Hairpin wire motor stator

Abstract

The present application provides a hairpin-shaped wire motor stator, which comprises a core, a plurality of slot positions and a plurality of hairpin-shaped wires. The core comprises a first side and a second side opposite to each other for the wires to protrude. The plurality of slot positions are arranged on the core along the circumferential direction and are formed in M slot layers adjacent in the radial direction, M being an odd number greater than or equal to 5. The plurality of hairpin-shaped wires are configured into the slot positions and connected to form a plurality of windings. The hairpin-shaped wires comprise a plurality of first U-shaped wires configured in the outermost slot layer in the radial direction and a plurality of second U-shaped wires configured in the innermost slot layer in the radial direction. Each first U-shaped wire comprises a U-shaped segment configured in the outermost slot layer in the radial direction and protruding from the first side of the core. Each second U-shaped wire comprises a U-shaped segment configured in the innermost slot layer in the radial direction and protruding from the second side of the core.

Description

Technical Field

[0001] This invention relates to a motor stator, and more particularly to a motor stator with a hairpin-shaped conductor. Background Technology

[0002] Existing motor stators using hairpin-shaped conductors often employ U-shaped hairpin conductors to span the slots of the motor core, thereby achieving the required winding circuit design. Generally, for ease of soldering, the leads of the U-shaped hairpin conductors to be soldered are concentrated on the same side of the motor core. However, for some motor stators (such as stators with an odd number of slots), adjusting the conductor span on the soldering side of the motor core is difficult, increasing the difficulty of soldering and consuming more time. In view of this, motor manufacturers are actively seeking appropriate conductor configuration methods to more effectively reduce the time and production costs required to manufacture motor stators. Summary of the Invention

[0003] This invention proposes a hairpin-shaped conductor stator to solve the problems of the prior art.

[0004] According to one embodiment of the present invention, a hairpin-shaped conductor motor stator includes an iron core, a plurality of slots, and a plurality of hairpin-shaped conductors. The iron core is annular, defining a rotor receiving space at its center. The iron core includes a first side and a second side axially opposite to each other. The plurality of slots are located on the iron core, surrounding the rotor receiving space in a circumferential direction and forming a plurality of radially adjacent M slot layers, where M is an odd number greater than or equal to 5. The plurality of hairpin-shaped conductors are disposed within the slots and connected to form a plurality of windings. The plurality of hairpin-shaped conductors include three types of U-shaped conductors and two types of straight conductors. A plurality of first-type U-shaped conductors, each comprising two legs, are disposed in the outermost radial slot layer. A plurality of second-type U-shaped conductors, each comprising two legs, are disposed in the innermost radial slot layer. A plurality of third-type U-shaped conductors, each comprising two legs, respectively disposed in two radially adjacent slot layers, the two adjacent slot layers being located between the outermost and innermost slot layers. A plurality of first-type straight conductors, each comprising a straight intermediate section, disposed in the radially innermost slot layer. A plurality of second-type straight conductors, each comprising a straight intermediate section, disposed in the radially outermost slot layer.

[0005] According to another embodiment of the present invention, a hairpin-shaped conductor motor stator includes an iron core, a plurality of slots, and a plurality of hairpin-shaped conductors. The iron core includes a first side and a second side opposite to each other for the conductors to protrude. The plurality of slots are arranged circumferentially on the iron core and form a plurality of radially adjacent M slot layers, where M is an odd number greater than or equal to 5. The plurality of hairpin-shaped conductors are configured into the slots and connected to form a plurality of windings. The hairpin-shaped conductors include a plurality of first U-shaped conductors configured in the radially outermost slot layer and a plurality of second U-shaped conductors configured in the radially innermost slot layer. Each first U-shaped conductor includes a U-shaped segment configured in the radially outermost slot layer and protruding from the first side of the iron core. Each second U-shaped conductor includes a U-shaped segment configured in the radially innermost slot layer and protruding from the second side of the iron core.

[0006] The hairpin-shaped conductor stator of the present invention uses a variety of U-shaped conductors and a variety of straight conductors, which are appropriately arranged on the motor core with an odd number of slots of 5 or more. This allows for easy adjustment of the span between the conductors on both sides of the core, reducing the difficulty of welding and connecting the wires, thereby reducing the time required for wiring and saving manufacturing costs.

[0007] The above description will be given in detail below with reference to the embodiments, and a further explanation of the technical solution of the present invention will be provided. Attached Figure Description

[0008] To make the above and other objects, features, advantages and embodiments of the present invention more apparent and understandable, the accompanying drawings are described below:

[0009] Figure 1 This is a circuit diagram illustrating the motor stator according to an embodiment of the present invention;

[0010] Figure 2 This is a top view showing the motor stator core according to an embodiment of the present invention;

[0011] Figure 3 This is a schematic diagram showing the wire configuration of the winding U1 of the U phase of the 48-slot motor stator according to an embodiment of the present invention;

[0012] Figure 4 This is a schematic diagram showing the wire configuration of the winding U2 of the U phase of the 48-slot motor stator according to an embodiment of the present invention;

[0013] Figure 5 This is a schematic diagram showing the wire configuration of the winding W1 of phase W of the 48-slot motor stator according to an embodiment of the present invention;

[0014] Figure 6 This is a schematic diagram showing the wire configuration of the winding W2 of the W phase of the 48-slot motor stator according to an embodiment of the present invention;

[0015] Figure 7This is a schematic diagram showing the wire configuration of the winding V1 of the V phase of the 48-slot motor stator according to an embodiment of the present invention;

[0016] Figure 8 This is a schematic diagram showing the wire configuration of the winding V2 of the V phase of the 48-slot motor stator according to an embodiment of the present invention;

[0017] Figure 9 This is a schematic diagram showing the wiring of the U, W, and V phase windings of the 48-slot motor stator on the first side of the iron core according to an embodiment of the present invention.

[0018] Figure 10 This is a schematic diagram showing the wiring of the U, W, and V phase windings of the 48-slot motor stator on the second side of the iron core according to an embodiment of the present invention.

[0019] Figure 11 This is a perspective view showing a 48-slot motor stator according to an embodiment of the present invention;

[0020] Figure 12 This is a schematic diagram illustrating the configuration of the first type of U-shaped conductor used in a motor stator according to an embodiment of the present invention;

[0021] Figure 13 This is a schematic diagram illustrating the configuration of a second type of U-shaped conductor in a motor stator according to an embodiment of the present invention;

[0022] Figure 14 This is a schematic diagram illustrating the configuration of a third type of U-shaped conductor in a motor stator according to an embodiment of the present invention;

[0023] Figure 15 This is a schematic diagram illustrating the configuration of a first type of straight conductor in a motor stator according to an embodiment of the present invention;

[0024] Figure 16 This is a schematic diagram illustrating the configuration of a second type of straight conductor in a motor stator according to an embodiment of the present invention;

[0025] Figure 17 This illustrates the conductor configuration of the motor stator on the first side of the iron core according to an embodiment of the present invention;

[0026] Figure 18 It is shown Figure 17 Side view of the first side of the motor stator core;

[0027] Figure 19 This illustrates the conductor configuration of the motor stator on the second side of the iron core according to an embodiment of the present invention; and

[0028] Figure 20 It is shown Figure 19 Side view of the second side of the motor stator core.

[0029] Explanation of reference numerals in the attached figures

[0030] 50: Circuit

[0031] 52: Electrical neutral terminal

[0032] U:Phase

[0033] V: Phase

[0034] W: Phase

[0035] P1 / P2 / P3 / P4 / P5 / P6 / P7 / P8: Polar regions

[0036] U1 / U2: Windings

[0037] W1 / W2: Windings

[0038] V1 / V2: Windings

[0039] 100: Motor stator

[0040] 110: Iron core

[0041] 110a: The first side of the iron core

[0042] 110b: The second side of the iron core

[0043] 112: The first type of U-shaped conductor

[0044] 112a: The U-shaped segment of the first type of U-shaped conductor

[0045] 112b: Legs of the first type of U-shaped conductor

[0046] 112c: The lead of the first type of U-shaped conductor

[0047] 114: Second type of U-shaped conductor

[0048] 114a: The U-shaped segment of the second type of U-shaped conductor

[0049] 114b: Legs of the second type of U-shaped conductor

[0050] 114c: The lead of the second type of U-shaped wire

[0051] 116: The first type of straight conductor

[0052] 116a: The straight middle section of the first type of straight conductor

[0053] 116b: The lead of the first type of straight conductor

[0054] 116c: The lead of the first type of straight conductor

[0055] 118: The third type of U-shaped conductor

[0056] 118a: The U-shaped segment of the third type of U-shaped conductor

[0057] 118b: Legs of the third type of U-shaped conductor

[0058] 118c: The lead of the third type of U-shaped wire

[0059] 119: Second type of straight conductor

[0060] 119a: The straight middle section of the second type of straight conductor

[0061] 119b: The lead of the second type of straight conductor

[0062] 119c: The lead of the second type of straight conductor

[0063] 150: Rotor housing space

[0064] 500: First type of U-shaped conductor assembly

[0065] 510: Second type of U-shaped conductor group

[0066] C1 / C2 / C3: Connecting parts

[0067] H1 / H2 / H3 / H4 / H5: Height Detailed Implementation

[0068] To make the description of the present invention more detailed and complete, reference can be made to the accompanying drawings and the various embodiments described below, in which the same numbers represent the same or similar elements. On the other hand, well-known elements and steps are not described in the embodiments to avoid unnecessarily limiting the present invention. In the embodiments and claims, unless specifically defined in the text, "a" and "the" can refer to one or more. The terms "input line" and "output line" used in the specification have the same meaning (or can be interchanged). Furthermore, the description of "clockwise winding" in the specification is to help understand the relative positions of the input / output lines, and can also be understood as "counterclockwise winding" based on the relative positions of the input / output lines. In other words, from a mechanical configuration perspective, there is no such thing as an input / output line. From a circuit perspective, the positive [⊕] contact can be understood as the input line, and the negative [⊙] contact can be understood as the output line.

[0069] Please refer to Figure 1 The circuit diagram of the motor stator according to an embodiment of the present invention is shown. The circuit 50 includes windings of phases U, V, and W. Each (U, V, W) phase winding includes two windings connected in parallel (i.e., U1, U2, W1, W2, V1, V2). The negative terminal [⊙] of each winding is connected to the electrical neutral end 52, and the positive terminal [⊕] of ​​each winding is connected to the corresponding electrical phase terminal (e.g., the electrical phase terminal of phases U, V, and W).

[0070] Please refer to Figure 2This figure shows a top view of a 48-slot motor stator core according to an embodiment of the present invention. This core 110 is used to realize a motor stator having 8 pole regions, 48 ​​slots, 5 layers of wire, and 2 parallel windings. Each slot (illustrated as 1-48) comprises radially adjacent slot positions (i.e., "boxes" in the figure), and each slot position can accommodate a hairpin-shaped conductor. All slots are located circumferentially around the rotor housing space 150 and form multiple radially adjacent slot layers (L1-L5). The 8 pole regions (P1-P8) equally divide the core 110 circumferentially, and each pole region has U, W, and V phases. Pole region P1 includes slots 1-6, pole region P2 includes slots 7-12, pole region P3 includes slots 13-18, pole region P4 includes slots 19-24, pole region P5 includes slots 25-30, pole region P6 includes slots 31-36, pole region P7 includes slots 37-42, and pole region P8 includes slots 43-48. The circumferential distance between slots in a single pole region is defined as a pole pitch. Each slot has 5 radial slots for inserting 5 slot layers of hairpin wires, numbered L1 to L5 from the outside in. The annular core 110 defines a rotor housing space 150 for accommodating the rotor. Slot layer L5 is closest to the rotor housing space 150 and is therefore the innermost layer, while slot layer L1 is furthest from the rotor housing space 150 and is therefore the outermost layer. In embodiments of the present invention, the slots in these pole regions have the same or nearly the same cross-sectional dimensions, and the spacing between the slots is also the same or nearly the same, but this is not a limitation.

[0071] Please refer to Figure 3 This diagram illustrates the conductor configuration of the winding U1 of the U-phase of a 48-slot motor stator according to an embodiment of the present invention. Taking a motor stator with an 8-pole region, 48 slots, and 5 layers of wire implemented using the aforementioned core 110, and with each of the U, V, and W phases having two parallel windings, as an example, the core 110 includes opposite sides. The diagram uses solid and dashed lines to represent the "viewing side" and "opposite side" respectively to aid in explaining the conductor connections and slot-crossing winding configuration. Although the diagram uses straight lines and V-shaped lines to represent conductor connections / slot crossings, these are merely illustrative and not intended to be limiting.

[0072] Taking phase U as an example, the conductor of winding U1 starts from the slot position of slot layer L1 in slot 1 and is viewed from the iron core 110 side (e.g.) Figure 11 After the first side 110a) enters the line U1⊕, then on the opposite side of the iron core 110 (e.g.) Figure 11The second side 110b) is connected to the slot L2 of slot 7 of the U phase, then to the slot L3 of slot 14 of the U phase on the core viewing side, then to the slot L4 of slot 20 of the U phase on the opposite core side, then to the slot L5 of slot 26 of the U phase on the core viewing side, and then to the slot L5 of slot 32 of the U phase on the opposite core side. The winding U1 is wound clockwise from slot 1 to slot 32. The winding U1 is then connected to the slot L4 of slot 26 of the U phase on the core viewing side, then to the slot L3 of slot 20 of the U phase on the opposite core side, then to the slot L2 of slot 14 of the U phase on the core viewing side, and then to the slot L1 of slot 8 of the U phase on the opposite core side. Winding U1 is wound counterclockwise from slot 32 to slot 8, and then clockwise from the core viewing side to slot L1 of slot 14 of phase U. Winding U1 then connects to slot L2 of slot 20 of phase U on the opposite core side, then to slot L3 of slot 25 of phase U on the core viewing side, then to slot L4 of slot 31 of phase U on the opposite core side, then to slot L5 of slot 37 of phase U on the core viewing side, and finally to slot L5 of slot 43 of phase U on the opposite core side. Winding U1 is then wound clockwise from slot 8 to slot 43. Winding U1 is then connected to slot L4 of slot 37 of the U-phase on the core viewing side, then to slot L3 of slot 31 of the U-phase on the opposite core side, then to slot L2 of slot 25 of the U-phase on the core viewing side, and finally to slot L1 of slot 19 of the U-phase on the opposite core side. Winding U1 is wound counterclockwise from slot 43 to slot 19. Winding U1 is then connected clockwise from slot 25 to slot L1 of U-phase on the core viewing side, then to slot 31 to slot L2 of U-phase on the opposite core side, then to slot 38 to slot L3 of U-phase on the core viewing side, then to slot 44 to slot L4 of U-phase on the opposite core side, then to slot 2 to slot L5 of U-phase on the core viewing side, and finally to slot 8 to slot L5 of U-phase on the opposite core side. Winding U1 is then wound clockwise from slot 19 to slot 8. Winding U1 is then connected to slot L4 of slot 2 of phase U on the core viewing side, then to slot L3 of slot 44 of phase U on the opposite core side, then to slot L2 of slot 38 of phase U on the core viewing side, and finally to slot L1 of slot 32 of phase U on the opposite core side. Winding U1 is wound counterclockwise from slot 8 to slot 32.Winding U1 is then connected to slot L1 of slot 38 of phase U on the core viewing side, then to slot L2 of slot 44 of phase U on the opposite core side, then to slot L3 of slot 1 of phase U on the core viewing side, then to slot L4 of slot 7 of phase U on the opposite core side, then to slot L5 of slot 13 of phase U on the core viewing side, and finally to slot L5 of slot 19 of phase U on the opposite core side. Winding U1 is wound clockwise from slot 32 to slot 19. Winding U1 is then connected to slot L4 of slot 13 of phase U on the core viewing side, then to slot L3 of slot 7 of phase U on the opposite core side, then to slot L2 of slot 1 of phase U on the core viewing side, and finally to slot L1 of slot 43 of phase U on the opposite core side. Winding U1 is wound counterclockwise from slot 19 to slot 43, and exits at this slot U1⊙.

[0073] Please refer to Figure 4 This diagram illustrates the wire configuration of the winding U2 of the U-phase of the 48-slot motor stator according to an embodiment of the present invention. (Continued) Figure 4The conductors of winding U1 and winding U2 enter from the viewing side of the core in slot L1 of slot 2, then connect to slot L2 of slot 8 of phase U on the opposite side of the core, then connect to slot L3 of slot 13 of phase U on the viewing side of the core, then connect to slot L4 of slot 19 of phase U on the opposite side of the core, then connect to slot L5 of slot 25 of phase U on the viewing side of the core, and finally connect to slot L5 of slot 31 of phase U on the opposite side of the core. Winding U2 is wound clockwise from slot 2 to slot 31. Winding U2 then connects to slot L4 of slot 25 of the U-phase on the core viewing side, then to slot L3 of slot 19 of the U-phase on the opposite core side, then to slot L2 of slot 13 of the U-phase on the core viewing side, and finally to slot L1 of slot 7 of the U-phase on the opposite core side. From this point, winding U2 is wound counterclockwise from slot 31 to slot 7. Winding U2 is then connected to slot L1 of slot 13 of phase U on the core viewing side, then to slot L2 of slot 19 of phase U on the opposite core side, then to slot L3 of slot 26 of phase U on the core viewing side, then to slot L4 of slot 32 of phase U on the opposite core side, then to slot L5 of slot 38 of phase U on the core viewing side, and finally to slot L5 of slot 44 of phase U on the opposite core side. Winding U2 is wound clockwise from slot 7 to slot 44. Winding U2 is then connected to slot L4 of slot 38 of the U-phase on the core viewing side, then to slot L3 of slot 32 of the U-phase on the opposite core side, then to slot L2 of slot 26 of the U-phase on the core viewing side, and finally to slot L1 of slot 20 of the U-phase on the opposite core side. Winding U2 is wound counterclockwise from slot 44 to slot 20. Winding U2 is then connected clockwise from slot 20 to slot 7 on the core viewing side to slot L1 of slot 26 of phase U, then to slot L2 of slot 32 of phase U on the opposite core side, then to slot L3 of slot 37 of phase U on the core viewing side, then to slot L4 of slot 43 of phase U on the opposite core side, then to slot L5 of slot 1 of phase U on the core viewing side, and finally to slot L5 of slot 7 of phase U on the opposite core side. Winding U2 is thus wound clockwise from slot 20 to slot 7. Winding U2 is then connected to slot L4 of slot 1 of phase U on the core viewing side, then to slot L3 of slot 43 of phase U on the opposite core side, then to slot L2 of slot 37 of phase U on the core viewing side, and finally to slot L1 of slot 31 of phase U on the opposite core side. Winding U2 is wound counterclockwise from slot 7 to slot 31.Winding U2 is then connected to slot L1 of slot 37 of phase U on the core viewing side, then to slot L2 of slot 43 of phase U on the opposite core side, then to slot L3 of slot 2 of phase U on the core viewing side, then to slot L4 of slot 8 of phase U on the opposite core side, then to slot L5 of slot 14 of phase U on the core viewing side, and finally to slot L5 of slot 20 of phase U on the opposite core side. Winding U2 is wound clockwise from slot 31 to slot 20. Winding U2 is then connected to slot L4 of slot 14 of phase U on the viewing side of the core, then to slot L3 of slot 8 of phase U on the opposite side of the core, then to slot L2 of slot 2 of phase U on the viewing side of the core, and finally to slot L1 of slot 44 of phase U on the opposite side of the core. Winding U2 is wound counterclockwise from slot 20 to slot 44, and exits at this slot U2⊙. All the conductors of windings U1 and U2 then fill all the slots of phase U in the core.

[0074] Please refer to Figure 5 This diagram illustrates the conductor configuration of the winding W1 of the 48-slot motor stator W phase according to an embodiment of the present invention. The conductors of winding W1 are configured within the slots of the iron core W phase, and the manner in which the conductors cross the slots circumferentially and radially is the same as that of winding U1, and therefore will not be repeated.

[0075] Please refer to Figure 6 This diagram illustrates the conductor configuration of the winding W2 of the 48-slot motor stator W phase according to an embodiment of the present invention. The conductors of winding W2 are configured within the slots of the iron core W phase, and the manner in which the conductors cross the slots circumferentially and radially is the same as that of winding U2, and therefore will not be repeated.

[0076] Please refer to Figure 7 This diagram illustrates the conductor configuration of the winding V1 of the V-phase stator of a 48-slot motor according to an embodiment of the present invention. The conductors of winding V1 are configured within the slots of the V-phase core, and their circumferential crossing of slots and radial crossing of slot layers are the same as those of winding U1, therefore, they will not be described again.

[0077] Please refer to Figure 8 This diagram illustrates the conductor configuration of the V2 winding of the V-phase of the 48-slot motor stator according to an embodiment of the present invention. The conductors of the V2 winding are configured within the slots of the V-phase of the iron core, and the manner in which the conductors cross the slots circumferentially and radially is the same as that of the conductors of the U2 winding, and therefore will not be described again.

[0078] Please refer to Figure 9This diagram illustrates the wiring of the U, W, and V phase windings of a 48-slot motor stator on the first side 110a of the iron core according to an embodiment of the present invention. When the windings U1, U2, W1, W2, V1, and V2 are all arranged on the iron core, the conductors on the first side 110a of the iron core are represented by solid lines to indicate the protruding "U-shaped segments" of the U-shaped conductors, and by bold rectangular frames to indicate "foot connections" and dashed lines to indicate "foot ends". The two ends of the U-shaped segments of the first type of U-shaped conductor are located in the outermost slot layer (i.e., slot layer L1) in the radial direction. The two ends of the U-shaped segments of the second type of U-shaped conductor (the third type of U-shaped conductor described below) are located in the two adjacent middle slot layers (i.e., slot layers L2-L3) in the radial direction. The "foot connections" on the first side 110a are located in the two adjacent inner slot layers (i.e., slot layers L4-L5) in the radial direction. The outermost tank layer (i.e., tank layer L1) has additional pins U1⊕, U2⊕, W1⊕, W2⊕, V1⊕, and V2⊕ connected to the corresponding electrical phase terminals (e.g., the electrical phase terminals of phases U, V, and W), and additional pins U1⊙, U2⊙, W1⊙, W2⊙, V1⊙, and V2⊙ connected to the electrical neutral terminal (Neutral End).

[0079] Please refer to Figure 10 This diagram illustrates the wiring of the U, W, and V phase windings of a 48-slot motor stator on the second side 110b of the iron core according to an embodiment of the present invention. When the windings U1, U2, W1, W2, V1, and V2 are all arranged on the iron core, the protruding "U-shaped segment" of the U-shaped conductor is represented by a solid line on the second side 110b of the iron core, and the "foot connection" is represented by a bold rectangular frame. Both ends of the U-shaped segment of the U-shaped conductor (the second type of U-shaped conductor described below) are located in the innermost slot layer (i.e., slot layer L5) radially. The "foot connection" on this second side 110b is located in the two outermost slot layers (i.e., slot layers L1-L2) and the two middle slot layers (i.e., slot layers L3-L4) radially adjacent to each other.

[0080] Please refer to Figure 11 This illustration shows a 48-slot motor stator 100 according to an embodiment of the present invention, which implements the aforementioned three-phase motor stator with 8 pole regions, 48 ​​slots, 5 layers of wire, and 2 parallel windings. The first side 110a and the second side 110b of the iron core 110, which are axially opposite to each other, respectively correspond to the aforementioned... Figure 9 The first side 110a and Figure 10 The second side 110b.

[0081] Please refer to Figures 12-14This diagram illustrates the configuration of three types of U-shaped conductors used in a motor stator according to an embodiment of the present invention. The first type of U-shaped conductor 112 includes a U-shaped segment 112a, two legs 112b, and two feet 112c. The U-shaped segment 112a protrudes from the first side 110a of the core 110, the two feet 112c protrudes from the second side 110b of the core 110, and the two legs 112b are disposed within slots in the core 110. The second type of U-shaped conductor 114 includes a U-shaped segment 114a, two legs 114b, and two feet 114c. The U-shaped segment 114a protrudes from the second side 110b of the core 110, the two feet 114c protrudes from the first side 110a of the core 110, and the two legs 114b are disposed within slots in the core 110. The third type of U-shaped conductor 118 includes a U-shaped segment 118a, two legs 118b, and two feet 118c. The U-shaped segment 118a protrudes from the first side 110a of the iron core 110, the two feet 118c protrude from the second side 110b of the iron core 110, and the two legs 118b are disposed within the slots of the iron core 110. The three configurations of the U-shaped conductors will be described in detail below.

[0082] Please refer to Figure 15 , Figure 16 This diagram illustrates the configuration of two types of straight conductors used in a motor stator according to an embodiment of the present invention. The first type of straight conductor 116 includes a straight intermediate section 116a and two opposite ends 116b and 116c. End 116b protrudes from the first side 110a of the core 110, and end 116c protrudes from the second side 110b of the core 110. The straight intermediate section 116a is disposed within a slot in the core 110. The second type of straight conductor 119 includes a straight intermediate section 119a and two opposite ends 119b and 119c. End 119b protrudes from the first side 110a of the core 110, and end 119c protrudes from the second side 110b of the core 110. The straight intermediate section 119a is disposed within a slot in the core 110. The configuration of the two U-shaped conductors will be described in detail below.

[0083] Please refer to Figure 17 This illustration shows the conductor configuration of the motor stator on the first side 110a of the iron core according to an embodiment of the present invention. The conductor configuration includes a plurality of first-type U-shaped conductors 112. Each first-type U-shaped conductor 112 has two legs 112b disposed in the outermost radial slot layer L1. Therefore, when its U-shaped segment 112a protrudes from the first side 110a of the iron core, it is also disposed in the outermost radial layer. The two legs 112b are separated by a slot-crossing distance of one pole pitch in the circumferential direction (see also [reference]). Figure 9The outermost U-shaped segment of the slot layer). Multiple first-type U-shaped conductors 112 form three groups of first-type U-shaped conductor groups 500 on the first side 110a of the iron core. Each first-type U-shaped conductor group 500 includes six partially overlapping U-shaped segments 112a of the first-type U-shaped conductors 112. The conductor configuration also includes multiple third-type U-shaped conductors 118, each of which has two legs 118b positioned radially adjacent to two slot layers (i.e., L2-L3). These two adjacent slot layers are located between the outermost slot layer (L1) and the innermost slot layer (L5). Therefore, when its U-shaped segment 118a protrudes from the first side 110a of the iron core, it is also positioned in the radially intermediate slot layer (please refer to the same reference). Figure 9 The U-shaped section of the intermediate slot layer). The conductor configuration also includes multiple second-type straight conductors 119, each of which includes a straight intermediate section 119a disposed in the outermost slot layer (L1) in the radial direction. Therefore, when its foot 119a protrudes from the first side 110a of the iron core, it is also disposed in the outermost layer in the radial direction (please refer to the same). Figure 9 The outermost slot layer's feet). The wire configuration also includes multiple feet 114c of a second type of U-shaped wire 114 and multiple feet 116b of a first type of straight wire 116. Each of the two feet 114c of the second type of U-shaped wire 114 is individually connected to the first foot 116b of the corresponding adjacent first type of straight wire 116.

[0084] Please refer to Figure 18 , showing Figure 17 A side view of the first side 110a of the motor stator core. The tops of all connecting portions C1 of the two ends 114c of the second type U-shaped conductor 114 are flush with the tops of the first ends 116b of the corresponding adjacent first type straight conductor 116, and their axial height H2 protruding from the core is greater than the axial height H1 (H2>H1) of the U-shaped segment 112a of the first type U-shaped conductor 112 protruding from the core, so that the welding of the ends is not affected by the U-shaped segment. Furthermore, the tops of the ends 119b of the plurality of second type straight conductors 119 are flush with the tops of the tops of the ends 119b, and their axial height H3 protruding from the core is greater than the axial height H1 (H1) of the U-shaped segment 112a of the first type U-shaped conductor 112, and also higher than the aforementioned height H2 (H3>H2>H1), so that the ends 119b of the second type straight conductors 119 can be connected to the corresponding electrical phase terminal or electrical neutral terminal.

[0085] Please refer to Figure 19 This illustrates the conductor configuration of the motor stator on the second side 110b of the core according to an embodiment of the present invention. The conductor configuration includes a plurality of second-type U-shaped conductors 114, each of which includes two legs 114b (see reference). Figure 13All of them are arranged in the innermost slot layer (L5) in the radial direction. Therefore, when its U-shaped section 114a protrudes from the second side 110b of the iron core, it is also arranged in the innermost slot layer L5 in the radial direction, and the two legs 114b are separated by a slot distance of one pole in the circumferential direction (please refer to the same). Figure 10 The innermost U-shaped segment of the slot). These second-type U-shaped conductors 114 comprise four sets of second-type U-shaped conductor groups 510, equidistantly arranged in the slots in the circumferential direction. Each second-type U-shaped conductor group 510 comprises six partially overlapping U-shaped segments 114a of the second-type U-shaped conductors 114. Each second-type U-shaped conductor group 510 spans the distance between two pole pitches (the motor stator comprises eight pole regions, and the four second-type U-shaped conductor groups 510 equally divide the eight pole regions, thus each second-type U-shaped conductor group 510 spans two pole pitches). The conductor configuration also includes multiple leads 112c of first-type U-shaped conductors 112, multiple leads 118c of third-type U-shaped conductors 118, and multiple leads 116c of first-type straight conductors 116. The straight middle segment 116a of each first-type straight conductor 116 (refer to...) Figure 15 The first type of U-shaped conductor 112 has two ends 112c connected to one of the two ends 118c of the corresponding adjacent third type of U-shaped conductor 118 on the second side 110b of the core. The first type of straight conductor 116 has one end 116c connected to one of the two ends 118c of the corresponding adjacent third type of U-shaped conductor 118 on the second side 110b of the core.

[0086] Please refer to Figure 20 It shows Figure 19 A side view of the second side 100b of the motor stator core. The tops of all the connecting portions C2 of the two ends 112c of the first type U-shaped conductor 112 and the two ends 118c of the corresponding adjacent third type U-shaped conductor 118 are flush with each other, and the axial height H4 protruding from the core is greater than the axial height H5 protruding from the core of the U-shaped segment 114a of the second type U-shaped conductor 114 (H4>H5), so that the welding of the ends is not affected by the U-shaped segment. The tops of all the connecting portions C3 of the second end 116c of the first type straight conductor 116 and the two ends 118c of the corresponding adjacent third type U-shaped conductor 118 are flush with each other, and the axial height H4 protruding from the core 110 is greater than the axial height H5 protruding from the core 110 of the second type U-shaped conductor 114 (H4>H5), so that the welding of the ends is not affected by the U-shaped segment. In addition, the top of all connecting parts C2 is flush with the top of all connecting parts C3, which can speed up the welding construction of the foot end.

[0087] Although the three types of U-shaped conductors and two types of straight conductors mentioned above are only examples of motor cores with 48 slots and 5 slot layers, they can also be applied to motor cores with an odd number of slot layers (5 or more) (the number of slots is not limited).

[0088] The hairpin-shaped conductor stator of the present invention uses a variety of U-shaped conductors and a variety of straight conductors, which are appropriately arranged on the motor core with an odd number of slots of 5 or more. This allows for easy adjustment of the span between the conductors on both sides of the core, reducing the difficulty of welding and connecting the wires, thereby reducing the time required for wiring and saving manufacturing costs.

[0089] Although the present invention has been disclosed above by way of embodiments, it is not intended to limit the present invention. Any person skilled in the art can make various modifications and refinements without departing from the spirit and scope of the present invention. Therefore, the scope of protection of the present invention shall be determined by the appended claims.

Claims

1. A hairpin-shaped conductor motor stator, comprising: The iron core is annular in shape, used to define a rotor housing space at the center of the iron core, wherein the iron core includes a first side and a second side that are axially opposite to each other; Multiple slots are located on the iron core, the multiple slots are arranged circumferentially around the rotor receiving space, and form multiple radially adjacent slot layers of M, where M is an odd number greater than or equal to 5; and Multiple hairpin-shaped wires are configured to be inserted into the multiple slots and connected to form multiple windings. The multiple hairpin-shaped wires include: A plurality of first-type U-shaped conductors, each of the plurality of first-type U-shaped conductors comprising two legs, each disposed in the outermost groove layer in the radial direction; A plurality of second-type U-shaped conductors, each of the plurality of second-type U-shaped conductors comprising two legs, each disposed in the radially innermost groove layer; A plurality of third-type U-shaped conductors, each of the plurality of third-type U-shaped conductors comprising two legs respectively disposed in two radially adjacent slot layers, the two adjacent slot layers being located between the outermost slot layer and the innermost slot layer; A plurality of first-type straight conductors, each of the plurality of first-type straight conductors including a straight intermediate segment, disposed in a groove layer radially superiorly; and A plurality of second-type straight conductors, each of the plurality of second-type straight conductors comprising a straight intermediate segment disposed in the outermost groove layer in the radial direction.

2. The hairpin-shaped conductor motor stator according to claim 1, wherein each of the first type of U-shaped conductors includes a U-shaped segment protruding from the first side of the iron core and two legs protruding from the second side of the iron core. Each of the second type of U-shaped conductors includes a U-shaped segment protruding from the second side of the iron core and two legs protruding from the first side of the iron core. Each of the third type of U-shaped conductors includes a U-shaped segment protruding from the first side of the iron core and two legs protruding from the second side of the iron core.

3. The hairpin-shaped conductor motor stator of claim 1, wherein each of the first type of straight conductors includes a first leg protruding from the first side of the iron core and a second leg protruding from the second side of the iron core, and Each of the second type of straight conductor includes a first leg protruding from the first side of the iron core and a second leg protruding from the second side of the iron core.

4. The hairpin-shaped conductor motor stator according to claim 3, wherein the first leg of the second type of straight conductor is connected to the phase terminal or the neutral terminal, and The two ends of the second type of U-shaped conductor are respectively connected to the first end of the corresponding adjacent first type of straight conductor.

5. The hairpin-shaped conductor motor stator according to claim 3, wherein the two ends of the first type of U-shaped conductor are respectively connected to one of the two ends of the corresponding adjacent third type of U-shaped conductor, and The second leg of the first type of straight conductor is connected to one of the two legs of the corresponding adjacent third type of U-shaped conductor.

6. The hairpin-shaped conductor motor stator according to claim 1, wherein the iron core includes a plurality of pole regions in the circumferential direction, each of the plurality of pole regions includes a plurality of the slots, the distance between the two legs of the first type of U-shaped conductor across the slots in the circumferential direction is the pole pitch, wherein the distance between the two legs of the second type of U-shaped conductor across the slots in the circumferential direction is the pole pitch.

7. The hairpin-shaped conductor motor stator according to claim 1, wherein the plurality of first U-shaped conductors comprises a plurality of first U-shaped conductor groups arranged in the circumferential direction into the corresponding plurality of slots, wherein each of the plurality of first U-shaped conductor groups comprises a plurality of partially overlapping first U-shaped conductors.

8. The hairpin-shaped conductor motor stator according to claim 7, wherein the plurality of second U-shaped conductors comprises a plurality of second U-shaped conductor groups, which are equidistantly arranged in the corresponding plurality of slots in the circumferential direction, wherein each of the plurality of second U-shaped conductor groups comprises a plurality of partially overlapping second U-shaped conductors.

9. The hairpin-shaped conductor motor stator according to claim 4, wherein the connection portion of the two ends of the second type of U-shaped conductor and the first end of the corresponding adjacent first type of straight conductor protrudes from the iron core at a greater axial height than the U-shaped segment of the first type of U-shaped conductor protruding from the iron core.

10. The hairpin-shaped conductor motor stator according to claim 4, wherein the first leg of the second type of straight conductor protrudes from the iron core at a greater axial height than the U-shaped segment of the first type of U-shaped conductor protrudes from the iron core at a greater axial height.

11. The hairpin-shaped conductor motor stator according to claim 5, wherein the connection portion of the two ends of the first type of U-shaped conductor and one of the two ends of the corresponding adjacent third type of U-shaped conductor protrudes from the iron core at a greater axial height than the U-shaped segment of the second type of U-shaped conductor protrudes from the iron core.

12. The hairpin-shaped conductor motor stator according to claim 5, wherein the connection portion of the second leg of the first type of straight conductor and one of the two legs of the corresponding adjacent third type of U-shaped conductor protrudes from the core at a greater axial height than the U-shaped segment of the second type of U-shaped conductor protrudes from the core.

13. A hairpin-shaped conductor motor stator, comprising: The iron core includes a first side and a second side opposite to each other for the wires to protrude; Multiple slots are arranged circumferentially on the iron core, forming multiple radially adjacent M slot layers, where M is an odd number greater than or equal to 5; and Multiple hairpin-shaped conductors are configured to be inserted into the multiple slots and connected to form multiple windings. The multiple hairpin-shaped conductors include multiple first-type U-shaped conductors configured in the outermost slot layer in the radial direction and multiple second-type U-shaped conductors configured in the innermost slot layer in the radial direction. Each of the multiple first-type U-shaped conductors includes a U-shaped segment configured in the outermost slot layer in the radial direction and protruding from the first side of the iron core. Each of the multiple second-type U-shaped conductors includes a U-shaped segment configured in the innermost slot layer in the radial direction and protruding from the second side of the iron core. The plurality of hairpin-shaped conductors further include a plurality of third U-shaped conductors, each of the plurality of third U-shaped conductors including a U-shaped segment disposed across two radially adjacent slot layers, the two radially adjacent slot layers being located between the outermost slot layer and the innermost slot layer, the U-shaped segment of the third U-shaped conductor protruding from the first side of the core; The plurality of hairpin-shaped conductors further comprises a plurality of first-type straight conductors disposed in the radially upper inner groove layer, and a plurality of second-type straight conductors disposed in the radially upper outermost groove layer. The first type of straight conductor is used to connect the second type of U-shaped conductor and the third type of U-shaped conductor, and The second type of straight conductor is used to connect the phase terminal or the neutral terminal, and the second type of straight conductor is also used to connect the third type of U-shaped conductor.

14. The hairpin-shaped conductor motor stator of claim 13, wherein the first type of straight conductor protrudes from the first side of the iron core to connect to the second type of U-shaped conductor and protrudes from the second side of the iron core to connect to the third type of U-shaped conductor, and The second type of straight conductor protrudes from the first side of the iron core to connect to the electrical phase terminal or the electrical neutral terminal, and the second type of straight conductor protrudes from the second side of the iron core to connect to the third type of U-shaped conductor.

15. The hairpin-shaped conductor motor stator according to claim 13, wherein the iron core includes a plurality of pole regions in the circumferential direction, each of the plurality of pole regions includes a plurality of the slots, and the span in the circumferential direction of the U-shaped segment of the first type of U-shaped conductor and the U-shaped segment of the second type of U-shaped conductor are both pole pitches.

16. The hairpin-shaped conductor motor stator of claim 13, wherein the plurality of first U-shaped conductors form a plurality of first U-shaped conductor groups, which are arranged in the circumferential direction into the corresponding plurality of slots, wherein each of the plurality of first U-shaped conductor groups includes a plurality of partially overlapping U-shaped segments of the first U-shaped conductors.

17. The hairpin-shaped conductor motor stator of claim 16, wherein the plurality of second U-shaped conductors form a plurality of second U-shaped conductor groups, which are arranged in the circumferential direction into the corresponding plurality of slots, wherein each of the plurality of second U-shaped conductor groups includes a plurality of partially overlapping U-shaped segments of the second U-shaped conductors.

18. The hairpin-shaped conductor motor stator of claim 17, wherein the iron core comprises a plurality of pole regions in the circumferential direction, each of the plurality of pole regions comprising a plurality of the slots, and the plurality of second U-shaped conductor groups are arranged in the circumferential direction at equal intervals, the interval being two pole pitches.

Images