Insulation end plate of flat wire motor stator and flat wire motor stator

Abstract

The present invention discloses an insulating end plate of a flat wire motor stator and a flat wire motor stator, comprising a first insulating end plate for cooperating with a first axial end face of a stator core and a second insulating end plate for cooperating with a second axial end face of the stator core, wherein the first insulating end plate comprises: a first outer ring frame; a first support bar for supporting a curved portion of an upper portion of a flat wire winding, one end of the first support bar being fixed to the first outer ring frame, the first support bar being a plurality and being arranged at intervals along the circumference of the first outer ring frame; a first inner ring frame, the first inner ring frame being located inside the first outer ring frame and being fixed to the other end of the first support bar, and a first insertion through hole being formed between any two adjacent first support bars and the first outer ring frame and the first inner ring frame. The present invention provides an insulating end plate of a flat wire motor stator and a flat wire motor stator, and the present invention can improve the production efficiency of the flat wire motor stator and the qualified rate of the flat wire motor stator.

Description

Technical Field

[0001] The invention relates to the technical field of motor stators, and in particular to an insulating end plate of a flat wire motor stator and a flat wire motor stator. Background Art

[0002] As the requirements for high power density, high reliability and high voltage of new energy vehicle motors continue to increase, flat copper wire motors have been widely used due to their higher slot fill rate, better heat dissipation and better NVH performance. At present, the most mainstream flat copper wire armature winding in the market adopts the Hairpin process. The characteristic of this process is that after the formed winding is inserted into the stator core, all the pin ends need to be twisted according to a certain rule, and then the corresponding coils are connected by welding to form a complete winding.

[0003] During the pin twisting process, the flat copper wires between all the slots on both ends of the core need to be tightened by inserting pins. The installation and removal of the pins are troublesome, which affects the production cycle, and the tightness of the pin installation affects the quality of the subsequent twisting winding. In addition, during the twisting process, the protruding part of the slot insulation paper is easily crushed or axially moved, affecting the safe creepage distance between the winding and the core. The above problems will lead to low armature production efficiency and low product qualification rate. Summary of the invention

[0004] In view of the problems existing in the prior art, the present invention provides an insulating end plate of a flat wire motor stator and a flat wire motor stator. The present invention can improve the production efficiency of the flat wire motor stator and increase the qualified rate of the flat wire motor stator.

[0005] The technical solutions to the above problems are as follows:

[0006] The insulating end plate of the flat wire motor stator comprises a first insulating end plate for cooperating with a first axial end face of the stator core and a second insulating end plate for cooperating with a second axial end face of the stator core, wherein the first insulating end plate comprises:

[0007] A first outer ring skeleton;

[0008] A first support bar for supporting the bent portion of the upper portion of the flat wire winding, one end of the first support bar being fixed to the first outer ring skeleton, and the first support bars being in plurality and arranged at intervals along the circumference of the first outer ring skeleton;

[0009] A first inner ring skeleton, the first inner ring skeleton is located inside the first outer ring skeleton and is fixed to the other end of the first support bar, and a first insertion hole is formed between any two adjacent first support bars and the first outer ring skeleton and the first inner ring skeleton;

[0010] The second insulating end plate comprises:

[0011] A second outer ring skeleton;

[0012] A second support bar for supporting the bent portion at the bottom of the flat wire winding, one end of the second support bar being fixed to the second outer ring frame, and the second support bars being in plurality and arranged at intervals along the circumference of the second outer ring frame;

[0013] The second inner ring skeleton is located inside the second outer ring skeleton and is fixed to the other end of the second support bar, and a second through hole is formed between any two adjacent second support bars and the second outer ring skeleton and the second inner ring skeleton.

[0014] The flat wire motor stator includes a stator core, a flat wire winding, slot insulating paper, and a first insulating end plate and a second insulating end plate. The first insulating end plate cooperates with the first axial end face of the stator core, and the second insulating end plate cooperates with the second axial end face of the stator core. The slot insulating paper passes through the first through hole and the wire embedding groove on the stator core in sequence and then cooperates with the second through hole. One end of the flat wire winding passes through the first through hole, the wire embedding groove on the stator core, and the second through hole in sequence. When one end of the flat wire winding is twisted, the first support bar supports the upper curved portion of the flat wire winding, and the second support bar supports the lower curved portion of the flat wire winding.

[0015] The present invention pre-installs a first insulating end plate on the first axial end face of the stator core, installs a second insulating end plate on the second axial end face, supports the upper curved portion of the flat wire winding through the first support bar, and supports the lower curved portion of the flat wire winding through the second support bar. On the one hand, the flat wire winding is prevented from axial movement of the curved portion during the twisting, which causes the curved portion to press too much on the slot insulation paper and cause the slot insulation paper to break. On the other hand, when twisting, there is no need to install and remove the complicated process of the twisting limit pin between the wire embedding slots of the stator core, thereby eliminating the need to add a telescopic device for the limit pin next to the twisting device, reducing the cost of the equipment, and saving time without installing and removing the twisting limit pin, thereby improving production efficiency. In addition, the bending curvature of the flat wire winding is controlled by the first insulating end plate and the second insulating end plate, so that the creepage distance between the flat wire winding and the stator core is controlled, thereby ensuring the insulation performance of the stator. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is a three-dimensional view of the first insulating end plate.

[0017] Figure 2 This is a front view of the first insulating end plate.

[0018] Figure 3 for Figure 2 Enlarged view of part P in .

[0019] Figure 4 is a cross-sectional view of the first insulating end plate.

[0020] Figure 5 It is a three-dimensional view of the second insulating end plate.

[0021] Figure 6 for Figure 5 Enlarged view of part N in .

[0022] Figure 7 It is a rear view of the second insulating end plate.

[0023] Figure 8 for Figure 7 Enlarged view of the Q section in .

[0024] Fig. 9 is a cross-sectional view of the second insulating end plate.

[0025] Fig.10 This is a cross-sectional view of the stator of a flat wire motor.

[0026] Fig.11 for Fig.10 Enlarged view of the M part in .

[0027] Fig.12 This is an exploded view of the flat wire motor stator.

[0028] Markings in the accompanying drawings:

[0029] A first insulating end plate A, a first outer ring skeleton 1, a first annular skeleton 1a, a first boss 1b, a first assembly groove 1c, a first support bar 2, a first inner ring skeleton 3, and a first through hole 4.

[0030] The second insulating end plate B, the second outer ring skeleton 5, the second annular skeleton 5a, the second boss 5b, the second assembly groove 5c, the second support bar 6, the second inner ring skeleton 7, the second through hole 8, and the step 8a.

[0031] Stator core 11, flat wire winding 12, slot insulation paper 13. DETAILED DESCRIPTION

[0032] like Figures 1 to 12 As shown, the insulating end plate of the flat wire motor stator of the present invention includes a first insulating end plate A for cooperating with the first axial end face of the stator core 11 and a second insulating end plate B for cooperating with the second axial end face of the stator core 11. The first insulating end plate A and the second insulating end plate B are preferably injection molded. The structures of the injection molded first insulating end plate A and the second insulating end plate B are as follows.

[0033] The first insulating end plate A comprises a first outer ring skeleton 1, a first support bar 2, and a first inner ring skeleton 3. The first outer ring skeleton 1 comprises a first annular skeleton 1a and a first boss 1b. The first annular skeleton 1a is fixed to the first boss 1b, and one end of the first support bar 2 is fixed to the inner circumference of the first annular skeleton 1a and the first boss 1b. A first assembly groove 1c is provided on the outer circumference of the first outer ring skeleton 1.

[0034] The first support bar 2 supports the upper curved portion of the flat wire winding 12, one end of the first support bar 2 is fixed to the first outer ring frame 1, and the first support bar 2 is multiple and arranged at intervals along the circumference of the first outer ring frame 1; the first inner ring frame 3 is located inside the first outer ring frame 1 and is fixed to the other end of the first support bar 2. The inner diameter of the first inner ring frame 3 is equal to the inner diameter of the stator core 11. The first inner ring frame 3 plays a role in increasing rigidity in the first insulating end plate A.

[0035] A first through hole 4 is formed between any two adjacent first support bars 2 and the first outer ring frame 1 and the first inner ring frame 3. The first through hole 4 is rectangular, the width W1 of the first through hole 4 = the width of the stator core wire slot + 0.3 mm, the height L1 of the first through hole 4 = the height of the stator core wire slot + 0.3 mm, and the depth H1 of the first through hole 4 = the designed creepage distance height.

[0036] The second insulating end plate B includes a second outer ring skeleton 5, a second support bar 6, and a second inner ring skeleton 7. The second outer ring skeleton 5 includes a second annular skeleton 5a and a second boss 5b. The second annular skeleton 5a is fixed to the second boss 5b. One end of the second support bar 6 is fixed to the inner circumference of the second annular skeleton 5a and the second boss 5b. A second assembly groove 5c is provided on the outer circumference of the second outer ring skeleton 5.

[0037] The second support bar 6 supports the bent portion at the bottom of the flat wire winding 12. One end of the second support bar 6 is fixed to the second outer ring skeleton 5. There are multiple second support bars 6 and they are arranged at intervals along the circumference of the second outer ring skeleton 5. The second inner ring skeleton 7 is located inside the second outer ring skeleton 5 and is fixed to the other end of the second support bar 6. The inner diameter of the second inner ring skeleton 7 is equal to the inner diameter of the stator core 11. The second inner ring skeleton 7 plays a role in increasing the rigidity in the second insulating end plate B.

[0038] A second through hole 8 is formed between any two adjacent second support bars 6, the second outer ring frame 5 and the second inner ring frame 7. A step 8a is provided in the second through hole 8 to limit the end of the slot insulation paper 12, that is, the second through hole 8 is a step hole, and the end of the slot insulation paper 12 abuts against the step 8a.

[0039] Since the second through hole 8 is a stepped hole, the width W2 of the small diameter hole of the second through hole 8 = the width of the stator core wire embedding slot - 2 times the slot insulation paper thickness; the height L2 of the small diameter hole of the second through hole 8 = the width and height of the stator core wire embedding slot - the slot insulation paper thickness, and the depth H2 of the small diameter hole of the second through hole 8 = the designed creepage distance height × 2 / 3. The width W3 of the large diameter hole of the second through hole 8 = W2 + 1mm; the height L3 of the large diameter hole of the second through hole 8 = L2 + 1mm, and the depth H3 of the large diameter hole of the second through hole 8 = the designed creepage distance height.

[0040] The flat wire motor stator comprises a stator core 11, a flat wire winding 12, and slot insulating paper 13, and also comprises the above-mentioned first insulating end plate A and second insulating end plate B, wherein the first insulating end plate A cooperates with the first axial end face of the stator core 11, and the second insulating end plate B cooperates with the second axial end face of the stator core 11, and the first insulating end plate A and the second insulating end plate B are respectively bonded to the axial end faces of the stator core 11 by glue, and the glue is preferably epoxy glue, and after the epoxy glue is cured, the stator core 11 is respectively fixed to the first insulating end plate A and the second insulating end plate B and then integrated, and then the slot insulating paper 13 is sequentially passed through the first through hole 4 and the wire embedding groove on the stator core 11 and then matched with the second through hole 8, and one end of the flat wire winding 12 is sequentially passed through the first through hole 4, the wire embedding groove on the stator core 11, and the second through hole 8.

[0041] Before the flat wire winding 12 passes through the first through hole 4, the embedded wire on the fixed core 11, and the second through hole 8 in sequence, its upper part has been twisted accordingly to deform it. When one end of the flat wire winding 12 is subsequently twisted, the flat wire winding 12 will move axially after being subjected to the twisting force. Therefore, the first support bar 2 supports the curved portion of the upper part of the flat wire winding 12, which can prevent the curved portion of the upper part of the flat wire winding 12 from damaging the upper end of the slot insulation paper 13. During the twisting process of one end of the flat wire winding 12, the lower part of the flat wire winding 12 gradually bends to form a curved portion. The curved portion of the lower part of the flat wire winding 12 is supported by the second support bar 6, which can prevent the curved portion of the lower part of the flat wire winding 12 from damaging the lower end of the slot insulation paper 13.

[0042] The present invention has the following beneficial effects:

[0043] 1. By eliminating the installation of the limit pins before the winding twisting process, the production efficiency of the product is improved.

[0044] 2. By adding the limiting feature of slot insulation paper on the insulating end plate, the safe creepage distance between the winding and the core is guaranteed, and the product qualification rate and reliability are improved.

[0045] The examples described above are only some embodiments of the present invention, rather than all of them. Based on the examples in the present invention, all other embodiments obtained by ordinary technicians in this field without making any creative work are within the scope of protection of the present invention.

Claims

1. The insulating end plate of the flat wire motor stator is characterized by: It comprises a first insulating end plate (A) for cooperating with a first axial end surface of a stator core (11) and a second insulating end plate (B) for cooperating with a second axial end surface of the stator core (11), wherein the first insulating end plate (A) comprises: A first outer ring skeleton (1); A first support bar (2) for supporting the upper curved portion of the flat wire winding (12), one end of the first support bar (2) being fixed to the first outer ring skeleton (1), and the first support bars (2) being multiple and arranged at intervals along the circumference of the first outer ring skeleton (1); A first inner ring skeleton (3), the first inner ring skeleton (3) is located inside the first outer ring skeleton (1) and is fixed to the other end of the first support bar (2), and a first insertion hole (4) is formed between any two adjacent first support bars (2) and the first outer ring skeleton (1) and the first inner ring skeleton (3); The second insulating end plate (B) comprises: A second outer ring skeleton (5); A second support bar (6) for supporting the bent portion at the bottom of the flat wire winding (12), one end of the second support bar (6) being fixed to the second outer ring skeleton (5), and the second support bars (6) being multiple and arranged at intervals along the circumference of the second outer ring skeleton (5); The second inner ring skeleton (7) is located inside the second outer ring skeleton (5) and is fixed to the other end of the second support bar (6), and a second through hole (8) is formed between any two adjacent second support bars (6) and the second outer ring skeleton (5) and the second inner ring skeleton (7).

2. The insulating end plate of the flat wire motor stator according to claim 1, characterized in that: The first outer ring skeleton (1) comprises a first annular skeleton (1a) and a first boss (1b); the first annular skeleton (1a) is fixed to the first boss (1b); one end of the first support bar (2) is fixed to the inner circumference of the first annular skeleton (1a) and the first boss (1b).

3. The flat wire motor stator insulating end plate according to claim 1 or 2, characterized in that: A first assembly groove (1c) is provided on the outer peripheral surface of the first outer ring skeleton (1).

4. The insulating end plate of the flat wire motor stator according to claim 1, characterized in that: The second outer ring skeleton (5) comprises a second annular skeleton (5a) and a second boss (5b), the second annular skeleton (5a) is fixed to the second boss (5b), and one end of the second support bar (6) is fixed to the inner circumference of the second annular skeleton (5a) and the second boss (5b).

5. The insulating end plate of the flat wire motor stator according to claim 4 or 5, characterized in that: A second assembly groove (5c) is provided on the outer peripheral surface of the second outer ring skeleton (5).

6. The insulating end plate of the flat wire motor stator according to claim 1, characterized in that: A step (8a) for limiting the end of the slot insulation paper (12) is provided in the second through hole (8).

7. A flat wire motor stator, comprising a stator core (11), a flat wire winding (12), and slot insulation paper (13), characterized in that: It also includes the first insulating end plate (A) and the second insulating end plate (B) as described in any one of claims 1 to 6, the first insulating end plate (A) cooperates with the first axial end face of the stator core (11), the second insulating end plate (B) cooperates with the second axial end face of the stator core (11), the slot insulating paper (13) passes through the first through hole (4) and the wire embedding groove on the stator core (11) in sequence and then cooperates with the second through hole (8), one end of the flat wire winding (12) passes through the first through hole (4), the embedded wire on the stator core (11), and the second through hole (8) in sequence, when one end of the flat wire winding (12) is twisted, the first support bar (2) forms support for the upper curved portion of the flat wire winding (12), and the second support bar (6) forms support for the lower curved portion of the flat wire winding (12).

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