches, and the output end of the first branch is circumferentially different from the output end of the second branch by one stator slot and radially by one slot layer.

9. The stator assembly according to claim 8, characterized in that Each phase winding includes two branches, and the incoming end of the first branch and the incoming end of the second branch differ by 2y-1 stator slots in the circumferential direction and by one slot layer in the radial direction.

10. A motor, characterized in that: The stator assembly comprises the stator assembly according to any one of claims 1 to 9.

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