Flat wire motor

Abstract

The invention provides a flat wire motor which comprises N branches connected in parallel, each branch comprises three neutral parts, the first neutral part comprises a first leg part and a first connecting part, the third neutral part comprises a third leg part and a third connecting part, one end of the first leg part is connected with one end of the first connecting part, and the other end of the first connecting part is connected with the other end of the third connecting part. One end of the third leg part is connected with one end of the third connecting part; the first connecting part is connected with the second connecting part; the first leg part, the first connecting part, the third leg part and the third connecting part are integrally formed to form a Hair-pin structure; the cross sections of the first leg part, the first connecting part, the third leg part and the third connecting part are rectangular and have the same sectional area; wherein N is a positive integer. According to the invention, a bus copper bar is replaced by the hairpin connecting part, so that the occupied space is greatly reduced, and the use of welding is reduced.

Description

Technical Field

[0001] The present application relates to the field of motors, and in particular to the technical field of flat wire motors. Background Art

[0002] The main motor category of the drive motor or generator in the new energy vehicle industry is the permanent magnet synchronous motor. In the past decade, the winding of the permanent magnet synchronous motor has been mainly round copper wire. As the country's requirements for the power density and torque density of automotive motors become higher and higher, round copper wire cannot improve the power density and torque density due to the bottleneck of slot fill rate. In recent years, the development of flat wires has become increasingly mature, and its higher slot fill rate has achieved high power density, torque density and good NVH performance and thermal performance. The entire new energy industry is deploying flat wires, and flat wires have become a trend. However, the winding of flat wires is quite different from that of round copper wires. The mainstream line type currently used for flat wires is the hairpin line, and the mainstream connection method is the star connection method. After the flat wire is formed, the position of the neutral point connection line is relatively fixed, and the neutral point is short-circuited together after welding through the busbar. The busbar is formed by a copper busbar, which occupies the space at the end of the winding and increases the material cost of the copper busbar. Especially for the winding arrangement of multiple branches in parallel, it occupies more space at the end, making wiring more difficult when space is limited.

[0003] Currently, most neutral point connections are made by copper busbar welding, which not only increases the copper busbar material cost, but also occupies motor space. In a multi-branch motor structure, the height of the entire motor end is increased. In the case of limited space, if the busbar cross-section is too small, it will cause serious heating and other problems, and it is difficult to arrange in a narrow motor space. Summary of the invention

[0004] The present invention provides a flat wire motor, which realizes the connection of the neutral point through a hairpin connection structure, simplifies the lead-out wire connection device, and reduces the space occupied by the end.

[0005] On the one hand, the present application provides a flat wire motor, comprising N parallel branches, and each of the branches comprises three neutral parts, the first neutral part comprises a first leg and a first connecting part, the third neutral part comprises a third leg and a third connecting part, one end of the first leg is connected to one end of the first connecting part, and one end of the third leg is connected to one end of the third connecting part; the first connecting part is connected to the second connecting part; the first leg, the first connecting part, the third leg and the third connecting part are integrally formed to form a Hair-pin structure; the cross-sections of the first leg, the first connecting part, the third leg and the third connecting part are all rectangular and have the same cross-sectional area; wherein N is a positive integer.

[0006] Furthermore, the Hair-pin structure is obtained by splicing the first connection part and the first connection part, the other end of the first connection part is provided with a first inlay part, and the other end of the third connection part is provided with a second inlay part, the first inlay part and the second inlay part are plugged in and pre-tightened to form a hairpin connection part, thereby realizing electrical connection; the cross-sections of the first connection part, the first leg, the third connection part, the third leg and the hairpin connection part are all rectangular and have the same cross-sectional area.

[0007] Furthermore, the branches are connected in a star configuration.

[0008] Furthermore, it is characterized in that N is 4.

[0009] Furthermore, the first connection portion is obtained by a bending process from the first leg portion; and the third connection portion is obtained by a bending process from the third leg portion.

[0010] Furthermore, the second neutral portion has a second leg portion and a second connecting portion, one end of the second leg portion is connected to one end of the second connecting portion, and the other end of the second connecting portion is connected to the hairpin connecting portion by welding.

[0011] Furthermore, the first inlay portion comprises a first plate and a second plate, the first plate and the second plate form an opening, and the second inlay portion comprises a protrusion matched with the opening.

[0012] Furthermore, a side of the opening facing the second plate has a plurality of protrusions.

[0013] Furthermore, the first plate and the second plate are parallel.

[0014] Furthermore, the first plate and the second plate have a certain angle for clamping each other.

[0015] Compared with the prior art, the present invention has the following beneficial effects:

[0016] 1) The present application replaces the copper busbar in the prior art with the flat wire of the coil itself, thereby reducing production costs, simplifying the lead-out wire connection device, and reducing the space occupied by the end.

[0017] 2) Since the present application uses the extension portion of the coil itself to connect the neutral point, that is, the cross-sectional area of ​​the connecting portion is the same as the cross-sectional area of ​​the coil, the adaptation process is omitted.

[0018] 3) The first connection part and the third connection part of the present application are integrally formed, which reduces the use of welding, reduces the failure rate, and improves reliability. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0020] Figure 1 It is a copper busbar device for connecting the three-phase current and the neutral point of a four-branch parallel flat wire motor in the prior art;

[0021] Figure 2 It is a schematic diagram of the neutral point connection in the prior art;

[0022] Figure 3 It is a copper busbar device for connecting the three-phase current and the neutral point of the four-branch parallel flat wire motor of this embodiment;

[0023] Figure 4 This is a schematic diagram of the neutral point connection in this embodiment;

[0024] Figure 5 This is a schematic diagram of the explosion decomposition of the neutral point of a single branch in this embodiment;

[0025] Figure 6 Schematic diagram of the card issuing connection portion of this embodiment. DETAILED DESCRIPTION

[0026] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0027] Figure 1 The figure shows a common 4-branch parallel flat wire motor structure in the prior art. Figure 1 As shown, the flat wire motor uses a busbar 1 to achieve neutral point connection. Figure 2 for Figure 1 The diagram below shows the neutral point connection structure of the flat wire motor. Figure 2 As shown, the flat wire motor has 4 branches, each branch has three neutral points, and the three neutral points are connected to the busbar 1 by welding. The busbar is also provided with an A-phase lead-out copper bar 2, a B-phase lead-out copper bar 3 and a C-phase lead-out copper bar 4. Figure 2 As shown, in the prior art, the neutral point 11 is connected to the busbar via a welding connection position 12 .

[0028] However, in the case of multiple branches connected in parallel, the cross-section of the busbar 1 must reach a certain area to ensure the passage of large current. If the cross-section of the busbar is too small, it will cause serious heating and other problems. However, the limited space size of the motor is limited, and the cross-sectional area and layout of the busbar 1 will be restricted. In addition, for different types of flat wire motors, busbars with appropriate cross-sectional areas must be matched, which undoubtedly increases the design difficulty.

[0029] In this regard, the present application adopts a flat wire coil (ie, the coil itself is extended) instead of the bus bar 1 to connect each neutral point, which not only reduces production costs, reduces occupied space, reduces the use of welding, but also eliminates the cross-sectional area adaptation process.

[0030] Figure 3 The flat wire motor 7 of this embodiment is shown. Figure 4 FIG. 1 shows a schematic diagram of the neutral connection point connection structure of the flat wire motor of this embodiment. Figure 3 As shown, the flat wire motor 7 includes a first connecting portion 8 and a third connecting portion 9; Figure 5 A schematic diagram of the connection between the first connection part 8 and the third connection part 9 is shown. Figure 6 The structure of the first connecting portion 8 and the third connecting portion 9 is further shown.

[0031] like Figure 4 As shown, the flat wire motor has 4 parallel branches, and each branch has three neutral points, namely: the first neutral part, the second neutral part and the third neutral part. The first neutral part includes the first leg 5 and the first connecting part 8, the third neutral point has the third leg 6 and the third connecting part 9, and the second neutral part includes the second leg 7 and the second connecting part (not shown in the figure). One end of the first leg 5 is connected to one end of the first connecting part 8; one end of the third leg 6 is connected to one end of the third connecting part 9; one end of the second leg 7 is connected to one end of the second connecting part. The second connecting part is located at one end of the second leg. Among them, the first neutral part, the second neutral part and the third neutral part all contain neutral points that need to be connected.

[0032] The first leg portion 5, the first connecting portion 8, the third leg portion 6 and the third connecting portion 9 may be integrally formed.

[0033] See also Figure 4 The first leg 5, the first connecting portion 8, the third leg 6 and the third connecting portion 9 are integrally formed to form a Hair-pin structure, that is, the first leg 5, the first connecting portion 8, the third leg 6 and the third connecting portion 9 are the same flat wire coil. In this embodiment, the combination of the first connecting portion 8 and the third connecting portion 9 replaces the busbar in the prior art, thereby reducing space occupation.

[0034] At the same time, the second leg 7 and the second connection part form an I-pin structure, and the second connection part is connected to the Hair-pin structure by welding. Overall, the I-pin structure is connected to the Hair-pin structure by welding. The specific welding position can be on the first connection part 8 or on the third connection part 9, preferably, the middle position of the combination of the first connection part 8 and the third connection part 9.

[0035] In addition, the cross-sectional areas of the first leg portion 5 , the first connecting portion 8 , the second leg portion 6 and the third connecting portion 9 are all rectangular and have the same area.

[0036] Optionally, the first leg portion 5, the first connecting portion 8, the third leg portion 6 and the third connecting portion 9 are formed by splicing together multiple sections.

[0037] like Figure 5 As shown, the other end of the first connecting portion 8 is provided with a first inlay portion, and the other end of the third connecting portion 9 is provided with a second inlay portion, and the first inlay portion and the second inlay portion are plugged in and pre-tightened to form a hairpin connecting portion 10, thereby realizing electrical connection; the hairpin connecting portion 10 has the same cross-sectional area as the first leg portion 5.

[0038] Figure 5 FIG. 1 shows a partial schematic diagram of the card issuing connection portion 10 of this embodiment. Figure 6 The schematic diagram of the card issuing connection part is further shown. Figure 5 and Figure 6 As shown, the first inlay part has a first plate 801 and a second plate 802, the first plate 801 and the second plate 802 form an opening, and the second inlay part has a protrusion 901 adapted to the opening. The opening can be rectangular, circular, triangular or the like.

[0039] Optionally, the first connection portion 8 can be formed by bending the first leg portion 5 , that is, the two are the same flat wire. Similarly, the third connection portion 9 can be formed by bending the third leg portion 6 .

[0040] Optionally, the first connection portion 8 and the first leg portion 5 are integrally formed, and the two are made of the same material. Similarly, the third connection portion 9 and the third leg portion 6 are integrally formed, and the two are made of the same material.

[0041] Optionally, the first leg 5, the second leg 7 and the third leg 6 all extend along the rotation axis direction of the motor;

[0042] Optionally, the first connection portion 8 and the third connection portion 9 extend circumferentially along the rotation direction of the motor.

[0043] Optionally, the angle between the first leg portion 5 and the first connecting portion 8 is greater than or equal to 90 degrees. Similarly, the angle between the third leg portion 6 and the third connecting portion 9 is greater than or equal to 90 degrees.

[0044] Optionally, the angle between the second leg portion 7 and the second connecting portion is 180 degrees, that is, the second leg portion 7 and the second connecting portion form a rectangle.

[0045] Optionally, the first plate 801 and the second plate 802 are parallel.

[0046] Optionally, the first plate 801 and the second plate 802 have a certain angle for clamping each other.

[0047] Optionally, the side of the opening facing the second plate 802 has a plurality of protrusions, and the plurality of protrusions are serrated as a whole, and the protrusions are used to increase the connection reliability. At the same time, the protrusion 901 has a first surface and a second surface opposite to the first surface. The first surface has a groove matching the plurality of protrusions on one side of the second plate 802, thereby achieving the effect of strengthening the connection strength.

[0048] Optionally, the second connection portion of the second leg 7 is connected to the hairpin connection portion 10 by welding, and the second connection portion covers the first plate 801, the second plate 802 and the protrusion 901, that is, the weld covers the hairpin connection portion 10. The above connection method not only connects the second leg 7, but also strengthens the connection strength between the first connection portion 8 and the second connection portion 9.

[0049] It should be noted that the connection method between the second connecting part and the hairpin connecting part 10 is not limited to welding, and electrical connection can also be achieved through other methods, such as pin connection, that is, the second connecting part is a pin structure, and the first plate, the second plate and the protrusion in the hairpin connection have a hole for the second connecting part to pass through, that is, the first connecting part, the second connecting part and the third connecting part constitute a pin structure.

[0050] The "equal" or "same" or "equal" disclosed in the present invention must take into account the distribution of engineering parameters, and the error distribution is within ±30%; the definition of "parallel" of two line segments or two straight lines is that the angle between the two line segments or two straight lines is less than or equal to 45 degrees; the definition of "perpendicular" of two line segments or two straight lines is that the angle between the two line segments or two straight lines is within the range of [60, 120] degrees; the definition of "phase mismatch" also needs to take into account the distribution of engineering parameters, and the error distribution of the degree of mismatch is within ±30%. In addition, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also includes other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. Without more constraints, an element defined by the phrase "comprises a ..." does not exclude the existence of other identical elements in the process, method, article or apparatus comprising the element.

[0051] The various embodiments in this specification are described in a progressive manner, and each embodiment focuses on the differences from other embodiments. The same or similar parts between the various embodiments can be referenced to each other.

[0052] The above description of the disclosed embodiments enables one skilled in the art to implement or use the present invention. Various modifications to these embodiments will be apparent to one skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention will not be limited to the embodiments shown herein, but rather to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A flat wire motor, characterized in that: It includes N parallel branches, and each of the branches includes 3 neutral parts, the first neutral part includes a first leg and a first connecting part, the third neutral part includes a third leg and a third connecting part, one end of the first leg is connected to one end of the first connecting part, and one end of the third leg is connected to one end of the third connecting part; the first connecting part is connected to the second connecting part; the first leg, the first connecting part, the third leg and the third connecting part are integrally formed to form a Hair-pin structure; the cross-sections of the first leg, the first connecting part, the third leg and the third connecting part are all rectangular and have the same cross-sectional area; wherein N is a positive integer.

2. The flat wire motor according to claim 1, characterized in that: The hair-pin structure is obtained by splicing the first connection part and the first connection part, the other end of the first connection part is provided with a first inlay part, and the other end of the third connection part is provided with a second inlay part, the first inlay part and the second inlay part are plugged and pre-tightened to form a hairpin connection part, thereby realizing electrical connection; the cross-sections of the first connection part, the first leg part, the third connection part, the third leg and the hairpin connection part are all rectangular and have the same cross-sectional area.

3. The flat wire motor according to claim 1 or 2, characterized in that: The branches are connected in star configuration.

4. The flat wire motor according to claim 1 or 2, characterized in that: N is 4.

5. The flat wire motor according to claim 1 or 2, characterized in that: The first connection portion is obtained by a bending process of the first leg portion; and the third connection portion is obtained by a bending process of the third leg portion.

6. The flat wire motor according to claim 1 or 2, characterized in that: The second neutral portion has a second leg portion and a second connecting portion, one end of the second leg portion is connected to one end of the second connecting portion, and the other end of the second connecting portion is connected to the hairpin connecting portion by welding.

7. The flat wire motor according to claim 2, characterized in that: The first inlay portion comprises a first plate and a second plate, the first plate and the second plate form an opening, and the second inlay portion comprises a protrusion matched with the opening.

8. The flat wire motor according to claim 7, characterized in that: The opening has a plurality of protrusions on one side facing the second plate.

9. The flat wire motor according to claim 7, characterized in that: The first plate and the second plate are parallel.

10. The flat wire motor according to claim 7, characterized in that: The first plate and the second plate have a certain angle for clamping each other.

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