Stator structure with stator winding composed of multiple layers of flat conductors

Abstract

The invention discloses a stator structure with a stator winding composed of multiple layers of flat conductors, the stator structure comprises a stator core and stator winding assemblies, the stator core is provided with a plurality of stator slots, the stator winding assemblies are arranged in the stator slots, slot insulation structures are arranged in the stator slots, and the stator winding assemblies are arranged in the slot insulation structures. The stator winding assembly and the stator iron core are arranged in the stator slots in a radial direction, so that the stator winding assembly and the stator iron core are insulated, the stator winding assembly comprises a plurality of stator windings, each stator winding is formed by stacking and splicing a plurality of layers of flat conductors, and each stator slot is internally provided with a plurality of layers of stator windings along the radial direction. The stator structure provided by the invention is suitable for various types of motors, and has the advantages of reducing high-frequency alternating current loss generated by the stator winding, greatly reducing the height of the end part of the stator winding and the like on the premise of ensuring the insulating property of the stator winding, so that the operation efficiency of the motor can be effectively improved.

Description

Technical Field

[0001] The invention relates to the technical field of motors, and in particular to a stator structure with a stator winding composed of multiple layers of flat conductors. Background Art

[0002] With the continuous improvement of new energy vehicle technology, electric drive systems are increasingly developing towards high power density, high volume density, and high efficiency. Therefore, it is particularly important to improve motor efficiency and volume density.

[0003] A flat wire motor is a motor that uses flat wires instead of traditional round wires in the stator winding. The flat wires of a flat wire motor can be packed more tightly into the stator slots, improving slot utilization, so that more copper wires can be accommodated in the same volume, increasing the power density of the motor. At the same time, since flat wire motors can reduce the size and weight of the motor at the same power, this helps to achieve miniaturization and lightweighting of the motor, which is very attractive for application scenarios such as new energy vehicles that have strict requirements on space and weight. Therefore, flat wire motors are often used in drive motors for new energy vehicles, as well as other occasions that require high power density and high efficiency, such as industrial automation, household appliances, and aerospace.

[0004] However, with the development trend of high speed, the traditional flat wire motor has a large AC loss under high frequency conditions due to the large cross-sectional area of ​​its flat wire winding and obvious skin effect and proximity effect, which has a particularly serious impact on the efficiency of the flat wire motor. Summary of the invention

[0005] In view of the above-mentioned deficiencies in the prior art, the technical problem to be solved by the present invention is: how to provide a stator structure with a stator winding composed of multiple layers of flat conductors that can effectively reduce high-frequency AC losses and thereby improve motor efficiency.

[0006] In order to solve the above technical problems, the present invention adopts the following technical solutions: A stator structure with a stator winding composed of multiple layers of flat conductors, comprising a stator core and a stator winding assembly, wherein the stator core is provided with a plurality of stator slots, the stator winding assembly is arranged in the stator slots, a slot insulation structure is arranged in the stator slots to insulate the stator winding assembly and the stator core, the stator winding assembly comprises a plurality of stator windings, each stator winding is formed by stacking multiple layers of flat conductors, and multiple layers of stator windings are arranged in each stator slot along the radial direction.

[0007] Preferably, the multi-layer flat conductors of each stator winding are insulated by an interlayer insulation structure, and the multi-layer flat conductors constituting each stator winding are insulated as a whole by a main insulation structure.

[0008] Preferably, the thickness of the flat conductor is 0.05 mm-2 mm.

[0009] Preferably, the main insulation structure includes an insulation film wrapping structure, an injection molded part structure, and an overall coating structure.

[0010] Preferably, the insulating film wrapping structure is formed by integrally winding each stator winding with an insulating film, and the thickness of the insulating film is 0.01 mm-0.2 mm.

[0011] Preferably, the injection molded part structure is formed by injection molding of insulating material, and after the injection molded part structure is sleeved on the stator winding, it is spliced ​​by means of buckling and slotting, or the injection molded part structure is directly injection molded into a sleeve and sleeved on the stator winding.

[0012] Preferably, the overall coating structure is formed by stacking multiple layers of flat conductors into a stator winding, and then coating or extruding the entire stator winding with an insulating layer, so that the insulating layer is directly fixed on the surface of the entire stator winding.

[0013] Preferably, the interlayer insulation structure includes a nano-evaporation insulation layer structure, a paint film structure, and a brushed insulation glue layer structure.

[0014] Preferably, the interlayer insulation structure is a single-sided insulation structure and a double-sided insulation structure, and the double-sided insulation structure includes a half-enclosed double-sided insulation structure and a full-enclosed double-sided insulation structure.

[0015] Preferably, the method for stacking multiple layers of flat conductors in the stator winding includes: Flat conductors with single-sided insulation structure are stacked continuously; Flat conductors with double-sided insulation structure are stacked continuously; Flat conductors with double-sided insulation structures and flat conductors without insulation structures are stacked at intervals.

[0016] Compared with the prior art, the present invention has the following advantages: 1. Each stator winding of the present invention is composed of multiple layers of flat conductors. Inside each stator winding, multiple layers of flat conductors are separated and insulated by interlayer insulation structures. At the same time, multiple layers of flat conductors are stacked into a whole and insulated by the main insulation structure to form a whole stator winding similar to an ordinary flat wire motor. This is a layer of stator winding. Multiple stator windings form a stator winding assembly with low high-frequency AC loss, and finally installed in the stator slot. Each stator slot is equipped with n layers of stator windings, where n is a positive integer. Therefore, the present invention can effectively reduce the skin effect and proximity effect by adopting a structure of stacking multiple layers of flat conductors, thereby reducing AC losses and improving the efficiency of the motor.

[0017] 2. When the stator winding of the flat wire motor in the prior art adopts the continuous wave winding technology, the end length of the stator winding can be effectively shortened, thereby reducing the height of the stator winding end, reducing material usage, reducing DC resistance, reducing copper loss, and improving efficiency. However, the process is difficult to overcome due to problems such as winding formation and arrangement. The stator winding structure of the present invention can effectively reduce the hardness of the stator winding, simplify the difficulties of the continuous wave winding technology, and enable the technical solution of the present invention to be further applied to the drive motor industry.

[0018] 3. The multi-layer thin high-conductivity metal material structure of the present invention can be flexibly applied to stator slots of different shapes and sizes, and even to rotor slots of asynchronous motors, and has wide adaptability.

[0019] 4. The stator structure of the present invention is applicable to various types of motors. Under the premise of ensuring the insulation performance of the stator winding, the present invention has the advantages of reducing the high-frequency AC loss generated by the stator winding, greatly reducing the height of the stator winding end, etc., thereby effectively improving the operating efficiency of the motor. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Attached Figure 1 It is a schematic structural diagram of a stator structure of the present invention having a stator winding composed of multiple layers of flat conductors; Attached Figure 2 It is a schematic diagram of the insulation structure in the stator structure of the stator winding composed of multiple layers of flat conductors of the present invention; Attached Figure 3 It is a schematic diagram of a main insulation structure in a stator structure of a stator winding composed of multiple layers of flat conductors according to the present invention; Attached Figure 4 It is a schematic diagram of an interlayer insulation structure in a stator structure of a stator winding composed of multiple layers of flat conductors according to the present invention; Attached Figure 5 It is a schematic diagram of the combination of different interlayer insulation structures in the stator structure of the stator winding with multiple layers of flat conductors of the present invention; Attached Figure 6 A schematic diagram of a stator structure when a stator winding composed of multiple layers of flat conductors is used and a Hair-pin winding is used; Attached Figure 7 A schematic diagram of a stator structure when a stator winding composed of multiple layers of flat conductors is used and a continuous wave winding is used; Explanation of the reference numerals: stator core 1 , stator winding 2 , stator slot 3 , slot insulation structure 4 , main insulation structure 5 , insulation film wrapping structure 501 , injection molding structure 502 , overall coating structure 503 , interlayer insulation structure 6 , flat conductor 7 . DETAILED DESCRIPTION

[0021] In order to make the purpose, technical scheme and advantages of the embodiments of the present invention clearer, the technical scheme in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. The components of the embodiments of the present invention generally described and shown in the drawings here can be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of the present invention provided in the drawings is not intended to limit the scope of the claimed invention, but merely represents selected embodiments of the present invention. Based on the embodiments in the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work belong to the scope of protection of the present invention.

[0022] It should be noted that similar numbers and letters represent similar items in the following drawings, so once an item is defined in one drawing, it does not need to be further defined and explained in the subsequent drawings. In the description of the present invention, it should be noted that the orientation or position relationship indicated by the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inside", "outside", etc. is based on the orientation or position relationship shown in the drawings, or the orientation or position relationship in which the invention product is usually placed when used, which is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation of the present invention. In addition, the terms "first", "second", "third", etc. are only used to distinguish the description, and cannot be understood as indicating or implying relative importance. In addition, the terms "horizontal", "vertical", etc. do not mean that the components are absolutely horizontal or suspended, but can be slightly tilted. For example, "horizontal" only means that its direction is more horizontal than "vertical", and does not mean that the structure must be completely horizontal, but can be slightly tilted. In the description of the present invention, it is also necessary to explain that, unless otherwise clearly specified and limited, the terms "set", "install", "connect", and "connect" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal communication of two elements. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0023] As attached Figure 1 To the attached Figure 5As shown, the present invention provides a stator structure with a stator winding composed of multiple layers of flat conductors, including a stator core 1 and a stator winding assembly. The stator core 1 is composed of soft magnetic materials such as silicon steel sheets, amorphous alloys, SMC, etc., and can be composed of single-piece stacking or other methods such as injection molding. The thickness of the single-piece core composed of single-piece stacking ranges from 0.01mm to 0.5mm.

[0024] The stator core 1 is provided with a plurality of stator slots 3 . The stator slots 3 may be in various shapes, such as rectangular, trapezoidal, and other regular or irregular shapes. The number of the stator slots 3 is adjusted according to the electromagnetic design.

[0025] As attached Figure 2 As shown, the stator winding assembly is arranged in the stator slot 3, and a slot insulation structure 4 is arranged between the stator winding assembly and the stator slot 3. The slot insulation structure 4 is used to insulate the stator winding assembly and the stator core, and its composition includes various types of insulating paper, insulating film, injection molding structure or other structures that can play an insulating role. The shape of the stator winding assembly needs to be able to adapt to the structure of the stator slot 3. Most of the stator winding assembly is embedded in the stator slot 3, and the two ends of the stator winding assembly extend out of the stator slot 3 to form the stator winding end. The stator winding assembly includes a plurality of stator windings 2, each of which is composed of multiple layers of flat conductors 7, and multiple layers of stator windings 2 are arranged in each stator slot 3 along the radial direction. Therefore, each stator winding 2 of the present scheme is composed of multiple layers of flat conductors 7 stacked together, and the insulation structure is used to make its insulation performance meet the requirements, forming a whole stator winding 2 similar to an ordinary flat wire structure, which is a layer of stator winding 2. There are a total of n layers of stator windings 2 in the stator slot 3, n is a positive integer, and the specific number of layers is determined according to the electromagnetic design.

[0026] In this embodiment, the thickness of the flat conductor 7 is 0.05 mm-2 mm. The width of the flat conductor 7 is modified according to the electromagnetic design requirements. The stator winding 2 includes a continuous wave winding (such as the attached Figure 7 As shown), Hair-pin winding (as shown in the attached Figure 6 As shown), I-pin winding, X-pin winding and other winding forms.

[0027] Specifically, the insulation structure of each stator winding 2 is used to provide insulation performance for itself, including an interlayer insulation structure 6 and a main insulation structure 5, wherein the multi-layer flat conductors 7 of each stator winding 2 are insulated by the interlayer insulation structure 6, and the multi-layer flat conductors 7 constituting each stator winding 2 are insulated as a whole by the main insulation structure 5.

[0028] As attached Figure 3 As shown, in this embodiment, the main insulation structure 5 includes an insulation film wrapping structure 501 (attached Figure 3(a)), injection molded part structure 502 (attached Figure 3 (b)), the overall coating structure 503 (attached Figure 3 As shown in (c)). The insulating film wrapping structure 501 is formed by winding each stator winding 2 with an insulating film, and the thickness of the insulating film is 0.01mm-0.2mm, and the overlapping rate is determined according to the design requirements. The injection molded part structure 502 is formed by injection molding with an insulating material. The injection molded part structure 502 is sleeved on the stator winding 2 and then spliced ​​by buckling or slotting, or the injection molded part structure 502 is directly injection molded into a sleeve and sleeved on the stator winding 2. The overall coating structure 503 is formed by stacking multiple layers of flat conductors 7 into a stator winding 2, and then coating or extruding the stator winding 2 as a whole with an insulating layer, so as to directly fix the insulating layer on the surface of the entire stator winding 2.

[0029] As attached Figure 4 As shown, in this embodiment, the interlayer insulation structure 6 includes a nano-evaporation insulation layer structure, a paint film structure, and a brushing insulation glue layer structure. The interlayer insulation structure 6 is arranged on each flat conductor 7. The interlayer insulation structure 6 can adopt a single-side insulation structure (such as the attached Figure 4 (a) in the figure) and double-sided insulation structure, the double-sided insulation structure includes a half-wrapped double-sided insulation structure (as shown in the attached Figure 4 (b) in the figure) and the fully enclosed double-sided insulation structure (as shown in the attached Figure 4 (as shown in (c) in the figure).

[0030] As attached Figure 5 As shown, the following methods can be used when stacking multiple layers of flat conductors: 1. Use flat conductors with single-side insulation structure to stack continuously, as shown in the attached Figure 5 As shown in (a) in the figure, each layer of flat conductors 7 adopts a single-side insulation structure, and the insulation structure of each layer of flat conductors 7 is located on the same side, such as located on the upper side or the lower side of each layer of flat conductors 7.

[0031] 2. Flat conductors with double-sided insulation structure are continuously stacked; that is, each layer of flat conductors 7 adopts a double-sided insulation structure, which can be a full-cover double-sided insulation structure, such as the attached Figure 5 As shown in (c) in the figure, it is also possible to use a half-enclosed double-sided insulation structure as shown in the attached Figure 5 As shown in (b) in the figure, a fully enclosed double-sided insulation structure or a half-enclosed double-sided insulation structure is randomly adopted.

[0032] 3. Flat conductors with double-sided insulation and flat conductors without insulation are stacked at intervals, as shown in the attached Figure 5As shown in (d) in the figure; that is, when one of the flat conductors 7 adopts a double-sided insulation structure, the adjacent flat conductor 7 can adopt a bare conductor, and the form of the double-sided insulation structure here is not limited.

[0033] Of course, in actual use, there are other stacking methods, such as stacking flat conductors 7 with double-sided insulation structures and flat conductors 7 with single-sided insulation structures at intervals, two layers of double-layer insulation structures followed by a layer of bare conductor or a single-sided insulation structure, and different stacking methods can also be used inside the multi-layer stator winding 2 located in the same stator slot 3. The specific stacking method can be selected as needed during use, so it will not be described in detail in this application.

[0034] Compared with the prior art, each stator winding 2 of the present invention is composed of multiple layers of flat conductors 7, and each of the multiple layers of flat conductors 7 is separated and insulated by an interlayer insulation structure 6. At the same time, the multiple layers of flat conductors 7 are stacked into a whole and insulated by a main insulation structure 5 to form a whole stator winding 2 similar to an ordinary flat wire motor. This is a layer of stator winding 2, and multiple stator windings 2 form a stator winding assembly with low high-frequency AC loss, and finally installed in the stator slot 3. Each stator slot 3 is equipped with n layers of stator windings 2, where n is a positive integer. Therefore, the present invention can effectively reduce the skin effect and the proximity effect by adopting a structure of stacking multiple layers of flat conductors, thereby reducing AC losses and improving the efficiency of the motor. When the stator winding 2 of the flat wire motor of the prior art adopts the continuous wave winding technology, the end length of the stator winding 2 can be effectively shortened, thereby reducing the height of the stator winding end, reducing material usage, reducing DC resistance, reducing copper loss, and improving efficiency. However, the process is difficult to overcome due to problems such as winding formation and arrangement. The stator winding structure of the present invention can effectively reduce the hardness of the stator winding 2, simplify the difficulties of the continuous wave winding technology, and enable the technical solution of the present invention to be further applied to the drive motor industry. The multi-layer thin high-conductivity metal material structure of the present invention can be flexibly applied to stator slots 3 of different shapes and sizes, and even in asynchronous motor rotor slots, and has a wide range of adaptability.

[0035] Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of the present invention rather than to limit the technical solution. Those skilled in the art should understand that those modifications or equivalent substitutions of the technical solution of the present invention that do not depart from the purpose and scope of the technical solution should be included in the scope of the claims of the present invention.

Claims

1. A stator structure with a stator winding composed of multiple layers of flat conductors, comprising a stator core and a stator winding assembly, wherein the stator core is provided with a plurality of stator slots, and the stator winding assembly is arranged in the stator slots, characterized in that: A slot insulation structure is provided in the stator slot to insulate the stator winding assembly and the stator core. The stator winding assembly includes a plurality of stator windings, each of which is formed by stacking multiple layers of flat conductors. Multiple layers of stator windings are provided in each stator slot along the radial direction.

2. The stator structure with a stator winding composed of multiple layers of flat conductors according to claim 1, characterized in that: The multi-layer flat conductors of each stator winding are insulated by an interlayer insulation structure, and the multi-layer flat conductors constituting each stator winding are insulated as a whole by a main insulation structure.

3. The stator structure with a stator winding composed of multiple layers of flat conductors according to claim 1, characterized in that: The thickness of the flat conductor is 0.05 mm-2 mm.

4. The stator structure with a stator winding composed of multiple layers of flat conductors according to claim 2, characterized in that: The main insulation structure includes an insulation film wrapping structure, an injection molded part structure, and an overall coating structure.

5. The stator structure with a stator winding composed of multiple layers of flat conductors according to claim 4, characterized in that: The insulating film wrapping structure is formed by winding each stator winding as a whole with an insulating film, and the thickness of the insulating film is 0.01mm-0.2mm.

6. The stator structure with a stator winding composed of multiple layers of flat conductors according to claim 4, characterized in that: The injection molded part structure is formed by injection molding of insulating materials, and after the injection molded part structure is sleeved on the stator winding, it is spliced ​​by buckling and slotting, or the injection molded part structure is directly injection molded into a sleeve and sleeved on the stator winding.

7. The stator structure with a stator winding composed of multiple layers of flat conductors according to claim 4, characterized in that: The overall coating structure is formed by stacking multiple layers of flat conductors into a stator winding, and then coating or extruding the entire stator winding with an insulating layer, so that the insulating layer is directly fixed on the surface of the entire stator winding.

8. The stator structure with a stator winding composed of multiple layers of flat conductors according to claim 2, characterized in that: The interlayer insulation structure includes a nano-evaporation insulation layer structure, a paint film structure, and a brushing insulation glue layer structure.

9. The stator structure with a stator winding composed of multiple layers of flat conductors according to claim 2, characterized in that: The interlayer insulation structure includes a single-side insulation structure and a double-side insulation structure, and the double-side insulation structure includes a half-enclosed double-side insulation structure and a full-enclosed double-side insulation structure.

10. The stator structure with a stator winding composed of multiple layers of flat conductors according to claim 9, characterized in that: Methods for stacking multiple layers of flat conductors in stator windings include: Flat conductors with single-sided insulation structure are stacked continuously; Flat conductors with double-sided insulation structure are stacked continuously; Flat conductors with double-sided insulation structures and flat conductors without insulation structures are stacked at intervals.

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