An electric machine and a vehicle having the same

Abstract

The application provides a motor and a vehicle with the same. The motor comprises a shell, a stator assembly and a circuit board. The inner circumferential surface of the stator core is provided with stator slots, and the stator slots are provided with pin winding. The circuit board is located in the shell, and the circuit board is arranged opposite to one end of the stator core. The surface of the circuit board away from the stator core is provided with a wiring circuit area, the wiring circuit area is arranged opposite to each coil of the pin winding, the plug-in conductor of each coil is electrically connected with the circuit of the wiring circuit area, the wiring circuit area is provided with a wiring terminal, and the wiring terminal is electrically connected with the circuit of the wiring circuit area. The plug-in conductor is directly connected with the circuit of the wiring circuit area, without the need to change the complex manufacturing processes such as twisting and welding of the pin winding coil. By changing the circuit connection structure of the wiring circuit area, different series turns can be realized, different motor output external characteristics can be met, and the manufacturing generalization level of the vehicle driving motor is improved.

Description

Technical Field

[0001] This invention relates to the field of electric motor technology, and more specifically, to an electric motor and a vehicle having the same. Background Technology

[0002] As the performance of new energy vehicles continues to improve, the power density requirements for motors are becoming increasingly stringent. As a key performance factor, the design and manufacturing of motor stator windings have become a core competitive advantage for electric drive systems. Current stator winding technologies for drive motors primarily focus on increasing the slot fill factor, leading to the emergence of new types of motor windings such as precision wire routing and pin-wound flat wire windings. However, these new windings require specialized automated equipment for mass production, resulting in significant equipment investment and insufficient flexibility. To meet different motor output characteristics, the number of turns in the motor windings needs to be flexibly adjusted. For pin-wound windings, adjusting the number of turns increases the difficulty of design and manufacturing. Different design schemes require different molds for forming the pin coils, posing challenges to the platformization and standardization of motors.

[0003] Currently, multiple coils in the stator winding of a motor are twisted and welded together to form a winding circuit. The manufacturing process of the above-mentioned stator winding electrical connection method is complex, the wiring efficiency is low, and the winding end height is large, which is not conducive to the miniaturization of the motor. Summary of the Invention

[0004] The main objective of this invention is to provide an electric motor and a vehicle having the same, in order to solve the technical problems of complex manufacturing process and low wiring efficiency of the electrical connection method of the pin stator winding.

[0005] To achieve the above objectives, according to one aspect of the present invention, an electric motor is provided, comprising: a housing; a stator assembly located within the housing, the stator assembly including a stator core, a stator slot provided on the inner circumferential surface of the stator core, and a pin winding inserted into the stator slot; and a circuit board located within the housing, the circuit board being disposed opposite to one end of the stator core, and a wiring circuit area being provided on the surface of the circuit board away from the stator core, the wiring circuit area being disposed opposite to each coil constituting the pin winding, the insertion conductor of each coil being electrically connected to the circuit of the wiring circuit area, and a terminal being provided on the wiring circuit area, the terminal being electrically connected to the circuit of the wiring circuit area.

[0006] Furthermore, the circuit board has a disc structure and is coaxially arranged with the stator core; a clearance hole is provided at the center of the circuit board, through which the output shaft of the motor passes.

[0007] Furthermore, an annular limiting groove is provided on the inner wall of the housing, and the outer edge of the circuit board is embedded in the limiting groove.

[0008] Furthermore, the circuit board is provided with multiple lead holes, and pads are provided around the lead holes. The pads are electrically connected to the circuit of the wiring circuit area, and the coil's insertion conductor passes through the lead hole and is electrically connected to the pad.

[0009] Furthermore, the circuit board is equipped with winding markings, which correspond to the pads.

[0010] Furthermore, there is a gap between the circuit board and the stator core.

[0011] Furthermore, it also includes: an end cap, which is connected to the open end of the housing, and a through hole is provided on the end cap, through which the wiring terminal extends out of the housing.

[0012] Furthermore, there are three terminals, which are evenly arranged along the circumference of the circuit board.

[0013] Furthermore, the pin winding includes at least one layer of coil, which has a U-shaped structure.

[0014] According to another aspect of the present invention, a vehicle is provided, including an electric motor, which is the electric motor described above.

[0015] By applying the technical solution of this invention, the insertion conductors of each coil forming the pin winding are electrically connected to the circuit of the wiring circuit area to form a winding loop. The insertion conductors of each coil can be directly connected to the circuit of the wiring circuit area, eliminating the need to modify complex manufacturing processes such as twisting and welding of the pin winding coils. By simply changing the circuit connection structure of the wiring circuit area, different numbers of series turns can be achieved to meet different motor output characteristics, improving the standardization of vehicle drive motor manufacturing, reducing the complexity of the stator winding electrical connection process, and increasing wiring efficiency. Simultaneously, since each insertion conductor is connected to the circuit of the wiring circuit area, the insertion conductors provide support for the circuit board, eliminating the need for other support components, simplifying the motor structure, and reducing connection steps. Furthermore, this wiring method results in a smaller winding end height, which is beneficial for the miniaturization design of the motor. Attached Figure Description

[0016] The accompanying drawings, which form part of this application, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings:

[0017] Figure 1 A schematic diagram of a motor according to an embodiment of the present invention is shown;

[0018] Figure 2 A schematic diagram of the stator assembly according to an embodiment of the electric motor is shown;

[0019] Figure 3 It shows Figure 2 A cross-sectional schematic diagram;

[0020] Figure 4 A schematic diagram showing the connection relationship between the stator assembly and the circuit board is shown;

[0021] Figure 5 A schematic diagram of the coil structure according to an embodiment of the electric motor is shown;

[0022] Figure 6 A schematic diagram of the coil distribution according to an alternative embodiment of the electric motor according to the present invention is shown;

[0023] Figure 7 A circuit diagram of the wiring circuit area of ​​a circuit board according to an alternative embodiment of a motor according to the present invention is shown;

[0024] Figure 8 A circuit diagram of the wiring circuit area of ​​a circuit board according to another alternative embodiment of the motor according to the present invention is shown.

[0025] The above figures include the following reference numerals:

[0026] 100. Housing; 101. End cap; 102. Spacer; 103. Bearing;

[0027] 200. Stator assembly; 201. Stator core; 202. Pin winding; 203. Stator slot; 204. Coil; 205. Connecting conductor; 206. Connecting conductor; 207. First winding module; 208. Second winding module; 209. Third winding module; 210. Fourth winding module;

[0028] 300. Circuit board; 301. Wiring circuit area; 302. Terminal block;

[0029] 400. Rotor assembly; 401. Output shaft. Detailed Implementation

[0030] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0031] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0032] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such terms can be used interchangeably where appropriate so that the embodiments of this application described herein can be implemented, for example, in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover a non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0033] Exemplary embodiments according to this application will now be described in more detail with reference to the accompanying drawings. However, these exemplary embodiments may be implemented in many different forms and should not be construed as being limited to the embodiments set forth herein. It should be understood that these embodiments are provided so that the disclosure of this application is thorough and complete, and that the concept of these exemplary embodiments is fully conveyed to those skilled in the art. In the drawings, for clarity, the thickness of layers and regions may be exaggerated, and the same reference numerals are used to denote the same devices, and therefore their description will be omitted.

[0034] Combination Figures 1 to 8 As shown, according to a specific embodiment of this application, an electric motor is provided.

[0035] Specifically, such as Figure 1 As shown, the motor includes a housing 100, a stator assembly 200, and a circuit board 300. The stator assembly 200 is located inside the housing 100 and includes a stator core 201. A stator slot 203 is provided on the inner circumferential surface of the stator core 201, and a pin winding 202 is inserted into the stator slot 203. The circuit board 300 is located inside the housing 100 and is positioned opposite one end of the stator core 201. A wiring circuit area 301 is provided on the surface of the circuit board 300 away from the stator core 201. The wiring circuit area 301 is positioned opposite each coil 204 that makes up the pin winding 202. The insertion conductors 205 of each coil 204 are electrically connected to the wiring circuit area 301. A terminal block 302 is provided on the wiring circuit area 301 and is electrically connected to the wiring circuit area 301.

[0036] Furthermore, such as Figure 1As shown, the motor also includes an end cover 101 and a rotor assembly 400. The end cover 101 is connected to the open end of the housing 100, encapsulating the rotor assembly 400 and the stator assembly 200 within the housing 100. The stator core 201 is sleeved on the outside of the rotor assembly 400. The rotor assembly 400 is coaxially connected to the output shaft 401. The output shaft 401 is rotatably connected to the housing 100 and the end cover 101 via a bearing 103, and the end of the output shaft 401 extends out of the housing 100.

[0037] In the embodiments of this application, the insertion conductors 205 of each coil 204 constituting the pin winding 202 are electrically connected to the circuit of the wiring circuit area 301 to form a winding loop. The insertion conductors 205 of each coil 204 can be directly connected to the circuit of the wiring circuit area 301, eliminating the need to modify complex manufacturing processes such as twisting and welding of the coils 204 in the pin winding 202. By simply changing the circuit connection structure of the wiring circuit area 301, different numbers of series turns can be achieved to meet different motor output characteristics, improving the standardization of vehicle drive motor manufacturing, reducing the complexity of the stator winding electrical connection process, and increasing wiring efficiency. Simultaneously, since each insertion conductor 205 is connected to the circuit of the wiring circuit area 301, the insertion conductors 205 provide support for the circuit board 300, eliminating the need for other supporting components, simplifying the motor structure, and reducing connection steps. Furthermore, this wiring method results in a smaller winding end height, which is beneficial for the miniaturization design of the motor.

[0038] like Figure 1 As shown, the circuit board 300 has a disc structure and is coaxially arranged with the stator core 201. A clearance hole is provided at the center of the circuit board 300, through which the motor output shaft 401 passes. The disc structure of the circuit board 300 significantly increases its cross-sectional area, allowing the wiring circuit area 301 to directly align with the insertion conductors 205 of each coil 204. This eliminates the need for secondary processing, such as bending, at the ends of the insertion conductors 205 to accommodate the wiring circuit area 301, further simplifying the wiring process.

[0039] To prevent the circuit board 300 from moving axially within the housing 100, an annular limiting groove is provided on the inner wall of the housing 100. The outer edge of the circuit board 300 is embedded in the limiting groove, which axially limits the circuit board 300.

[0040] To facilitate the embedding of the circuit board 300 into the limiting groove, a tapered chamfer can be provided at the end of the limiting groove away from the stator core 201. The tapered chamfer serves as a guide.

[0041] Specifically, the wiring circuit area 301 is located on the side of the circuit board 300 away from the stator core 201. The insertion conductor 205 of the coil 204 needs to pass through the circuit board 300 and be electrically connected to the circuit of the wiring circuit area 301. The circuit board 300 has multiple lead holes, and pads are arranged around the lead holes. The pads are electrically connected to the circuit of the wiring circuit area 301, and the insertion conductor 205 of the coil 204 passes through the lead holes and is electrically connected to the pads.

[0042] To facilitate inspection of the winding circuit wiring, the circuit board 300 is equipped with winding markings, which correspond to the pads.

[0043] like Figure 1 , Figure 4 As shown, there is a gap space 102 between the circuit board 300 and the stator core 201. The setting of the gap space 102 increases the length of the protruding end of the pin winding 202, which facilitates the adjustment of the correspondence between the pin winding 202 and the lead hole on the circuit board 300.

[0044] like Figure 1 As shown, the end cap 101 has a through hole, through which the terminal block 302 extends from the housing 100. The terminal block 302 is located on the outside of the housing 100 to prevent it from being connected to an external power source.

[0045] like Figure 4 As shown, there are three terminals 302, which are evenly arranged around the circumference of the circuit board 300.

[0046] Furthermore, the pin winding 202 includes at least one layer of coil 204, which has a U-shaped structure. For example... Figure 2 , Figure 3 As shown, the pin winding 202 is composed of two layers of coils 204, which increases the difficulty of wiring the stator assembly 200. The above wiring method is suitable for stator assemblies 200 with multiple layers of coils 204, simplifying the wiring process. Figure 5 As shown, coil 204 is a U-shaped structure formed by bending, including insertion conductor 205 and connecting conductor 206. Coil 204 has good overall performance.

[0047] The coil 204 is formed by bending a single conductor or a bundle (or multiple conductors). During motor operation, the coil 204, composed of multiple conductors, consumes less power, thereby increasing the motor's output power.

[0048] like Figure 6As shown, a detailed description is given using a 48-slot, two-layer stator assembly 200 as an example. The pin winding 202 is divided into four winding modules, each including two layers of coils 204, with six coils in each layer. The inner and outer coils of each winding module are described in detail.

[0049] The inner coils of each winding module: In the first winding module 207, both ends of each coil 204 are marked, with the following labels in order: A1+, A5+, C1-, C5-, B1+, B5+, A1-, A5-, C1+, C5+, B1-, and B5-. In the second winding module 208, both ends of each coil 204 are marked, with the following labels in order: A2+, A6+, C4-, C8-, B2+, B6+, A2-, A6-, C4+, C8+, B2-, and B6-. In the third winding module 209, both ends of each coil 204 are marked, with the following labels in order: A3+, A7+, C7-, C3-, B3+, B7+, A3-, A7-, C7+, C3+, B3-, and B7-. The two ends of each coil 204 in the inner layer of the fourth winding module 210 are marked, and the markings are as follows: A4+, A8+, C2-, C6-, B4+, B8+, A4-, A8-, C2+, C6+, B4-, B8-.

[0050] The outer coils of each winding module: The two ends of each coil 204 in the outer layer of the first winding module 207 are marked as follows: A9+, A13+, C9-, C13-, B9+, B13+, A9-, A13-, C9+, C13+, B9- and B13-.

[0051] The two ends of each coil 204 on the outer layer of the second winding module 208 are marked as follows: A10+, A14+, C12-, C16-, B10+, B14+, A10-, A14-, C12+, C16+, B10-, and B14-.

[0052] The two ends of each coil 204 on the outer layer of the third winding module 209 are marked as follows: A11+, A15+, C15-, C11-, B11+, B15+, A11-, A15-, C15+, C11+, B11-, and B15-.

[0053] The two ends of each coil 204 in the outer layer of the fourth winding module 210 are marked as follows: A12+, A16+, C10-, C14-, B12+, B16+, A12-, A16-, C10+, C14+, B12-, B16-.

[0054] like Figure 7 As shown, the circuit board 300 will... Figure 6 The coils 204 described above are connected in series. Each pad on the circuit board has a corresponding winding label. Specifically, the circuit on circuit board 300 is as follows: pad A1+ is connected to phase A terminal 302; pad C1+ is connected to phase C terminal 302; pad B1+ is connected to phase B terminal 302; pad A1- is connected to pad A2+; pad C1- is connected to pad C2+; pad B1- is connected to pad B2+; pad A2- is connected to pad A3+; pad C2- is connected to pad C3+; pad B2- is connected to pad B3+; and pad A3- is connected to pad A4+. +Connection, pad C3- connects to pad C4+, pad B3- connects to pad B4+, pad A4- connects to pad A5+, pad C4- connects to pad C5+, pad B4- connects to pad B5+, pad A5- connects to pad A6+, pad C5- connects to pad C6+, pad B5- connects to pad B6+, pad A6- connects to pad A7+, pad C6- connects to pad C7+, pad B6- connects to pad B7+, pad A7- connects to pad A8+, pad C7- connects to pad C8+, pad B7- connects to pad B8+. Pad A8 is connected to pad A9+, pad C8 is connected to pad C9+, pad B8 is connected to pad B9+, pad A9 is connected to pad A10+, pad C9 is connected to pad C10+, pad B9 is connected to pad B10+, pad A10 is connected to pad A11+, pad C10 is connected to pad C11+, pad B10 is connected to pad B11+, pad A11 is connected to pad A12+, pad C11 is connected to pad C12+, pad B11 is connected to pad B12+, pad A12 is connected to pad A13+. Pad C12- connects to pad C13+, pad B12- connects to pad B13+, pad A13- connects to pad A14+, pad C13- connects to pad C14+, pad B13- connects to pad B14+, pad A14- connects to pad A15+, pad C14- connects to pad C15+, pad B14- connects to pad B15+, pad A15- connects to pad A16+, pad C15- connects to pad C16+, pad B15- connects to pad B16+, and pad A16- connects to both pad C16- and pad B16-. Connect the markings on each coil 204 to... Figure 7 The winding marks on the pads shown are matched one-to-one, and then soldered to achieve... Figure 6 The inner and outer layers of the pin windings are connected in series.

[0055] like Figure 8 As shown, the circuit board 300 will... Figure 6The coils 204 described above are connected in parallel. Each pad on the circuit board has a corresponding winding identifier. The circuit on the circuit board 300 specifically includes two parallel branches. The first branch is as follows: pad A1 is connected to pad A2+, pad C1 is connected to pad C2+, pad B1 is connected to pad B2+, pad A2 is connected to pad A3+, pad C2 is connected to pad C3+, pad B2 is connected to pad B3+, pad A3 is connected to pad A4+, pad C3 is connected to pad C4+, and pad B3 is connected to pad B4+. + Connections: Pad A4- connects to Pad A5+, Pad C4- connects to Pad C5+, Pad B4- connects to Pad B5+, Pad A5- connects to Pad A6+, Pad C5- connects to Pad C6+, Pad B5- connects to Pad B6+, Pad A6- connects to Pad A7+, Pad C6- connects to Pad C7+, Pad B6- connects to Pad B7+, Pad A7- connects to Pad A8+, Pad C7- connects to Pad C8+, Pad B7- connects to Pad B8+, and Pad A8- connects to both Pad C8- and Pad B8-. The second branch is as follows: Pad A9- connects to pad A10+, pad C9- connects to pad C10+, pad B9- connects to pad B10+, pad A10- connects to pad A11+, pad C10- connects to pad C11+, pad B10- connects to pad B11+, pad A11- connects to pad A12+, pad C11- connects to pad C12+, pad B11- connects to pad B12+, pad A12- connects to pad A13+, pad C12- connects to pad C13+, pad B... 12- is connected to pad B13+, pad A13- is connected to pad A14+, pad C13- is connected to pad C14+, pad B13- is connected to pad B14+, pad A14- is connected to pad A15+, pad C14- is connected to pad C15+, pad B14- is connected to pad B15+, pad A15- is connected to pad A16+, pad C15- is connected to pad C16+, pad B15- is connected to pad B16+, and pad A16- is connected to both pad C16- and pad B16-. The first and second branches are connected in parallel via terminals A, C, and B. Specifically, pads A1+ and A9+ are connected in parallel to terminal A 302, pads C1+ and C9+ are connected in parallel to terminal C 302, and pads B1+ and B9+ are connected in parallel to terminal B 302. The markings on each coil 204 are then aligned with... Figure 8 The winding marks on the pads shown are matched one-to-one, and then soldered to achieve... Figure 6 Parallel connection of inner and outer layer pin windings.

[0056] According to another specific embodiment of the present invention, a vehicle is provided, including a motor, which is the motor described in the above embodiment.

[0057] For ease of description, spatial relative terms such as "above," "on top of," "on the upper surface of," "above," etc., are used herein to describe the spatial positional relationship of a device or feature as shown in the figures to other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation beyond the orientation of the device as described in the figures. For example, if the device in the figures were inverted, a device described as "above" or "on top of" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0058] In addition to the above, it should be noted that the terms "one embodiment," "another embodiment," and "embodiment" used in this specification refer to specific features, structures, or characteristics described in connection with that embodiment, which are included in at least one embodiment described in the general description of this application. The appearance of the same expression in multiple places in the specification does not necessarily refer to the same embodiment. Furthermore, when a specific feature, structure, or characteristic is described in connection with any embodiment, the intention is to suggest that implementing such a feature, structure, or characteristic in conjunction with other embodiments also falls within the scope of this invention.

[0059] In the above embodiments, the descriptions of each embodiment have different focuses. For parts not described in detail in a certain embodiment, please refer to the relevant descriptions in other embodiments.

[0060] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. An electric motor, characterized in that, include: Casing (100); Stator assembly (200), the stator assembly (200) is located inside the housing (100), the stator assembly (200) includes a stator core (201), a stator slot (203) is provided on the inner circumferential surface of the stator core (201), and a pin winding (202) is inserted in the stator slot (203). A circuit board (300) is located inside the housing (100). The circuit board (300) is disposed opposite to one end of the stator core (201). A wiring circuit area (301) is provided on the surface of the circuit board (300) away from the stator core (201). The wiring circuit area (301) is disposed opposite to each coil (204) that makes up the pin winding (202). The insertion conductor (205) of each coil (204) is electrically connected to the circuit of the wiring circuit area (301). A terminal (302) is provided on the wiring circuit area (301). The terminal (302) is electrically connected to the circuit of the wiring circuit area (301). The circuit board (300) is provided with a plurality of lead holes, and the lead holes are provided with pads around their periphery. The pads are electrically connected to the circuit of the wiring circuit area (301). The plug conductor (205) of the coil (204) passes through the lead holes and is electrically connected to the pads. The circuit board (300) is provided with a winding mark, and the winding mark is provided in correspondence with the pad; The pin winding (202) is divided into four winding modules. Each winding module includes two layers of coils (204). The two ends of each coil (204) in the inner and outer layers of each winding module are marked. The markings of each coil (204) correspond one-to-one with the winding markings on the pads and are soldered to realize the series connection of the inner and outer layers of the pin winding (202) and / or the parallel connection of the inner and outer layers of the pin winding (202). There is a gap space (102) between the circuit board (300) and the stator core (201), and the pin winding (202) corresponds one-to-one with the lead hole on the circuit board (300).

2. The motor according to claim 1, characterized in that, The circuit board (300) has a disc structure and is coaxially arranged with the stator core (201). A clearance hole is provided at the center of the circuit board (300), and the output shaft (401) of the motor passes through the clearance hole and is arranged in the circuit board (300).

3. The motor according to claim 2, characterized in that, The inner wall of the housing (100) is provided with an annular limiting groove, and the outer edge of the circuit board (300) is embedded in the limiting groove.

4. The motor according to claim 1, characterized in that, Also includes: End cap (101) is connected to the open end of the housing (100). The end cap (101) has a through hole, and the terminal (302) extends out of the housing (100) through the through hole.

5. The motor according to claim 1, characterized in that, There are three terminals (302), and the three terminals (302) are evenly arranged along the circumference of the circuit board (300).

6. The motor according to any one of claims 1-5, characterized in that, The pin winding (202) includes at least one layer of the coil (204), which has a U-shaped structure.

7. A vehicle, comprising an electric motor, characterized in that, The motor is the motor described in any one of claims 1-6.

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