Continuous wave winding motor stator structure and motor

Abstract

A continuous wave winding motor stator structure disclosed by the present invention comprises a stator iron core and a stator winding, the stator iron core is provided with a plurality of stator grooves arranged at intervals in the circumferential direction of the stator iron core, the stator winding is embedded in the stator grooves, and the stator winding located in the stator grooves is an in-groove winding section. The stator winding outside the stator slot is an end winding section; the in-slot winding section is coated with a first insulating layer, and the end winding section is coated with a second insulating layer; the first insulating layer is composed of two U-shaped insulating grooves, two convex ribs are arranged on the outer surface of one side wall of each U-shaped insulating groove in the length direction of the U-shaped insulating grooves, and the two convex ribs are arranged at a groove opening and the connecting position of the groove bottom and the groove side wall respectively; and the other side wall of the U-shaped insulating groove is inserted between the winding section in the groove and the side wall, provided with the convex rib, of the other U-shaped insulating groove, so that the interference fit between the first insulating layer and the stator groove is facilitated. According to the invention, the stator winding and the stator core can be effectively fixed into a whole, the operation is convenient, the energy consumption is low, and the production efficiency is high.

Description

Technical Field

[0001] The present invention belongs to the technical field of motors, and relates to a continuous wave winding motor, and in particular to a stator structure of a continuous wave winding motor and a motor. Background Art

[0002] With the continuous advancement of new energy vehicle technology, electric drive systems are striving for ever-higher power density, efficiency, and NVH performance. Therefore, reducing the size and mass of the motor itself and improving efficiency and NVH performance are crucial. Continuous-wave winding motor stators eliminate welding and offer advantages over mainstream winding methods like U-pin and I-pin in terms of end height and conductivity, leading to their widespread adoption.

[0003] Traditionally, lacquer coating is used to provide insulation for the stator windings of continuous-wave motors and secure them to the stator core. However, this coating process is associated with high tooling investment, high energy consumption, and low production efficiency. To improve production efficiency, reduce production line investment, and eliminate the lacquer coating process, a new insulation coating is emerging as a future development trend in motor stator winding structures.

[0004] However, there are currently two ways to use insulation coating. The first is to perform insulation coating before online bending and forming. The insulation layer will deform or even break during the subsequent bending process. The second is to perform insulation coating after online bending and forming. Conventional methods such as extrusion cannot be used for coating. Continuous integral wrapping is usually used for insulation coating, but there will be gaps between the copper wire and the wrapping layer at the bend, and the wrapping layer in the straight part cannot fix the stator winding and the stator core to form a whole. Summary of the Invention

[0005] In view of the above-mentioned deficiencies in the prior art, the purpose of the present invention is to provide a continuous wave winding motor stator structure and a motor. The present invention can effectively fix the stator winding and the stator core into a whole, and is easy to operate, has low energy consumption and high production efficiency.

[0006] The technical solution of the present invention is achieved as follows: A continuous wave winding motor stator structure includes a stator core and a stator winding. The stator core has a plurality of stator slots spaced circumferentially around the stator core. The stator winding is embedded in the stator slots. The stator winding located in the stator slots is an in-slot winding segment, and the stator winding located outside the stator slots is an end winding segment.

[0007] The winding section in the slot is covered with a first insulating layer, and the end winding section is covered with a second insulating layer; the first insulating layer is composed of two U-shaped insulating slots, and two ribs are provided on the outer surface of one side wall of the U-shaped insulating slot along the length direction of the U-shaped insulating slot. The two ribs are respectively provided at the slot opening and the connection between the slot bottom and the slot side wall; the other side wall of the U-shaped insulating slot is inserted between the winding section in the slot and the side wall of the other U-shaped insulating slot provided with the rib, so as to facilitate the interference fit between the first insulating layer and the stator slot, thereby fixing the stator winding in the stator slot and achieving the fixation of the stator winding and the stator core.

[0008] Furthermore, the overlapping parts of the two U-shaped insulation grooves are fixed by ultrasonic welding, laser welding and bonding.

[0009] Furthermore, the first insulating layer is formed by injection molding of one material selected from PEEK, TPI, PEI and PPS.

[0010] Furthermore, the second insulating layer is provided on the end winding segment in a wrapping manner.

[0011] Furthermore, the second insulating layer is made of one of PEEK, PI, PEI, a lay-flat tape and a mica tape.

[0012] Furthermore, the upper and lower ends of the first insulating layer respectively extend toward the end winding segment by a distance to form a contact segment, and the contact segment is located between the end winding segment and the corresponding second insulating layer.

[0013] Furthermore, both ends of the second insulating layer extend toward the corresponding in-slot winding section by one end to form a contact section, and the contact section is located between the in-slot winding section and the corresponding first insulating layer.

[0014] Furthermore, the first insulating layer and the second insulating layer corresponding to the contact section are fixed by pasting and sintering.

[0015] Compared with the prior art, the present invention has the following beneficial effects: The first insulating layer on the surface of the in-slot winding segment corresponding to the stator winding of the present invention is formed by two U-shaped insulating slots staggered and interlocked. The upper and lower side walls of the U-shaped insulating slot are respectively provided with ribs. After the in-slot winding segment is covered, two ribs are respectively provided on the two side walls of the first insulating layer of the in-slot winding segment. Then, when embedding the wire, the stator winding can be pushed from the outside of the stator slot to the inside of the stator slot. In this way, the ribs will be squeezed by the stator slot, so that the stator winding and the stator slot form an interference fit, while also preventing the stator core from scratching and damaging the first insulating layer during the embedding process. Due to limited space, the end winding segments will be tightly contacted together, and then the contact points are fixed by welding or other methods, so that the in-slot winding segment, the end winding segment and the stator core are fixed to form a whole, achieving an integrated technical effect, which is conducive to improving the NVH performance of the motor. The whole process is easy to operate, has low energy consumption, high production efficiency, and has wide promotion and application value. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 -Schematic diagram of the stator structure of the continuous wave winding motor according to the present invention.

[0017] Figure 2 -Schematic diagram of the structure of the stator winding segment in the slot.

[0018] Figure 3 -Schematic diagram of the structure of the connection area between the first insulating layer and the second insulating layer Figure 1 .

[0019] Figure 4 -Schematic diagram of the structure of the connection area between the first insulating layer and the second insulating layer Figure 1 .

[0020] Among them: 1-stator core; 2-stator winding; 3-first insulation layer; 301-convex rib; 302-U-shaped insulation slot; 4-second insulation layer; 5-stator slot. DETAILED DESCRIPTION

[0021] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0022] See also Figures 1 to 4 A continuous wave winding motor stator structure includes a stator core 1 and a stator winding 2. The stator core 2 has a plurality of stator slots 5 circumferentially spaced around the stator core 1. The stator winding 2 is embedded in the stator slots 5. The stator winding 2 located in the stator slots 5 is an in-slot winding segment, and the stator winding 2 located outside the stator slots 5 is an end winding segment (that is, the stator winding located at both ends of the stator core is an end winding segment).

[0023] The in-slot winding segment is covered with a first insulating layer 3, and the end winding segment is covered with a second insulating layer 4. The first insulating layer 3 is composed of two U-shaped insulating slots 302. Two ribs 301 are provided on the outer surface of one side wall of the U-shaped insulating slot 302 along its length. The two ribs 301 are provided at the slot opening and the connection between the slot bottom and the slot side wall, respectively (one rib is provided at the slot opening, and the other rib is provided at the connection between the slot bottom and the slot side wall of the U-shaped insulating slot, and the two ribs are provided in parallel and spaced apart). The other side wall of the U-shaped insulating slot 302 is inserted between the in-slot winding segment and the side wall of the other U-shaped insulating slot 302 provided with the rib 301, facilitating an interference fit between the first insulating layer 3 and the stator slot 5, thereby fixing the stator winding 2 in the stator slot 5 and achieving fixation of the stator winding 2 and the stator core 1.

[0024] Here, the U-shaped insulating slot that forms the first insulating layer has ribs on its upper and lower sides. After the winding segment in the slot is covered, two ribs are provided on each side wall of the first insulating layer of the winding segment in the slot. Then, when inserting the wire, the stator winding can be pushed from outside the stator slot into the stator slot. In this way, the ribs will be squeezed by the stator slot, so that the stator winding and the stator slot form an interference fit, achieving the effect of fixing the winding segment in the slot, so that the winding segment in the slot and the stator core are fixed to form a whole. At the same time, it also prevents the stator core from scratching and damaging the first insulating layer during the wire insertion process. The entire process is easy to operate, has low energy consumption, high production efficiency, and has the value of wide promotion and application.

[0025] The stator winding here is a continuous wave flat wire structure or round wire winding, etc.

[0026] In a specific implementation, the overlapping portions of the two U-shaped insulation slots are fixed by ultrasonic welding, laser welding, and gluing to form staggered interlocking. In a specific implementation, the first insulation layer 3 is formed by injection molding, and the materials used include but are not limited to thermoplastic materials such as PEEK, TPI, PEI, and PPS.

[0027] In a specific implementation, the second insulating layer 4 is provided on the end winding section in a wrapping manner. Meanwhile, the insulating material used in the second insulating layer 4 includes but is not limited to PEEK, PI, PEI, lath-free tape and mica tape.

[0028] For specific implementation, see Figure 4 The upper and lower ends of the first insulating layer 3 extend toward the end winding section to form a contact section, which is located between the end winding section and the corresponding second insulating layer 4. Alternatively, see Figure 3The two ends of the second insulating layer 4 extend one end distance toward the corresponding in-slot winding segment to form a contact segment, which is located between the in-slot winding segment and the corresponding first insulating layer 3. The first insulating layer and the second insulating layer corresponding to the contact segment are fixed by gluing or sintering. Due to the limited space between the end winding segments, they are tightly contacted together. The contact points can be fixed by welding, gluing or winding. In this way, the in-slot winding segment, the end winding segment and the stator core form a whole, achieving the technical effect of integration, thereby improving the NVH performance of the motor.

[0029] Finally, it should be noted that the above embodiments of the present invention are merely examples for illustrating the present invention and are not intended to limit the embodiments of the present invention. Those skilled in the art will appreciate that other variations and modifications can be made based on the above description. It is not possible to enumerate all embodiments here. Any obvious variations or modifications arising from the technical solution of the present invention remain within the scope of protection of the present invention.

Claims

1. A continuous wave winding motor stator structure, comprising a stator core and a stator winding, wherein the stator core has a plurality of stator slots spaced apart around the stator core in the circumferential direction, and the stator winding is embedded in the stator slots, wherein the stator winding located in the stator slots is an in-slot winding segment, and the stator winding located outside the stator slots is an end winding segment; characterized in that: The winding section in the slot is covered with a first insulating layer, and the end winding section is covered with a second insulating layer; the first insulating layer is composed of two U-shaped insulating slots, and two convex ribs are provided on the outer surface of one side wall of the U-shaped insulating slot along the length direction of the U-shaped insulating slot, and the two convex ribs are respectively provided at the slot opening and the connection between the slot bottom and the slot side wall; the other side wall of the U-shaped insulating slot is inserted between the winding section in the slot and the side wall of the other U-shaped insulating slot provided with the convex rib, so as to facilitate the interference fit of the first insulating layer and the stator slot, so that the stator winding is fixed in the stator slot, and the stator winding and the stator core are fixed.

2. A continuous wave winding motor stator structure according to claim 1, characterized in that: The overlapping parts of the two U-shaped insulation grooves are fixed by ultrasonic welding, laser welding and bonding.

3. A continuous wave winding motor stator structure according to claim 1 or 2, characterized in that: The first insulating layer is formed by injection molding using one of PEEK, TPI, PEI and PPS.

4. The continuous wave winding motor stator structure according to claim 1, characterized in that: The second insulating layer is arranged on the end winding segment in a wrapping manner.

5. A continuous wave winding motor stator structure according to claim 1 or 4, characterized in that: The second insulating layer is made of one of PEEK, PI, PEI, a latitude tape and a mica tape.

6. The continuous wave winding motor stator structure according to claim 1, characterized in that: The upper and lower ends of the first insulating layer respectively extend toward the end winding segment by a distance to form a contact segment, and the contact segment is located between the end winding segment and the corresponding second insulating layer.

7. The continuous wave winding motor stator structure according to claim 1, characterized in that: Both ends of the second insulating layer extend toward the corresponding winding section in the slot by one end to form a contact section, and the contact section is located between the winding section in the slot and the corresponding first insulating layer.

8. A continuous wave winding motor stator structure according to claim 6 or 7, characterized in that: The first insulating layer and the second insulating layer corresponding to the contact section are fixed by means of bonding and sintering.

9. A continuous wave winding motor, characterized in that: A continuous wave winding motor stator structure comprising any one of claims 1 to 8.

Images