Stator assembly and electric machine

Abstract

The application provides a kind of stator assembly and motor, it is related to new energy automobile drive motor field, it is applied to motor, including stator core and multiphase winding, the circumferential of stator core is equipped with multiple slot body, slot body is equipped with M layer slot position for conductor wiring, each winding includes at least two parallel branch. Each branch includes multiple forward sections, reverse sections, first connection section and second connection section, and each branch coil is wound into the slot body of stator core with first span, second span, third span, the absolute value of the difference between second span and third span and first span is less than or equal to 2, so as to ensure that each winding installation slot position in each layer conductor is the same phase, while cancelling the insulating paper set in the slot body between different phases, so as to improve the slot fill factor of stator core, also can simplify the plug-in process of stator assembly, reduce insulation cost, improve the manufacturing efficiency of motor.

Description

Technical Field

[0001] This application relates to the field of drive motors for new energy vehicles, and in particular to a stator assembly and a motor. Background Technology

[0002] The drive motor in the electric vehicle's power system is a core component that ensures the electric vehicle's driving power.

[0003] A drive motor consists of windings and a stator core. The windings provide electrical energy input and establish a magnetic field, while the stator core provides the magnetic field path for the motor. The conductors within the windings are wound regularly around the stator core, and each conductor abuts against a different conductor layer in the same stator core slot. Since different conductor layers in the same stator core slot belong to different phases, adjacent winding conductors are prone to voltage breakdown. Therefore, insulating paper is placed inside the conductor slots to separate the winding conductors and prevent voltage breakdown.

[0004] However, in related technologies, the conductors in each layer of the stator core conductor slot have different phases. To prevent mutual interference between the conductor layers, insulating paper is placed between them for isolation. The installation of the insulating paper reduces the usable space of the stator core. This structure leads to a decrease in the slot fill factor of the stator core, thereby limiting the increase in the power of the drive motor. Summary of the Invention

[0005] This application provides a stator assembly and a motor that can improve the slot fill factor of the stator core and increase the driving power of the motor.

[0006] To achieve the above objectives, the embodiments of this application adopt the following technical solutions:

[0007] In a first aspect, this application provides a stator assembly for use in an electric motor, comprising: a stator core and a multiphase winding, wherein the stator core is provided with a plurality of slots in its circumference, and each slot is provided with M layers of slots for conductor wiring, wherein M is an even number; each phase winding includes at least two parallel branches, N≤M / 2;

[0008] Each branch includes multiple coil units and multiple first connecting segments. Each coil unit includes a forward segment, a reverse segment, and a second connecting segment. The forward segment is wound sequentially across layers from the first edge layer slot to the second edge layer slot along the circumference of the stator core in a first direction with a first span. The reverse segment is wound sequentially across layers from the second edge layer slot to the first edge layer slot in a second direction with the first span. The second connecting segment connects adjacent forward and reverse segments located in the second edge layer slot with a second span. Each first connecting segment connects between the forward and reverse segments of every two adjacent coil units with a third span, and the first connecting segment is located in the first edge layer slot. One of the first edge layer slot and the second edge layer slot is a first layer slot, and the other is an Mth layer slot. The first direction and the second direction are opposite.

[0009] The absolute value of the difference between the second span and the third span and the first span is less than or equal to 2.

[0010] As an optional implementation, each branch of each phase winding is arranged in a slot of the same slot body.

[0011] As an optional implementation, both the first connecting segment and the second connecting segment are wound around the first direction along the circumference of the stator core.

[0012] As an optional implementation, both the first connecting segment and the second connecting segment are wound around the second direction along the circumference of the stator core.

[0013] As an optional implementation, the at least two parallel branches included in each phase winding specifically include a first branch and a second branch;

[0014] The forward segment corresponding to the first branch is sequentially wound across layers from the first layer slot to the Mth layer slot, and the forward segment corresponding to the second branch is sequentially wound across layers from the Mth layer slot to the first layer slot, and the first directions corresponding to the first branch and the second branch are opposite.

[0015] As an optional implementation, the first span y is equal to the pole pitch of the motor;

[0016] The second span y1 satisfies the condition: y-2≤y1≤y+2; and

[0017] The third span y2 satisfies the condition: y-2≤y2≤y+2;

[0018] The first span y, the second span y1, and the third span y2 are all integers.

[0019] As an optional implementation, the magnetic poles of the two conductors connected to adjacent slots have opposite polarities.

[0020] As an optional implementation, one of the incoming and outgoing ends of each branch is located in the first layer slot, and the other is located in the Mth layer slot.

[0021] As an optional implementation, the motor winding is a three-phase winding, wherein the three-phase windings are wound in the same direction on the stator core and are 120° out of phase in space.

[0022] Secondly, this application provides an electric motor, including a rotor and a stator assembly as described in any of the preceding claims.

[0023] This application provides a stator assembly and a motor, including a stator core and multi-phase windings. The stator core has multiple slots circumferentially arranged, and each slot has M layers of slots for conductor wiring, where M is an even number. Each phase winding includes at least two parallel branches, N≤M / 2. Each branch includes multiple coil units and multiple first connecting sections. Each coil unit includes a forward section, a reverse section, and a second connecting section. The forward section is wound sequentially from the first edge layer slot to the second edge layer slot along the circumference of the stator core in a first direction with a first span. The reverse section is wound sequentially from the second edge layer slot in a second direction with the first span. The second connecting segment is wound across the first edge layer slot, and the second connecting segment is connected between the adjacent forward and reverse segments in the second edge layer slot with a second span. Each first connecting segment is connected between the forward and reverse segments of every two adjacent coil units with a third span, and the first connecting segment is located in the first edge layer slot. One of the first edge layer slot and the second edge layer slot is a first layer slot, and the other is a Mth layer slot. The first direction and the second direction are opposite. The absolute values ​​of the differences between the second span and the third span and the first span are both less than or equal to 2. Through the above-described stator assembly structure, different slots within the circumferential slots of the stator core are in phase, preventing voltage breakdown between adjacent windings. This also eliminates the need for insulating paper, thereby increasing the slot fill factor of the stator core and improving the motor's drive power. Attached Figure Description

[0024] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0025] Figure 1 A three-dimensional structural schematic diagram of the stator assembly provided in an embodiment of this application;

[0026] Figure 2 A top view of the stator assembly provided in an embodiment of this application;

[0027] Figure 3 A bottom view of the stator assembly provided in an embodiment of this application;

[0028] Figure 4 This is a schematic diagram of the conductor wiring slot structure of the stator assembly provided in an embodiment of this application;

[0029] Figure 5 A three-dimensional structural diagram of a single-phase winding of a stator assembly provided in an embodiment of this application;

[0030] Figure 6 A schematic diagram of the structure of the first type of conductor of the stator assembly provided in the embodiments of this application;

[0031] Figure 7 A schematic diagram of the structure of the second type of conductor in the stator assembly provided in the embodiments of this application;

[0032] Figure 8 A schematic diagram of the structure of a third type of conductor in a stator assembly provided in an embodiment of this application;

[0033] Figure 9 A schematic diagram of the structure of the fourth type of conductor in the stator assembly provided in the embodiments of this application;

[0034] Figure 10 This is a schematic diagram of the winding phase distribution of the stator assembly provided in an embodiment of this application;

[0035] Figure 11 A schematic diagram of the first branch connection of phase A winding provided in Embodiment 1 of this application;

[0036] Figure 12 A schematic diagram of the second branch connection of phase A winding provided in Embodiment 1 of this application;

[0037] Figure 13 A schematic diagram of the A-phase winding unfolded according to Embodiment 1 of this application;

[0038] Figure 14 A schematic diagram of the first branch connection of phase A winding in Embodiment 2 provided in this application;

[0039] Figure 15 A schematic diagram of the second branch connection of phase A winding provided in Embodiment 2 of this application;

[0040] Figure 16A schematic diagram of the first branch connection of phase A winding in Embodiment 3 provided in this application;

[0041] Figure 17 A schematic diagram of the second branch connection of phase A winding in Embodiment 3 provided in this application;

[0042] Figure 18 A schematic diagram of the A-phase winding deployment provided in Embodiment 3 of this application;

[0043] Figure 19 A schematic diagram of the first branch connection of phase A winding in Embodiment 4 provided for the present application;

[0044] Figure 20 A schematic diagram of the second branch connection of phase A winding provided in Embodiment 4 of this application;

[0045] Figure 21 This is a three-dimensional structural diagram of phase A winding in Embodiment 3 provided in this application.

[0046] Figure 22 Schematic diagram of the parallel branch connections of the stator assembly provided in the embodiments of this application Figure 1 ;

[0047] Figure 23 Schematic diagram of the parallel branch connections of the stator assembly provided in the embodiments of this application Figure 2 .

[0048] Explanation of reference numerals in the attached figures:

[0049] 100-Stator assembly;

[0050] 110 - Stator core; 120 - Winding; 130 - Class I conductor; 140 - Class II conductor; 150 - Class III conductor; 160 - Class IV conductor;

[0051] 1101 - Tank body; 1102 - Tank position;

[0052] 1201 - Inlet terminal; 1202 - Outlet terminal; 1203 - Welding terminal;

[0053] 1301 - First welding section; 1302 - First bending section; 1303 - First straight section; 1304 - Second bending section; 1305 - First lead wire section;

[0054] 1401 - Hairpin section; 1402 - Second welding section; 1403 - Third welding section; 1404 - Third bending section; 1405 - Fourth bending section; 1406 - Second straight section; 1407 - Third straight section. Detailed Implementation

[0055] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. In the absence of conflict, the following embodiments and features can be combined with each other.

[0056] In existing technology, the windings consist of conductors wound regularly around the stator core. The winding conductors abut against different conductor layers in the same stator core slot. Since these different conductor layers belong to different phases, adjacent winding conductors are prone to voltage breakdown. Therefore, insulating paper is placed inside the slots to separate the winding conductors and prevent voltage breakdown. The use of insulating paper reduces the usable space in the stator core. This structure leads to a decrease in the slot fill factor of the stator core, which in turn increases copper losses and the temperature rise of the multiphase windings. This limits the power density of the drive motor and also increases the insulation cost of the drive motor.

[0057] To overcome the shortcomings of existing technologies, this application provides a stator assembly suitable for motors. Each phase winding includes at least two parallel branches, and each branch includes multiple forward segments, reverse segments, a first connecting segment, and a second connecting segment. The forward segments, reverse segments, first connecting segments, and second connecting segments are wound regularly within the slots of the stator core at a certain span. This ensures that all conductor layers in each stator core slot are of the same phase, eliminating the need for insulating paper between different phases within the winding slots, improving slot fill factor, and simplifying the stator assembly wiring process.

[0058] The present invention will now be described in detail with reference to the accompanying drawings, so that those skilled in the art can have a clearer and more detailed understanding of the present invention.

[0059] Example 1

[0060] Figure 1 A three-dimensional structural schematic diagram of the stator assembly provided in an embodiment of this application; Figure 2 A top view of the stator assembly provided in an embodiment of this application; Figure 3 A bottom view of the stator assembly provided in an embodiment of this application; Figure 4 This is a schematic diagram of the conductor wiring slot structure of the stator assembly provided in an embodiment of this application; Figure 5 This is a three-dimensional structural diagram of a single-phase winding of a stator assembly provided in an embodiment of this application.

[0061] Firstly, such as Figures 1-4As shown, this application embodiment provides a stator assembly 100 for use in a motor, including a stator core 110 and multi-phase windings. The stator core 110 has a circumferentially provided slot 1101, and the slot 1101 has M layers of slots 1102 for conductor wiring, where M is an even number. Each phase winding includes at least two parallel branches, N≤M / 2. Each branch includes multiple coil units and multiple first connecting sections. Each coil unit includes a forward section, a reverse section, and a second connecting section. The forward section is wound along the circumference of the stator core 110 with a first span and in a first direction from the first edge layer slots to the second edge layer slots. The reverse segment is wound sequentially across layers from the second edge layer slot to the first edge layer slot with a first span along the second direction. The second connecting segment is connected between the adjacent forward and reverse segments located in the second edge layer slot with a second span. Each first connecting segment is connected between the forward and reverse segments of two adjacent coil units with a third span, and the first connecting segment is located in the first edge layer slot. The first edge layer slot and the second edge layer slot are, respectively, the first layer slot and the Mth layer slot, and the first direction and the second direction are opposite. The absolute values ​​of the differences between the second span and the third span and the first span are both less than or equal to 2.

[0062] As one possible implementation, each branch of each phase winding is arranged in slot 1102 of the same slot 1101.

[0063] Figure 6 A schematic diagram of the structure of the first type of conductor of the stator assembly provided in the embodiments of this application; Figure 7 A schematic diagram of the structure of the second type of conductor in the stator assembly provided in the embodiments of this application; Figure 8 A schematic diagram of the structure of a third type of conductor in a stator assembly provided in an embodiment of this application; Figure 9 This is a schematic diagram of the structure of the fourth type of conductor in the stator assembly provided in the embodiments of this application.

[0064] like Figures 1-9 In the stator assembly 100 shown, the conductor of the multiphase winding 120 is made of flat copper wire. The bare copper slot fill factor of the flat copper wire can reach more than 60%, which is much higher than that of the bare copper slot fill factor of the round copper wire. The higher the slot fill factor, the lower the DC resistance of the winding can be when the number of slots remains unchanged, thereby reducing the copper loss of the motor, improving the efficiency of the motor, increasing the driving range of electric vehicles, and reducing the cost of the powertrain.

[0065] like Figure 6As shown, the first type of conductor 130 in the stator assembly 100 includes a first welding section 1301, a first bending section 1302, a first straight section 1303, a second bending section 1304, and a first lead section 1305. The first straight section 1303 is disposed in the slot 1101 of the stator core 110. The first lead section 1305 and the second bending section 1304 are located at one end of the first straight section 1303, and the first bending section 1302 and the first welding section 1301 are located at the other end of the first straight section 1303. One end and the other end of the first straight section 1303 are arranged opposite each other along the axial direction of the stator core 110. The second bending section 1304 is used to connect the first lead section 1305 and the first straight section 1303, and the first bending section 1302 is used to connect the first welding section 1301 and the first straight section 1303. The first straight segment 1303 is located between the first welding segment 1301 and the first lead segment 1305. The first welding segment 1301 and the first lead segment 1305 are arranged opposite each other along the axial direction of the stator core 110, and the first welding segment 1301 and the first lead segment 1305 extend out of the slot 1101 along the axial direction of the stator core 110. The first lead segment 1305 in each branch winding eventually forms the inlet end 1201 or outlet end 1202 of the stator assembly 100.

[0066] like Figures 7-9The second type conductor 140, the third type conductor 150, and the fourth type conductor 160 are shown. Among them, the second type conductor 140 includes a hairpin section 1401, a second welding section 1402, a third welding section 1403, a third bending section 1404, a fourth bending section 1405, a second straight section 1406, and a third straight section 1407. The second straight segment 1406 and the third straight segment 1407 are parallel and are arranged radially spaced along the stator core 110. Both the second straight segment 1406 and the third straight segment 1407 are located in the slot 1101 of the stator core 110. The two ends of the hairpin segment 1401 are connected to the second straight segment 1406 and the third straight segment 1407, respectively. The third bent segment 1404 is used to connect the second welded segment 1402 and the second straight segment 1406. The fourth bent segment 1405 is used to connect the third welded segment 1403 and the third straight segment 1407. The hairpin segment 1401, the second welded segment 1402, and the third welded segment 1403 are arranged opposite each other along the axial direction of the stator core 110, and both the hairpin segment 1401, the second welded segment 1402, and the third welded segment 1403 extend out of the slot 1101 along the axial direction of the stator core 110. In this application, the third bend segment 1404 and the fourth bend segment 1405 can be parallel to each other, or they can be arranged opposite each other along the circumferential direction of the stator core 110. It should be noted that the third type conductor 150 and the fourth type conductor 160 also include the parts of the aforementioned third type conductor, and the function of each part is the same as that of the second type conductor 140. Therefore, this section only uses the second type conductor 140 as an example for explanation. Furthermore, the second type conductor 140... Figure 7 As shown, the third bend segment 1404 and the fourth bend segment 1405 are twisted in directions away from each other. The third type of conductor 150 is as follows... Figure 8 As shown, both the third bend 1404 and the fourth bend 1405 are twisted towards the direction of the fourth bend 1405. The fourth type conductor 160 is as follows... Figure 9 As shown, both the third bend segment 1404 and the fourth bend segment 1405 are twisted in the direction of the third bend segment 1404.

[0067] The first welding segment 1301 of the first type conductor 130, the second welding segment 1402 and the third welding segment 1403 of the second type conductor 140, the third type conductor 150 and the fourth type conductor 160 together form the welding end 1203 of the stator core 110 to connect the coil units of each winding.

[0068] Figure 22 Schematic diagram of the lead wire connection structure of the stator assembly provided in the embodiments of this application Figure 1In this embodiment, the leads of each phase winding are connected together to form a star connection. Taking a three-phase winding (phase A, phase B, and phase C) as an example, the tails of the two parallel branches of phase A winding are connected to the tails of the two parallel branches of phase B winding and the tails of the two parallel branches of phase C winding.

[0069] Figure 23 Schematic diagram of the lead wire connection structure of the stator assembly provided in the embodiments of this application Figure 2 In this embodiment of the application, the leads of each phase winding are connected end to end to form a delta connection. Taking a three-phase winding (phase A, phase B, and phase C) as an example, the two parallel branches of phase A winding, the two parallel branches of phase B winding, and the two parallel branches of phase C winding are connected end to end.

[0070] The stator assembly of this application will be described below with reference to an embodiment. This stator assembly is applicable to a 6-pole, 54-slot, 3-phase motor (including A-phase winding, B-phase winding, and C-phase winding). Each winding slot includes 6 layers of flat wire conductors, with a pole pitch of 9. Each pole has 3 slots per phase, and each phase winding includes 2 parallel branches. The horizontal axis refers to the 54 slots (1101), and the vertical axis refers to the 6 layers of slots.

[0071] The following describes specific embodiments of the stator assembly of this application.

[0072] Figure 11 A schematic diagram of the first branch connection of phase A winding provided in Embodiment 1 of this application; Figure 12 A schematic diagram of the second branch connection of phase A winding provided in Embodiment 1 of this application; Figure 13 This is a schematic diagram of the A-phase winding of Embodiment 1 provided in this application.

[0073] like Figures 11-13 As shown, each phase winding in this embodiment includes a first branch A1X1 and a second branch A2X2. The 54 slots in the stator assembly 100 are distributed circumferentially along the stator core 110, and each slot has 6 layers of slots radially distributed along the stator core 110: layer a, layer b, layer c, layer d, layer e, and layer f. Figures 11-13 The horizontal axis in the figure refers to 54 tanks, 1101. Figures 11-13 The vertical axis in the figure refers to the 6th layer of slots. Among them, the first branch A1X1 and the second branch A2X2 are both located in slot 1102 of the same tank body 1101.

[0074] When the first span y = 9, the second span y1 satisfies the condition: 7 ≤ y1 ≤ 11; and the third span y2 satisfies the condition: 7 ≤ y2 ≤ 11. Since only the conditions for the second span y1 and the third span y2 need to be met, this embodiment only takes one span combination as an example. That is:

[0075] First branch: First span y = 9; Second span y1 = 8, 10, 10, 11; Third span y2 = 8, 8, 8, 9.

[0076] Second branch: First span y = 9; Second span y1 = 9, 8, 8, 8; Third span y2 = 11, 10, 10, 8.

[0077] The winding method of the first branch A1X1 of phase A winding is as follows:

[0078] 1a→10b→19c→28d→37e→46f→38f→29e→20d→11c→2b→47a→39a→48b→3c→12d→21e→30f→20f→11e→2d→47c→38b→29a→21a→30b→39c→48d→3e→12f→2f→47e→38d→29c→20b→11a→3a→12b→21c→30d→39e→48f→37f→28e→19d→10c→1b→46a→37a→46b→1c→10d→19e→28f→

[0079] In this circuit, the first branch A1X1 of phase A winding has a first direction that is clockwise along the circumference of the stator core 110, and a second direction that is counterclockwise along the circumference of the stator core 110. The first edge layer slot is layer a, and the second edge layer slot is layer f. The forward segment is the part along the circumference of the stator core 110 in a clockwise direction, and the reverse segment is the part along the circumference of the stator core 110 in a counterclockwise direction. At this point, the first layer slot is layer a, the second layer slot is layer b, and so on, with the sixth layer slot being layer f.

[0080] The first forward segment of the first branch A1X1 enters from the first slot a along the first direction, and, with a first span y = 9, winds around to the second slot b. Similarly, with a first span y = 9, it winds across layers to the sixth slot f. At this point, the second connecting segment, with a second span y1 = 8, connects the conductor of the second edge layer slot f of the first forward segment along the second direction to the corresponding slot of the adjacent second edge layer slot f. After the connection with a second span y1 = 8, the first branch A1X1 exhibits its first reverse segment.

[0081] In the second edge layer slot f, the first reverse segment winds the conductor across layers to the corresponding slot layer in the second direction with a first span y = 9 until the conductor reaches the first edge layer slot a. In the first edge layer slot a, the first reverse segment winds the conductor of the first reverse segment onto the corresponding conductor of the second forward segment in the second direction with a third span y2 = 8.

[0082] According to the above pattern, the second span y1 = 10 of the second connecting segment corresponding to the second edge layer slot f; the third span y2 = 8 of the first connecting segment corresponding to the second edge layer slot a; the second span y1 = 10 of the second connecting segment corresponding to the third edge layer slot f; the third span y2 = 8 of the third edge layer slot a; the second span y1 = 11 of the second connecting segment corresponding to the fourth edge layer slot f; and the second span y2 = 9 of the second connecting segment corresponding to the fourth edge layer slot a.

[0083] The fifth forward segment is wound sequentially across layers from the first layer slot a according to the first span y = 9 along the first direction until the sixth layer slot f. At this time, the first branch A1X1 of the A-direction winding is completed.

[0084] In this embodiment, the magnetic polarities of adjacent forward and reverse segments in the first branch A1X1 of phase A winding are opposite in the slots corresponding to the first and second edge layers. Additionally, it should be noted that the directions of the first and second connecting segments are consistent with the second direction; that is, both the first and second connecting segments are wound counterclockwise along the circumference of the stator core 110.

[0085] The winding method of the second branch A2X2 of phase A winding is as follows:

[0086] 1f→46e→37d→28c→19b→10a→19a→28b→37c→46d→1e→10f→21f→12e→3d→48c→39b→30a→38a→47b→2c→11d→20e→29f→39f→30e→21d→12c→3b→48a→2a→11b→20c→29d→38e→47f→3f→48e→39d→30c→21b→12a→20a→29b→38c→47d→2e→11f→19f→10e→1d→46c→37b→28a→

[0087] In this circuit, the second branch A2X2 of phase A winding has a first direction that is counterclockwise along the circumference of the stator core 110, and a second direction that is clockwise along the circumference of the stator core 110. The first edge layer slot is layer f, and the second edge layer slot is layer a. The forward segment is the portion along the circumference of the stator core 110 in the counterclockwise direction, and the reverse segment is the portion along the circumference of the stator core 110 in the clockwise direction. At this point, the first layer slot is layer f, the second layer slot is layer e, and so on, with the sixth layer slot being layer a.

[0088] The first forward segment of the second branch A2X2 enters from the first slot f along the first direction, and, with a first span y = 9, winds around to the second slot e. Similarly, with a first span y = 9, it winds across layers to the sixth slot a. At this point, the second connecting segment, with a second span y1 = 9, connects the conductor of the first forward segment in the second edge layer slot a along the second direction to the corresponding slot in the adjacent second edge layer slot a. After the connection with a second span y1 = 9, the second branch A2X2 exhibits its first reverse segment.

[0089] In the second edge layer slot a, the first reverse segment winds the conductor across layers to the corresponding slot layer in the second direction with a first span y = 9, until the conductor reaches the first edge layer slot f. In the first edge layer f, the first reverse segment winds the conductor of the first reverse segment onto the corresponding conductor of the second forward segment in the first edge layer slot f with a third span y2 = 11 and in the second direction.

[0090] According to the above pattern, the second span y1 = 8 of the second connecting segment corresponding to the second edge layer slot a layer; the third span y2 = 10 of the first connecting segment corresponding to the second edge layer slot f layer; the second span y1 = 8 of the second connecting segment corresponding to the third edge layer slot a layer; the third span y2 = 10 of the third edge layer slot f layer; the second span y1 = 8 of the second connecting segment corresponding to the third edge layer slot a layer; the third span y2 = 10 of the third edge layer slot f layer; the second span y1 = 8 of the second connecting segment corresponding to the fourth edge layer slot a layer; and the second span y2 = 8 of the second connecting segment corresponding to the fourth edge layer slot f layer.

[0091] The fifth forward segment is wound sequentially across layers from the first slot f layer along the first direction according to the first span y = 9, until the sixth slot a layer. At this time, the second branch A2X2 of the A-direction winding is completed.

[0092] In this embodiment, the magnetic polarities of adjacent forward and reverse segments in the second branch A2X2 of phase A winding are opposite in the slots corresponding to the first and second edge layers. Furthermore, the directions of the first and second connecting segments are consistent with the second direction; that is, both the first and second connecting segments are wound clockwise along the circumference of the stator core 110.

[0093] In addition, the direction of the winding arrow in this embodiment is used to indicate the direction of the current in the conductor in the winding, and the direction of the arrow is the same as the winding direction of the flat wire conductor.

[0094] Example 2

[0095] The winding method in the stator assembly of this embodiment is similar to that in Embodiment 1 above. The difference lies in the different third spans of the first connecting segments corresponding to the forward and reverse segments of each branch in the first edge layer, and the different second spans of the second connecting segments corresponding to the forward and reverse segments of each branch in the second edge layer. In this embodiment, the winding method of each branch will not be described, but only the spans of the first connecting segments and the second connecting segments in the first and second edge layers will be explained.

[0096] Figure 14 A schematic diagram of the first branch connection of phase A winding in Embodiment 2 provided in this application; Figure 15 This is a schematic diagram of the second branch connection of phase A winding in Embodiment 2 provided in this application.

[0097] like Figures 14-15 As shown, each phase winding in this embodiment includes a first branch A1X1 and a second branch A2X2. The 54 slots in the stator assembly 100 are distributed circumferentially along the stator core 110, and each slot has 6 layers of slots radially distributed along the stator core 110: layer a, layer b, layer c, layer d, layer e, and layer f. Figures 14-15 The horizontal axis in the figure refers to 54 tanks, 1101. Figures 14-15 The vertical axis in the figure refers to the 6th layer of slots. Among them, the first branch A1X1 and the second branch A2X2 are both located in slot 1102 of the same tank body 1101.

[0098] When the first span y = 9, the second span y1 satisfies the condition: 7 ≤ y1 ≤ 11; and the third span y2 satisfies the condition: 7 ≤ y2 ≤ 11. Since only the conditions for the second span y1 and the third span y2 need to be met, this embodiment only takes one as an example. That is:

[0099] First branch: First span y = 9; Second span y1 = 7, 9, 9, 10; Third span y2 = 9, 10, 9, 9.

[0100] Second branch: First span y = 9; Second span y1 = 9, 9, 10, 9; Third span y2 = 10, 9, 9, 7.

[0101] The specific winding method of the first branch A1X1 of phase A winding is as follows:

[0102] 1a→10b→19c→28d→37e→46f→39f→30e→21d→12c→3b→48a→39a→48b→3c→12d→21e→30f→21f→12e→3d→48c→39b→30a→20a→29b→38c→47d→2e→11f→2f→47e→38d→29c→20b→11a→2a→11b→20c→29d→38e→47f→37f→28e→19d→10c→1b→46a→37a→46b→1c→10d→19e→28f→

[0103] Specifically, the second span y1 = 7 for the second connecting segment of the first branch A1X1 of phase A winding, corresponding to the first forward segment and the first reverse segment in the second edge layer slot f; the third span y2 = 9 for the first connecting segment of the first reverse segment and the second forward segment in the first edge layer slot a; the second span y1 = 9 for the second connecting segment of the second forward segment and the second reverse segment in the second edge layer slot f; the third span y2 = 10 for the first connecting segment of the second connecting segment of the second connecting segment of the third forward segment and the third reverse segment in the second edge layer slot f; the third span y2 = 9 for the first connecting segment of the third reverse segment and the fourth forward segment in the first edge layer slot a; the second span y1 = 10 for the second connecting segment of the second connecting segment of the third forward segment and the third reverse segment in the second edge layer slot f; and the second span y2 = 9 for the second connecting segment of the fourth reverse segment and the fifth forward segment in the first connecting segment of the second connecting segment of the first edge layer slot a.

[0104] The specific winding method of the second branch A2X2 of phase A winding is as follows:

[0105] 1f→46e→37d→28c→19b→10a→19a→28b→37c→46d→1e→10f→20f→11e→2d→47c→38b→29a→38a→47b→2c→11d→20e→29f→38f→29e→20d→11c→2b→47a→3a→12b→21c→30d→39e→48f→3f→48e→39d→30c→21b→12a→21a→30b→39c→48d→3e→12f→19f→10e→1d→46c→37b→28a→

[0106] Specifically, the second span y1 = 9 of the second connecting segment of the second branch A2X2 of phase A winding, corresponding to the first forward segment and the first reverse segment in the second edge layer slot a; the third span y2 = 10 of the first connecting segment of the first reverse segment and the second forward segment in the first edge layer slot f; the second span y1 = 9 of the second connecting segment of the second forward segment and the second reverse segment in the second connecting segment of the second edge layer slot a; the third span y2 = 9 of the first connecting segment of the second reverse segment and the third forward segment in the first edge layer slot f; the second span y1 = 10 of the second connecting segment of the third forward segment and the third reverse segment in the second connecting segment of the second connecting segment of the second edge layer slot a; the third span y2 = 9 of the first connecting segment of the third reverse segment and the fourth forward segment in the first connecting segment of the first edge layer slot f; the second span y1 = 9 of the second connecting segment of the fourth forward segment and the fourth reverse segment in the second connecting segment of the second connecting segment of the second edge layer slot a; and the second span y2 = 7 of the second connecting segment of the fourth reverse segment and the fifth forward segment in the first connecting segment of the first connecting segment of the first edge layer slot f.

[0107] Example 3

[0108] The winding method of the stator assembly in this embodiment is similar to that in Embodiment 1, except that the third span of the first connecting segment corresponding to the forward and reverse segments of each branch in the first edge layer is different, and the second span of the second connecting segment corresponding to the forward and reverse segments of each branch in the second edge layer is different; and the directions of the first and second connecting segments are different from those in Embodiments 1 and 2. Therefore, this embodiment will not describe the winding method of each branch, but will only describe the span of the first and second connecting segments in the first and second edge layers and the directions of the first and second connecting segments.

[0109] Figure 16 A schematic diagram of the first branch connection of phase A winding in Embodiment 3 provided in this application; Figure 17 A schematic diagram of the second branch connection of phase A winding in Embodiment 3 provided in this application; Figure 18 A schematic diagram of the A-phase winding deployment provided in Embodiment 3 of this application; Figure 21 This is a three-dimensional structural diagram of phase A winding in Embodiment 3 provided in this application.

[0110] like Figures 16-18 as well as Figure 21 As shown, each phase winding in this embodiment includes a first branch A1X1 and a second branch A2X2. The 54 slots in the stator assembly 100 are distributed circumferentially along the stator core 110, and each slot has 6 layers of slots radially distributed along the stator core 110: layer a, layer b, layer c, layer d, layer e, and layer f. Figures 16-18 The horizontal axis in the figure refers to 54 tanks, 1101. Figures 16-18The vertical axis in the figure refers to the 6th layer of slots. Among them, the first branch A1X1 and the second branch A2X2 are both located in slot 1102 of the same tank body 1101.

[0111] When the first span y = 9, the second span y1 satisfies the condition: 7 ≤ y1 ≤ 11; and the third span y2 satisfies the condition: 7 ≤ y2 ≤ 11. Since only the conditions for the second span y1 and the third span y2 need to be met, this embodiment only takes one as an example. That is:

[0112] First branch: First span y = 9; Second span y1 = 10, 8, 8, 7; Third span y2 = 10, 10, 10, 9.

[0113] Second branch: First span y = 9; Second span y1 = 9, 10, 10, 10; Third span y2 = 7, 8, 8, 10.

[0114] The specific winding method of the first branch A1X1 of phase A winding is as follows:

[0115] 1a→10b→19c→28d→37e→46f→2f→47e→38d→29c→20b→11a→21a→30b→39c→48d→3e→12f→20f→11e→2d→47c→38b→29a→39a→48b→3c→12d→21e→30f→38f→29e→20d→11c→2b→47a→3a→12b→21c→30d→39e→48f→1f→46e→37d→28c→19b→10a→19a→28b→37c→46d→1e→10f→

[0116] Specifically, the second span y1 = 10 for the second connecting segment of the first branch A1X1 of phase A winding, corresponding to the first forward segment and the first reverse segment in the second edge layer slot f; the third span y2 = 10 for the first connecting segment of the first reverse segment and the second forward segment in the first edge layer slot a; the second span y1 = 8 for the second connecting segment of the second forward segment and the second reverse segment in the second edge layer slot f; the third span y2 = 10 for the first connecting segment of the second reverse segment and the third forward segment in the first edge layer slot a; the second span y1 = 8 for the second connecting segment of the third forward segment and the third reverse segment in the second connecting segment of the second connecting segment of the second edge layer slot f; the third span y2 = 10 for the third reverse segment and the fourth forward segment in the first connecting segment of the first connecting segment of the first edge layer slot a; the second span y1 = 7 for the fourth forward segment and the fourth reverse segment in the second connecting segment of the second connecting segment of the fourth reverse segment and the fifth forward segment in the first connecting segment of the first edge layer slot a; and the second span y2 = 9 for the second connecting segment of the second connecting segment of the first connecting segment of the first edge layer slot a.

[0117] It should be noted that in this embodiment, the directions of the first connecting segment and the second connecting segment are both clockwise around the circumference of the stator core 110, that is, the directions of the first connecting segment and the second connecting segment are consistent with the first direction.

[0118] The specific winding method of the second branch A2X2 of phase A winding is as follows:

[0119] 37f→28e→19d→10c→1b→46a→37a→46b→1c→10d→19e→28f→21f→12e→3d→48c→39b→30a→20a→29b→38c→47d→2e→11f→3f→48e→39d→30c→21b→12a→2a→11b→20c→29d→38e→47f→39f→30e→21d→12c→3b→48a→38a→47b→2c→11d→20e→29f→19f→10e→1d→46c→37b→28a→

[0120] Specifically, the second span y1 = 9 for the second connecting segment of the first forward segment and the first reverse segment of the second branch A2X2 of phase A winding at the second edge layer slot a; the third span y2 = 7 for the first connecting segment of the first reverse segment and the second forward segment at the first edge layer slot f; the second span y1 = 10 for the second connecting segment of the second forward segment and the second reverse segment at the second edge layer slot a; the third span y2 = 8 for the first connecting segment of the second connecting segment of the second connecting segment of the third forward segment and the third reverse segment at the second edge layer slot a; the third span y2 = 8 for the first connecting segment of the second connecting segment of the third forward segment and the third reverse segment at the second edge layer slot a; the third span y2 = 8 for the first connecting segment of the third reverse segment and the fourth forward segment at the first edge layer slot f; the second span y1 = 10 for the second connecting segment of the fourth forward segment and the fourth reverse segment at the second edge layer slot a; and the second span y2 = 10 for the second connecting segment of the fourth reverse segment and the fifth forward segment at the first edge layer slot f.

[0121] It should be noted that in this embodiment, the directions of the first connecting segment and the second connecting segment are both clockwise around the circumference of the stator core 110, that is, the directions of the first connecting segment and the second connecting segment are consistent with the first direction.

[0122] Example 4

[0123] The winding method in the stator assembly of this embodiment is similar to that in Embodiment 3 above. The difference lies in the different third spans of the first connecting segments corresponding to the forward and reverse segments of each branch in the first edge layer, and the different second spans of the second connecting segments corresponding to the forward and reverse segments of each branch in the second edge layer. Therefore, this embodiment will not describe the winding method of each branch, but will only describe the spans of the first connecting segments and the second connecting segments in the first and second edge layers.

[0124] Figure 19 A schematic diagram of the first branch connection of phase A winding in Embodiment 4 provided for the present application; Figure 20 A schematic diagram of the second branch connection of phase A winding provided in Embodiment 4 of this application;

[0125] like Figures 19-20 As shown, each phase winding in this embodiment includes a first branch A1X1 and a second branch A2X2. The 54 slots in the stator assembly 100 are distributed circumferentially along the stator core 110, and each slot has 6 layers of slots radially distributed along the stator core 110: layer a, layer b, layer c, layer d, layer e, and layer f. Figures 19-20 The horizontal axis in the figure refers to 54 tanks, 1101. Figures 19-20 The vertical axis in the figure refers to the 6th layer of slots. Among them, the first branch A1X1 and the second branch A2X2 are both located in slot 1102 of the same tank body 1101.

[0126] When the first span y = 9, the second span y1 satisfies the condition: 7 ≤ y1 ≤ 11; and the third span y2 satisfies the condition: 7 ≤ y2 ≤ 11. Since only the conditions for the second span y1 and the third span y2 need to be met, this embodiment only takes one as an example. That is:

[0127] First branch: First span y = 9; Second span y1 = 11, 10, 10, 7; Third span y2 = 7, 9, 9, 10.

[0128] Second branch: First span y = 9; Second span y1 = 10, 9, 9, 7; Third span y2 = 7, 10, 10, 11.

[0129] The specific winding method of the first branch A1X1 of phase A winding is as follows:

[0130] 1a→10b→19c→28d→37e→46f→3f→48e→39d→30c→21b→12a→19a→28b→37c→46d→1e→10f→20f→11e→2d→47c→38b→29a→38a→47b→2c→11d→20e→29f→39f→30e→21d→12c→3b→48a→3a→12b→21c→30d→39e→48f→1f→46e→37d→28c→19b→10a→20a→29b→38c→47d→2e→11f→

[0131] Specifically, the second span y1 = 11 of the second connecting segment of the first branch A1X1 of phase A winding, corresponding to the first forward segment and the first reverse segment in the second edge layer slot f; the third span y2 = 7 of the first connecting segment of the first reverse segment and the second forward segment in the first edge layer slot a; the second span y1 = 10 of the second connecting segment of the second forward segment and the second reverse segment in the second edge layer slot f; the third span y2 = 9 of the first connecting segment of the second connecting segment of the second connecting segment of the third forward segment and the third reverse segment in the second connecting segment of the second connecting segment of the second edge layer slot f; the third span y2 = 9 of the first connecting segment of the third reverse segment and the fourth forward segment in the first connecting segment of the first edge layer slot a; the second span y1 = 7 of the second connecting segment of the second connecting segment of the second connecting segment of the second connecting segment of the second connecting segment of the first edge layer slot f; and the second span y2 = 10 of the second connecting segment of the second connecting segment of the fourth reverse segment and the fifth forward segment in the first connecting segment of the second connecting segment of the first edge layer slot a.

[0132] The specific winding method of the second branch A2X2 of phase A winding is as follows:

[0133] 38f→29e→20d→11c→2b→47a→37a→46b→1c→10d→19e→28f→21f→12e→3d→48c→39b→30a→21a→30b→39c→48d→3e→12f→2f→47e→38d→29c→20b→11a→2a→11b→20c→29d→38e→47f→37f→28e→19d→10c→1b→46a→39a→48b→3c→12d→21e→30f→19f→10e→1d→46c→37b→28a→

[0134] Specifically, the second span y1 = 10 for the second connecting segment of the first forward segment and the first reverse segment of the second branch A2X2 of phase A winding, corresponding to the second edge layer slot a; the third span y2 = 7 for the first connecting segment of the first reverse segment and the second forward segment, corresponding to the first edge layer slot f; the second span y1 = 9 for the second connecting segment of the second forward segment and the second reverse segment, corresponding to the second edge layer slot a; the third span y2 = 10 for the first connecting segment of the second connecting segment of the second connecting segment of the second connecting segment of the second connecting segment of the second connecting segment of the second edge layer slot f; the third span y2 = 10 for the third forward segment and the third reverse segment, corresponding to the second connecting segment of the second connecting segment of the second connecting segment of the second connecting segment of the second connecting segment of the second connecting segment of the third reverse segment and the fourth forward segment, corresponding to the first edge layer slot f; the second span y1 = 7 for the fourth forward segment and the fourth reverse segment, corresponding to the second connecting segment of the second connecting segment of the second connecting segment of the second connecting segment of the first edge layer slot f; and the second span y2 = 11 for the fourth reverse segment and the fifth forward segment, corresponding to the second connecting segment of the first connecting segment of the second connecting segment of the first edge layer slot f.

[0135] refer to Figure 10 , Figure 10 This is a schematic diagram of the winding phase distribution of the stator assembly provided in the embodiment of this application. Each slot 1101 in the figure has 6 layers of conductors, and the 6 layers of conductors in the same slot 1101 are all in the same phase.

[0136] It should be noted that in the above embodiments, the winding method of phase B and phase C is the same as that of phase A. The phase B winding can be 120° out of phase with respect to phase A.

[0137] In the embodiments provided in this application, the stator assembly 100 includes a stator core 110 and a multi-phase winding. The stator core 110 has a circumferentially provided slot 1101, and the slot 1101 has M layers of slots 1102 for conductor wiring, where M is an even number. Each phase winding includes at least two parallel branches, N≤M / 2. Each branch includes multiple coil units and multiple first connecting sections. Each coil unit includes a forward section, a reverse section, and a second connecting section. The forward section is wound along the circumference of the stator core 110 with a first span and in a first direction from the first edge layer slot to the second edge layer slot. The reverse section... The coil is wound sequentially from the second edge layer slot to the first edge layer slot with a first span along the second direction. A second connecting segment connects adjacent forward and reverse segments in the second edge layer slot with a second span. Each first connecting segment connects adjacent two coil units with a third span between the forward and reverse segments, and the first connecting segment is located in the first edge layer slot. One of the first and second edge layer slots is the first layer slot, and the other is the Mth layer slot, with the first and second directions opposite. The absolute values ​​of the differences between the second and third spans and the first span are all less than or equal to 2. This configuration ensures that all conductors in each stator core slot are in phase, eliminating the need for insulating paper between different phases in the slot, improving slot fill factor, and simplifying the stator assembly wiring process. Furthermore, each parallel branch can traverse all arranged conductor mounting positions, ensuring complete symmetry of the magnetic circuits of each parallel branch winding, maintaining a balanced potential among the parallel branches, and eliminating circulating current between branches.

[0138] Example 5

[0139] This application also provides an electric motor, including a rotor and a stator assembly as described above. The structure and function of each part of the stator assembly in this embodiment have been described in detail in the previous embodiments and will not be repeated here. The motor in this embodiment includes a rotor and the stator assembly described in the previous embodiments. This stator assembly ensures that all conductor layers in each stator core slot are in phase, eliminating the need for insulating paper between different phases in the slots, improving slot fill factor, and simplifying the wiring process of the stator assembly. Furthermore, each parallel branch can traverse all arranged conductor mounting positions, the magnetic circuits of each parallel branch winding are completely symmetrical, the potentials of each parallel branch remain balanced, and there is no circulating current between branches. Therefore, the motor including the aforementioned stator assembly can improve motor efficiency, reduce motor temperature rise, and also reduce motor insulation costs.

[0140] It should be noted that the terms "one embodiment," "embodiment," "exemplary embodiment," "some embodiments," etc., mentioned in the specification indicate that the described embodiment may include a specific feature, structure, or characteristic, but not every embodiment necessarily includes that specific feature, structure, or characteristic. Furthermore, such phrases do not necessarily refer to the same embodiment. Moreover, when a specific feature, structure, or characteristic is described in connection with an embodiment, implementing such a feature, structure, or characteristic in conjunction with other embodiments, whether explicitly described or not, is within the knowledge scope of those skilled in the art.

[0141] Generally speaking, terms should be understood at least in part by their use in context. For example, at least in part by context, the term "one or more" as used in the text can be used to describe any feature, structure, or characteristic of the singular meaning, or a combination of features, structures, or characteristics of the plural meaning. Similarly, at least in part by context, terms such as "a" or "the" can also be understood to convey either singular or plural usage.

[0142] It should be readily understood that the terms “on,” “above,” and “on top of” in this disclosure should be interpreted in the broadest possible sense, such that “on” means not only “directly on something” but also “on something” with an intermediate feature or layer therebetween, and that “above” or “on top of” means not only “on top of something” but also “on top of something” without an intermediate feature or layer therebetween (i.e., directly on something).

[0143] Furthermore, for ease of explanation, spatially relative terms such as "below," "below," "under," "above," and "above" may be used to describe the relationship of one element or feature relative to other elements or features as shown in the figures. Spatially relative terms are intended to encompass different orientations of the device in use or operation other than those shown in the figures. The device may have other orientations (rotated 90° or in other orientations), and the spatially relative descriptive terms used herein may be interpreted accordingly.

[0144] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A stator assembly used in a motor, characterized in that, include: The stator core and multi-phase windings are provided. The stator core has multiple slots around its circumference. Each slot has M layers of slots for conductor wiring, where M is an even number. Each phase winding includes at least two parallel branches, where N ≤ M / 2, where N is the number of branches in each phase winding. Each branch includes multiple coil units and multiple first connecting segments. Each coil unit includes a forward segment, a reverse segment, and a second connecting segment. The forward segment is wound sequentially across layers from the first edge layer slot to the second edge layer slot along the circumference of the stator core in a first direction with a first span. The reverse segment is wound sequentially across layers from the second edge layer slot to the first edge layer slot in a second direction with the first span. The second connecting segment connects adjacent forward and reverse segments located in the second edge layer slot with a second span. Each first connecting segment connects between the forward and reverse segments of every two adjacent coil units with a third span, and the first connecting segment is located in the first edge layer slot. One of the first edge layer slot and the second edge layer slot is a first layer slot, and the other is an Mth layer slot. The first direction and the second direction are opposite. The absolute values ​​of the differences between the second span and the third span and the first span are both less than or equal to 2; The winding of each phase includes at least two parallel branches, specifically the first branch and the second branch; The forward segment corresponding to the first branch is sequentially wound across layers from the first layer slot to the Mth layer slot, and the forward segment corresponding to the second branch is sequentially wound across layers from the Mth layer slot to the first layer slot, and the first directions corresponding to the first branch and the second branch are opposite; Wherein, the first span is represented by y, the second span by y1, and the third span by y2.

2. The stator assembly according to claim 1, characterized in that, Each branch of the winding of each phase is arranged in the slot of the same slot body.

3. The stator assembly according to claim 2, characterized in that, Both the first connecting segment and the second connecting segment are wound around the first direction along the circumference of the stator core.

4. The stator assembly according to claim 2, characterized in that, Both the first connecting segment and the second connecting segment are wound around the second direction along the circumference of the stator core.

5. The stator assembly according to any one of claims 1-4, characterized in that, The first span y is equal to the pole pitch of the motor; The second span y1 satisfies the condition: y-2≤y1≤y+2; and The third span y2 satisfies the condition: y-2≤y2≤y+2; The first span y, the second span y1, and the third span y2 are all integers.

6. The stator assembly according to any one of claims 1-4, characterized in that, The magnetic poles of the two conductors connected to adjacent slots are opposite.

7. The stator assembly according to any one of claims 1-4, characterized in that, One of the incoming and outgoing ends of each branch is located in the first layer slot, and the other is located in the Mth layer slot.

8. The stator assembly according to any one of claims 1-4, characterized in that, The motor winding is a three-phase winding, and the three-phase windings are wound in the same direction on the stator core and are 120° out of phase in space.

9. An electric motor, characterized in that, Includes the rotor and the stator assembly as described in any one of claims 1-8.

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