Flat wire for motor, stator, motor and vehicle

Abstract

The invention discloses a flat wire for a motor, a stator, a motor and a vehicle, the flat wire has a width direction and a thickness direction in an extension direction perpendicular to the flat wire, the flat wire comprises a flat wire body, the size of the flat wire body in the thickness direction is delta, the size of the flat wire body in the width direction is omega, and the width of the flat wire body in the width direction is omega. The elastic modulus E of the flat wire body meets the formula # imgabs0 #, mu is 0.5, and the unit is Gpa / mm; eta is 0.1 and is a dimensionless quantity. According to the embodiment of the invention, through the design of the flat wire body and the determination of the optimal relation among the width omega, the thickness delta and the elastic modulus E, the flat wire is enabled to be smaller in stress under a vibration working condition, the mechanical property and the key technology of lightweight design are balanced, meanwhile, the space utilization rate is improved, and the system is more miniaturized.

Description

Technical Field

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

[0002] With the rapid development of new energy vehicle technology, the performance requirements for automotive motors are getting higher and higher. While constantly pursuing high slot fill rate, high power density and high torque density of motors, it is difficult for round wire motors to break through the bottleneck of the new performance requirements of current drive motors. Flat wire motors can achieve performance requirements that round wire motors cannot meet. They have high slot fill rate, high power density, good heat dissipation and NVH performance, can greatly reduce the height of the motor winding end, reduce the amount of copper used and reduce the winding copper loss, thereby improving the efficiency of automotive drive motors.

[0003] However, the motor has a certain vibration, and the vehicle will pass through different vibration road conditions during driving, and the corresponding flat wire body will also vibrate. The vibrating flat wire body will have greater stress and become loose, deformed or even damaged. Summary of the invention

[0004] The present application aims to solve at least one of the technical problems existing in the prior art. To this end, one object of the present application is to provide a flat wire for a motor, wherein the flat wire has high strength and can reduce the problem of stress concentration.

[0005] The flat wire for a motor in the first aspect of the present application embodiment has a width direction and a thickness direction perpendicular to the extension direction of the flat wire, and comprises a flat wire body, the size of the flat wire body in the thickness direction is δ, the size of the flat wire body in the width direction is ω, and the elastic modulus of the flat wire body is E, satisfying:

[0006] Among them, μ is 0.5 and the unit is GPa / mm; η is 0.1 and is a dimensionless quantity; ω is in mm; δ is in mm; and E is in GPa.

[0007] According to the embodiments of the present application, by designing the flat wire body and determining the optimal relationship between the width ω, thickness δ, and elastic modulus E, the stress of the flat wire is smaller under vibration conditions, and the key technology of balancing mechanical properties and lightweight design is achieved. At the same time, the space utilization is improved, and the system is more miniaturized.

[0008] According to an embodiment of the present application, along the length direction of the flat wire, the flat wire includes a first connecting section, a first extension section, a transition section, a second extension section, and a second connecting section connected in sequence, the first extension section and the transition section are connected by radial bending in the width direction of the flat wire, the second extension section and the transition section are connected by radial bending in the thickness direction of the flat wire, and an angle is formed between the extension lines of the first extension section and the second extension section.

[0009] According to an embodiment of the present application, the angle between the first connecting section and the first extension section is an obtuse angle; and / or, the angle between the extension line of the first extension section and the extension line of the second extension section is an obtuse angle; and / or, the angle between the second connecting section and the second extension section is an obtuse angle.

[0010] According to an embodiment of the present application, the first connecting segment and the second connecting segment define a plane, and an angle θ between an extension line of the first extension segment and an extension line of the second extension segment in their orthographic projections on the plane satisfies: 90°≤θ≤150°.

[0011] According to an embodiment of the present application, the radius of the bending arc of the first extension section and the transition section is R1, satisfying: R1≥ω.

[0012] According to an embodiment of the present application, the bending radius of the second extension section and the transition section is R2, satisfying: R1≥δ.

[0013] According to an embodiment of the present application, it also includes a first pin and a second pin, the first pin is arranged at an end of the first connecting section away from the first extension section, and the second pin is arranged at an end of the second connecting section away from the second extension section, the first pin and the second pin are bent in a direction away from each other, or the first pin and the second pin are bent to the same side.

[0014] According to an embodiment of the present application, the wrapping layer includes a base layer, the base layer is wrapped around the outside of the flat wire body, and a coating is provided on the base layer.

[0015] According to an embodiment of the present application, the thickness of the coating is between 0.006 mm and 0.012 mm.

[0016] According to an embodiment of the present application, the wrapping layer further includes an insulating layer, and the insulating layer is wrapped around the outer side of the base layer.

[0017] According to an embodiment of the present application, the elastic modulus E of the flat wire body is 55 Gpa-125 Gpa.

[0018] According to an embodiment of the present application, the material of the flat wire body includes aluminum and at least one of the following: silicon, iron, magnesium, boron, copper, manganese, zinc and titanium.

[0019] According to an embodiment of the present application, the yield strength of the flat wire body is ≥65 MPa; and / or the tensile strength of the flat wire body is ≥110 MPa.

[0020] A second aspect of the present application provides a stator, which includes a stator core and a flat wire winding. The flat wire winding is formed by winding the flat wire for the motor described in the first aspect of the present application.

[0021] A third aspect of the present application provides a motor, comprising the stator described in the second aspect of the present application.

[0022] A fourth aspect of the present application provides a vehicle, comprising the motor described in the second aspect of the present application.

[0023] Additional aspects and advantages of the present application will be given in part in the description below, and in part will become apparent from the description below, or will be learned through the practice of the present application. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The above and / or additional aspects and advantages of the present application will become apparent and easily understood from the description of the embodiments in conjunction with the following drawings, in which:

[0025] Figure 1 is a schematic diagram of a flat wire before installation according to an embodiment of the present application;

[0026] Figure 2 is a schematic diagram of a flat wire after installation according to an embodiment of the present application;

[0027] Figure 3 is a schematic diagram of a partial structure of a flat wire according to an embodiment of the present application;

[0028] Figure 4 is a cross-sectional view of a flat wire according to an embodiment of the present application;

[0029] Figure 5 is a schematic diagram of a flat wire winding according to an embodiment of the present application;

[0030] Figure 6 is a schematic diagram of a stator according to an embodiment of the present application;

[0031] Figure 7 is a schematic diagram of a vehicle according to an embodiment of the present application.

[0032] Reference numerals:

[0033] Flat wire 100, flat wire winding 200, stator 300, stator core 310, motor 400, vehicle 500,

[0034] Flat wire body 10, wrapping layer 20, base layer 21, coating layer 211, insulating layer 22,

[0035] First connecting section 1 , first extending section 2 , transition section 3 , second extending section 4 , second connecting section 5 , first stitch 6 , second stitch 7 . DETAILED DESCRIPTION

[0036] The embodiments of the present application are described in detail below. The embodiments described below are exemplary and are only used to explain the present application, and cannot be understood as limiting the present application.

[0037] It should be noted that the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include one or more of the features. Further, in the description of this application, unless otherwise specified, the meaning of "plurality" is two or more.

[0038] The endpoints and any values ​​of the ranges disclosed in this application are not limited to the precise ranges or values, and these ranges or values ​​should be understood to include values ​​close to these ranges or values. For numerical ranges, the endpoint values ​​of each range, the endpoint values ​​of each range and the individual point values, and the individual point values ​​can be combined with each other to obtain one or more new numerical ranges, which should be regarded as specifically disclosed in this application.

[0039] In the present application, the terms "comprise" or "include" are open expressions, that is, including the contents specified in the present application but not excluding other contents.

[0040] For the flat wire of the motor, there are many factors that affect its stress performance. The applicant optimized it based on DOE (Design of Experiments) to screen the factors and key factors of stress response. Figure 1The flat wire body with a three-dimensional structure shown in the figure is used as the experimental object for simulation testing to obtain the stress cloud map of the flat wire body. At the same time, after a large number of test experiments, the relationship between the influencing factors such as expansion coefficient, aging temperature, aging time and elastic modulus E and the maximum stress of the flat wire body is specifically studied. Some experimental results are shown in Tables 1 to 4. Among them, the material of the flat wire body is aluminum alloy, and the motor alloy is prepared in the following way: take the raw material components of the aluminum alloy, perform solid solution treatment and aging treatment to obtain the aluminum alloy. The specific test method of the simulation test is: import the parameters of the flat wire body and the parameters of the vibration experiment into the finite element analysis element to simulate the flat wire body; among them, the parameters of the vibration experiment include: vibration time 22h, broadband frequency 10HZ~1000HZ, vibration condition RMS (Root Mean Square, effective value of vibration velocity): 27.8m / s 2 working conditions; there should be no mechanical damage or looseness after the test.

[0041] Table 1

[0042]

[0043] Table 2

[0044]

[0045] Table 3

[0046]

[0047] Table 4

[0048]

[0049]

[0050] It can be seen from Tables 1 to 4 that the factors and key factors of stress response are elastic modulus, which has a significant effect, while the expansion coefficient factor, aging temperature factor, and aging time factor have no significant effect on stress.

[0051] Among them, the elastic modulus is a measure of the size of an object's ability to resist elastic deformation. From a microscopic perspective, it is a reaction to the bond strength between atoms, ions or molecules, represented by E. E is expressed as the force per unit area, and the unit is N / m 2 (Mpa or Gpa).

[0052] Furthermore, when the length of the flat wire body is determined, when materials with different elastic modulus E are used as the flat wire body, the optional range of the thickness δ of the flat wire body is different. The applicant designs a reasonable relationship between the width ω of the flat wire body and the thickness δ of the flat wire body to improve the strength of the flat wire and reduce stress, thereby making the motor system more compact and lighter.

[0053] Therefore, the flat wire body with a three-dimensional structure was used as the experimental object, and optimization was carried out on the basis of DOE (Design of Experiments), and the factors and key factors of stress response were screened. At the same time, a large number of test experiments were carried out and verified in detail, such as Figure 1-Figure 4 As shown, the present application proposes a flat wire 100 for a motor 400 according to an embodiment. In the extending direction perpendicular to the flat wire 100, the flat wire 100 has a width direction F1 and a thickness direction F2. The flat wire 100 includes a flat wire body 10 and a wrapping layer 20. The size of the flat wire body 10 in the thickness direction F2 is δ, the size of the flat wire body 10 in the width direction F1 is ω, and the elastic modulus of the flat wire body 10 is E, which satisfies:

[0054]

[0055] Here, η is 0.1, which is a dimensionless quantity.

[0056] Here, δ is in mm; ω is in mm; and E is in GPa.

[0057] It should be noted that the flat wire body 10 here is perpendicular to the extension direction of the flat wire 100 in the thickness direction F2 and the width direction F3. For example, the flat wire 100 extends along the X direction, and the thickness direction F2 and the width direction F3 are perpendicular to the X direction. The size relationship between the dimension δ of the flat wire body 10 in the thickness direction F2 and the dimension ω of the flat wire body 10 in the width direction F1 is not limited, and δ can be greater than ω, less than ω, or equal to ω.

[0058] By designing the width, thickness and elastic modulus of the flat wire body 10 through the above formula, when the width ω of the flat wire body 10 is determined, when materials with different elastic moduli E are used as the flat wire body 10, the thickness δ of the flat wire body 10 is adjusted accordingly, thereby improving the strength of the flat wire body 10 and reducing stress, and the structure can meet the requirements of miniaturization, and the quality can also meet the requirements of lightweight, thereby increasing the power density.

[0059] According to the flat wire 100 for the motor 400 of the embodiment of the present application, by designing the flat wire body 10, the optimal relationship between the width ω, the thickness δ, and the elastic modulus E is determined, so that the stress of the flat wire 100 is small under vibration conditions, and the key technology of balancing mechanical properties and lightweight design is achieved. At the same time, a flat design is adopted, which can fill the stator slots more compactly and improve the slot fill rate, thereby improving space utilization, increasing the power density and efficiency of the motor 400, and facilitating the miniaturization design of the motor 400.

[0060] like Figure 1-Figure 4 As shown, according to an embodiment of the present application, along the length direction of the flat wire 100, the flat wire 100 includes a first connecting segment 1, a first extension segment 2, a transition segment 3, a second extension segment 4, and a second connecting segment 5 which are connected in sequence. The first extension segment 2 and the transition segment 3 are connected by radial bending with the width direction F1 of the flat wire 100 as a radial bending, and the second extension segment 4 and the transition segment 3 are connected by radial bending with the thickness direction F2 of the flat wire 100 as a radial bending, that is, the bending direction of the first extension segment 2 relative to the transition segment 3 is along the width direction of the flat wire 100, and the bending direction of the second extension segment 4 relative to the transition segment 3 is along the thickness direction of the flat wire 100, and the bending directions of the two extension segments relative to the transition segment 3 are different, thereby forming a three-dimensional structure in space, and an angle is formed between the extension lines of the first extension segment 2 and the second extension segment 4, thereby forming a model of the flat wire 100, the first connecting segment 1 and the second connecting segment 5 can be embedded in the stator slot, and the extension direction is changed by the first extension segment 2 and the second extension segment 4, and multiple flat wires 100 can be distributed and extended in a variety of combinations.

[0061] The first connecting section 1 , the first extending section 2 , the transition section 3 , the second extending section 4 , and the second connecting section 5 are integrally formed, thereby increasing the strength of the flat wire 100 and improving the installation accuracy of the flat wire 100 .

[0062] According to the embodiment of the present application, the angle between the first connecting section 1 and the first extending section 2 is an obtuse angle, thereby reducing the problem of stress concentration and the probability of fatigue cracking of the flat wire 100 .

[0063] According to the embodiment of the present application, the angle between the extension line of the first extension section 2 and the extension line of the second extension section 4 is an obtuse angle, thereby reducing the problem of stress concentration and the probability of fatigue cracking of the flat wire 100.

[0064] According to the embodiment of the present application, the angle between the second extension section 4 and the second connection section 5 is an obtuse angle, thereby reducing the problem of stress concentration and the probability of fatigue cracking of the flat wire 100 .

[0065] like Figure 3As shown, according to the embodiment of the present application, the first connecting section 1 and the second connecting section 5 determine a plane, and the angle between the extension line of the first extension section 2 and the extension line of the second extension section 4 on the plane is θ, which satisfies: 90°≤θ≤150°. When θ is too small, the angle formed between the first extension section 2 and the second extension section 4 is too small. When working under variable stress conditions, stress concentration will occur at the place where the cross-sectional size suddenly changes, and fatigue strength failure is prone to occur. In order to improve fatigue strength, the stress concentration sources and the degree of stress concentration should be reduced as much as possible.

[0066] Due to the flat design, θ is too large, resulting in a radial distance along the stator assembly being too large after welding the first leg and the second leg of the adjacent flat wire according to different winding methods, and cannot be filled more compactly, thereby reducing space utilization, which is not conducive to the power density and efficiency of the motor, and is not conducive to the miniaturization design of the motor.

[0067] By limiting θ to between 90°-150°, θ can be any value among 90°, 100°, 110°, 120°, 130°, 140°, 150° or a range between any two of them, thereby reducing the problem of stress concentration, reducing the probability of fatigue cracking of the flat wire 100, and improving space utilization.

[0068] like Figure 4 As shown, according to the embodiment of the present application, since the first extension section 2 and the transition section 3 are connected by radial bending in the width direction F1 of the flat wire 100, the bending radius of the first extension section 2 and the transition section 3 is R1, satisfying: R1≥ω, thereby reducing the curvature of the connection between the first extension section 2 and the transition section 3 and reducing the degree of stress concentration.

[0069] like Figure 4 As shown, according to an embodiment of the present application, since the second extension section 4 and the transition section 3 are connected by radial bending in the thickness direction F2 of the flat wire 100, the bending radius of the second extension section 4 and the transition section 3 is R2, satisfying: R1≥δ, thereby reducing the curvature of the connection between the second extension section 4 and the transition section 3 and reducing the degree of stress concentration.

[0070] like Figure 2 As shown, according to an embodiment of the present application, the flat wire 100 further includes a first pin 6 and a second pin 7, the first pin 6 is arranged at an end of the first connecting section 1 away from the first extension section 2, and the second pin 7 is arranged at an end of the second connecting section 5 away from the second extension section 4, the first pin 6 and the second pin 7 are bent in a direction away from each other, or the first pin 6 and the second pin 7 are bent to the same side, thereby facilitating the connection of adjacent flat wires 100, wherein the ends of the first pin 6 and the second pin 7 are provided with chamfers, and providing chamfers at the pin ends can also reduce stress concentration.

[0071] Specifically, the forming of the flat wire 100 includes: punching a straight flat wire 100 with a high aspect ratio into a new type of flat wire 100 having a first connecting section 1, a first extension section 2, a transition section 3, a second extension section 4, and a second connecting section 5 through a stamping forming device; then twisting the tail ends of the first connecting section 1 and the second connecting section 5 of the flat wire 100 along the radial direction of the stator 300 component according to different winding methods to form a first stitch 6 and a second stitch 7, and welding the first leg and the second leg of adjacent flat wires 100.

[0072] In the related technology, the influence on the surface performance of materials mainly includes the following three aspects: optimization of the surface structure of the material, introduction of residual compressive stress field, and increase of surface roughness. Due to the large number of high-speed and continuous projectiles of surface strengthening spraying hitting the surface of the material, it is like countless small hammers hammering the surface of the material. Part of the kinetic energy is absorbed by the surface of the material, forming a pressure pit on the surface of the material that is impacted. Strong plastic deformation occurs within a certain depth around the pressure pit, forming a plastic deformation layer of a certain thickness. In the plastic deformation layer, the organizational structure of the material changes, and the crystal block is refined, and the dislocation density and micro-distortion increase. The occurrence of this phenomenon causes the appearance of sub-grains and other structures in the deformation layer. In some cases, the phase structure in the material changes. This kind of strengthening is called organizational strengthening. Organizational strengthening makes it difficult for the crystals in the deformation layer to slip. At the same time, the slip organization of the material is prevented at the interface between the deformation strengthening layer and the interior. Normally, fatigue cracks of materials initiate on the surface of parts, and organizational strengthening will hinder the initiation of fatigue cracks on the surface of materials, thereby extending the nucleation life of fatigue cracks and improving the service life of materials.

[0073] In the process of strengthening the material surface, not only the surface structure of the material is optimized, but also a residual compressive stress layer of a certain thickness is introduced into the deformation layer under the action of cyclic plastic deformation. The introduction of the residual compressive stress layer can drive the cracks at the surface position from the surface layer to the sub-surface layer, effectively reducing the tensile stress generated by the external force or external torque in the surface layer. When the depth of the residual stress exceeds the depth of the microcracks, the propagation speed of the fatigue crack can be effectively prevented and reduced. Therefore, for parts with microcracks or notches, the strengthening effect of the residual stress is better than the organizational strengthening effect. As a result, pre-compressive stress can be generated on the surface of the flat wire body 10, thereby improving the fatigue resistance of the flat wire 100. Since the lower the surface roughness, the lower the fatigue strength, at the same time, through the surface strengthening treatment, compressive stress is generated on the surface to improve the fatigue resistance. After the improvement of the flat wire body 10, the surface roughness Ra = 1.6, and the HV> 38 after the surface strengthening treatment, it can resist the influence of fatigue.

[0074] like Figure 4As shown, according to an embodiment of the present application, the wrapping layer 20 includes a base layer 21, which is wrapped around the outside of the flat wire body 10, and a coating 211 is provided on the base layer 21. The base layer 21 can play a protective function, and the base layer 21 can facilitate the effective combination of the coating 211 and the flat wire body 10. The base layer 21 provided with the coating 211 is used to strengthen the strength of the flat wire body 10. By spraying the coating 211 on the base layer 21, excellent conductivity can be obtained, while improving the strength of the flat wire 100 and reducing stress concentration.

[0075] According to the embodiment of the present application, if the thickness of the coating 211 is too large, it will affect the conductive effect and reduce the adhesion strength; if the thickness of the coating 211 is too small, the resistance to salt spray, humidity and low temperature impact is reduced, which is not conducive to improving the strength of the flat wire. Therefore, the thickness of the coating 211 can be between 0.006mm-0.012mm, and the thickness of the coating 211 can be any point value among 0.006mm, 0.007mm, 0.008mm, 0.009mm, 0.01mm, 0.011mm, 0.012mm or any range value between the two. The main feature of the coating 211 is that it is adsorbed on the surface of the base layer 21; and migrates on the surface of the substrate until it is incorporated into the lattice to form the coating 211. The coating 211 is dense and flat, has good bonding with the substrate, and forms resistance to salt spray and 85℃, 85% humidity and -40℃ low temperature impact. Ensure adhesion and avoid falling off. The material of the coating 211 can be nickel, silver, etc.

[0076] According to an embodiment of the present application, the wrapping layer 20 further includes an insulating layer 22 , and the insulating layer 22 is wrapped around the outer side of the base layer 21 , thereby playing an insulating role and facilitating installation into the stator slot.

[0077] According to an embodiment of the present application, the insulating layer 22 is a high thermal conductivity layer.

[0078] The flat wire 100 is formed by an aluminum alloy molded part at any angle in a plane space, and is formed by a mold to form an arbitrary spatial structure. A single flat wire body 10 can be installed horizontally, vertically, or at any angle, and multiple flat wire bodies 10 can also be installed horizontally, vertically, or at any angle. Each flat wire body 10 is distributed according to a number of stator slots arranged at intervals along the circumference of the stator core 310, and is connected and extended outward.

[0079] According to the embodiment of the present application, the elastic modulus E of the flat wire body 10 is 55Gpa-125Gpa, and the optimal relationship between the width ω, thickness δ and elastic modulus E is determined, so that the flat wire 100 has less stress under vibration conditions, which is a key technology for balancing mechanical properties and lightweight design. At the same time, a flat design is adopted to fill the stator slots more compactly and improve the slot fill rate, thereby improving space utilization, increasing the power density and efficiency of the motor 400, and facilitating the miniaturization design of the motor 400.

[0080] According to an embodiment of the present application, the material of the flat wire body 10 includes aluminum, and at least one of silicon, iron, magnesium, boron, copper, manganese, zinc and titanium may be added to form an aluminum alloy to meet the requirements of lightweight and high-strength design.

[0081] According to an embodiment of the present application, the yield strength of the flat wire body 10 is ≥65 MPa, so the flat wire body has a relatively high yield strength.

[0082] According to the embodiment of the present application, the tensile strength of the flat wire body 10 is ≥110 MPa, so the flat wire body has a relatively high tensile strength.

[0083] According to the stator 300 of the embodiment of the present application, the stator 300 includes a stator core 310 and a flat wire winding 200 . The flat wire winding 200 is formed by winding the flat wire 100 mentioned above.

[0084] Among them, the flat wire winding 200 is composed of flat wires 100 arranged in a certain pattern. In the flat wire winding 200, the flat wires 100 can be distributed in parallel at the same interval. The flat wires 100 can be extended outward and distributed in a variety of combinations. The flat wires 100 form a multi-layer spatial three-dimensional layout in space. The distribution state and distribution size can be adjusted according to the use conditions. The connection and transition, forming angle, connection, plating and coating, insulation layer 22, and shielding layer of the flat wire 100 can adjust the parameters according to the use conditions, thereby forming a flat wire winding 200 with a compact structure, high space utilization, and more convenient production, use, installation and disassembly.

[0085] The flat wire winding 100 can be a flat wire assembled in series or in parallel, and the flat wire 100 can be single-layer or multi-layer, suitable for different numbers of connection structures, and can also achieve smaller volume and lighter weight while meeting the requirements of strength and reducing stress.

[0086] The flat wire winding 200 may include a plurality of winding layers, such as Figure 5As shown, the flat wire 100 in each winding layer is composed of a plurality of flat wires 100 connected end to end in the layer, and the same layer includes a first connecting portion and a second connecting portion arranged in parallel, and one end of the first flat wire 100 is connected to the end of the second flat wire 100 on the same side; in the same winding layer, the plug-in parts of the first flat wire 100 are respectively arranged in each slot group of the same conductor layer, and the plug-in parts of the second flat wire 100 are respectively arranged in each slot group of another conductor layer; each winding layer is provided with an intra-layer flat wire 100; the flat wire 100 is connected to the external system through a connection, and the extension section is in various angles and shapes, and various directions so that the flat wire 100 can be distributed and extended in various combinations.

[0087] The plurality of flat wires 100 form various types of flat wire groups. Each flat wire group includes a plurality of flat wires 100. The flat wires 100 in different flat wire groups are connected to achieve connection between different flat wire groups, thereby achieving a three-dimensional layout in space.

[0088] The flat wire winding 200 includes a multi-phase winding. For a branch of any phase winding in the flat wire winding 200, the flat wire 100 can be an integral conductor or a conductor welded from multiple flat wires 100. The flat wire 100 includes but is not limited to a U-shaped conductor segment.

[0089] like Figure 6 As shown, the flat wire winding 200 is formed by winding the flat wire 100 in the stator slot. By using the above-mentioned flat wire 100, the slot fill rate of the flat wire winding 200 can reach more than 70%, which is beneficial to improving the efficiency of the motor 400. The cross-section of the flat wire 100 can be a rectangular, trapezoidal or other flat cross-section, but is not limited to this.

[0090] In addition, if Figure 6 As shown, each parallel branch of the flat wire winding 200 can be composed of a group of continuous and complete vertically wound coils. Only the lead wires or neutral points of the overall motor 400 are brought together for welding. The winding has no redundant welding points, which reduces the complexity of the connection and realizes automated production. The use of vertical winding also greatly reduces thermal resistance, improves heat dissipation capacity, and increases the torque density of the motor 400.

[0091] According to the stator 300 of the embodiment of the present application, by adopting the above-mentioned flat wire 100, the vibration strength of the flat wire 100 is improved, the stress concentration is reduced, the flat wire 100 fills the stator slot more compactly, the slot fill rate is improved, and thus the space utilization rate is improved. The stator 300 has a compact overall structure, is easy to install, has a high connection efficiency, has a high space utilization rate, and is more convenient to produce and use.

[0092] The motor 400 according to the embodiment of the present application includes the stator 300 according to the embodiment of the present application.

[0093] Specifically, the motor 400 includes a casing and a stator 300 and a rotor housed in the casing. The rotor is coaxially arranged with the stator 300. The flat wire winding 200 can perform electromagnetic energy conversion and transmission. The rotor includes a rotor core and a rotating shaft. The permanent magnet is arranged on the rotor core. An air gap is left between the stator 300 and the rotor. The motor 400 here can be used as an induction motor 400. The application does not specifically limit the application scenario of the motor 400.

[0094] The position and direction of the flat wire 100 in the motor 400 can be adjusted along with other components. By adjusting the width, thickness and elastic modulus of the flat wire 100, the best is determined after simulation analysis, so that the strength is improved and the stress is reduced, and the system of the motor 400 is more integrated and the weight is lighter.

[0095] According to the motor 400 of the embodiment of the present application, by adopting the above-mentioned stator 300, the vibration strength of the flat wire 100 can be improved, thereby reducing stress concentration. The flat wire 100 fills the stator slot more compactly, improving the slot fill rate, thereby improving space utilization, increasing the power density and efficiency of the motor 400, and facilitating the miniaturization design of the motor 400.

[0096] According to the vehicle 500 of the embodiment of the present application, the vehicle 500 includes a body and a motor 400 according to the embodiment of the present application, and the motor 400 is located inside the body. By adopting the above-mentioned motor 400, the stress requirements of vibration conditions can be met, and a good strength effect can be achieved.

[0097] The flat wire design model is adopted to greatly improve the width and quality of the flat wire products. The invention improves the uniformity of flow by designing the shape, thickness and width of the flat wire, and solves the extrusion process problems of large expansion ratio and large width-to-thickness ratio.

[0098] The scheme of the present application will be explained below in conjunction with the examples. Those skilled in the art will appreciate that the following examples are only used to illustrate the present application and should not be considered as limiting the scope of the present application. Where specific techniques or conditions are not indicated in the examples, the techniques or conditions described in the literature in this area or the product specifications are followed.

[0099] Through DOE (Design of Experiments) single factor adjustment, 6 groups of flat wire body factor structures were designed, which are: width 3.3mm, thickness 2.6mm, elastic modulus 74.0Gpa; width 3.3mm, thickness 6.1mm, elastic modulus 72.0Gpa; width 4.2mm, thickness 2.0mm, elastic modulus 69.9Gpa; width 3.3mm, thickness 1.0mm, elastic modulus 68.0Gpa; width 3.3mm, thickness 25mm, elastic modulus 69.9Gpa; width 4.2mm, thickness 2.0mm, elastic modulus 35.0Gpa, as shown in Examples 1 to 3 and Comparative Examples 1 to 3.

[0100] Example 1

[0101] Table 5

[0102] Width of flat wire bodyω / mm Flat wire body thickness δ / mm Elastic modulus of flat wire body E / Gpa 3.3 2.6 74.0

[0103] According to the parameter relationship of the flat wire body:

[0104]

[0105] In Example 1, δ∈{1.12mm, 6.70mm}, δ=2.6mm satisfies the relationship.

[0106] Example 2

[0107] This embodiment is used to illustrate the flat wire body disclosed in this application, including most of the structures in Embodiment 1, and the difference is that:

[0108] Table 6

[0109] Width of flat wire bodyω / mm Flat wire body thickness δ / mm Elastic modulus of flat wire body E / Gpa 3.3 6.1 72.0

[0110] According to the parameter relationship of the flat wire body:

[0111]

[0112] In Example 2, δ∈{1.13mm,6.79mm}, δ=6.1mm, which satisfies the relationship.

[0113] Example 3

[0114] This embodiment is used to illustrate the flat wire body disclosed in this application, including most of the structures in Embodiment 1, and the difference is that:

[0115] Table 7

[0116] Width of flat wire bodyω / mm Flat wire body thickness δ / mm Elastic modulus of flat wire body E / Gpa 4.2 2.0 69.9

[0117] According to the parameter relationship of the flat wire body:

[0118]

[0119] In Example 3, δ∈{1.64mm,9.81mm}, δ=2mm, satisfying the relationship.

[0120] Comparative Example 1

[0121] This comparative example is used to compare and illustrate the flat wire body disclosed in this application, including most of the structures in Example 1, and the difference is that:

[0122] Table 8

[0123] Width of flat wire bodyω / mm Flat wire body thickness δ / mm Elastic modulus of flat wire body E / Gpa 3.3 1.0 68.0

[0124] According to the parameter relationship of the flat wire body:

[0125]

[0126] In Comparative Example 1, δ∈{1.16mm, 6.98mm}, δ=1.0mm, which does not satisfy the relationship.

[0127] Comparative Example 2

[0128] This comparative example is used to compare and illustrate the flat wire body disclosed in this application, including most of the structures in Example 1, and the difference is that:

[0129] Table 9

[0130] Width of flat wire bodyω / mm Flat wire body thickness δ / mm Elastic modulus of flat wire body E / Gpa 3.3 25 69.9

[0131] According to the parameter relationship of the flat wire body:

[0132]

[0133] In Comparative Example 2, δ∈{1.15mm, 6.89mm}, δ=25mm, which does not satisfy the relationship.

[0134] Comparative Example 3

[0135] This comparative example is used to compare and illustrate the flat wire body disclosed in this application, including most of the structures in Example 1, and the difference is that:

[0136] Table 10

[0137] Width of flat wire bodyω / mm Flat wire body thickness δ / mm Elastic modulus of flat wire body E / Gpa 4.2 2.0 35

[0138] According to the parameter relationship of the flat wire body:

[0139]

[0140] In comparative example 3, δ∈{2.30mm, 13.78mm}, δ=2mm, which does not satisfy the relationship.

[0141] Performance Testing

[0142] The flat wire body provided above was tested. The test method was to install the vibration parameters of the accessories and vibrate for 22 hours respectively; the frequency was in the broadband frequency of 10-1000HZ, and the power density was in the range of [0.2-30[(m / s 2 ) 2 / HZ] range, using vibration conditions RMS: (Root Mean Square, effective value of vibration velocity) 27.8m / s 2 working conditions; there should be no mechanical damage or looseness after the test.

[0143] The flat wire body stress test results obtained from the test results of Examples 1-3 and Comparative Examples 1-3 are filled in Table 11.

[0144] Table 11

[0145] Group Example 1 Example 2 Example 3 Comparative Example 1 Comparative Example 2 Comparative Example 3 Maximum stress / MPa 14.99 26.20 40.86 59.58 112.84 90.74

[0146] It can be seen from the test results in Table 11 that the flat wire body obtained by using the embodiment 1-3 defined by the relationship formula of the present application has a power density of [0.2-30[(m / s2) at a broadband frequency of 10-1000HZ 2 / HZ] range, using vibration conditions RMS (Root Mean Square, effective value of vibration velocity): 27.8m / s 2 The stress is small under working conditions, which can meet the stress requirements of vibration working conditions and has good strength effect.

[0147] Although the embodiments of the present application have been shown and described above, it can be understood that the above embodiments are exemplary and cannot be understood as limitations on the present application. Ordinary technicians in this field can change, modify, replace and modify the above embodiments within the scope of the present application.

Claims

1. A flat wire for a motor, characterized in that: In a direction perpendicular to the extension direction of the flat wire, the flat wire has a width direction and a thickness direction, The flat wire comprises a flat wire body, the size of the flat wire body in the thickness direction is δ, the size of the flat wire body in the width direction is ω, the elastic modulus of the flat wire body is E, and satisfies: Among them, μ is 0.5 and the unit is GPa / mm; η is 0.1 and is a dimensionless quantity, ω is in mm, δ is in mm, and E is in GPa.

2. The flat wire for a motor according to claim 1, characterized in that: Along the length direction of the flat wire, the flat wire includes a first connecting section, a first extending section, a transition section, a second extending section, and a second connecting section connected in sequence. The first extending section and the transition section are connected by radial bending in the width direction of the flat wire, and the second extending section and the transition section are connected by radial bending in the thickness direction of the flat wire. There is an angle between the extension lines of the first extending section and the second extending section.

3. The flat wire for a motor according to claim 2, characterized in that: The angle between the first connecting section and the first extending section is an obtuse angle; and / or, the angle between the extension line of the first extending section and the extension line of the second extending section is an obtuse angle; and / or, the angle between the second connecting section and the second extending section is an obtuse angle.

4. The flat wire for a motor according to claim 2, characterized in that: The first connecting segment and the second connecting segment define a plane, and an included angle between an extension line of the first extension segment and an extension line of the second extension segment on the plane is θ, which satisfies: 90°≤θ≤150°.

5. The flat wire for a motor according to claim 2, characterized in that: The radius of the curvature of the first extension section and the transition section is R1, satisfying: R1≥ω; and / or the radius of the curvature of the second extension section and the transition section is R2, satisfying: R1≥δ.

6. The flat wire for a motor according to claim 2, characterized in that: It also includes a first pin and a second pin, wherein the first pin is arranged at an end of the first connecting section away from the first extension section, and the second pin is arranged at an end of the second connecting section away from the second extension section, and the first pin and the second pin are bent in a direction away from each other, or the first pin and the second pin are bent to the same side.

7. The flat wire for a motor according to claim 1, characterized in that: The flat wire further comprises a base layer, the base layer is wrapped around the outside of the flat wire body, and a coating is arranged on the base layer.

8. The flat wire for a motor according to claim 7, characterized in that: The thickness of the coating is between 0.006 mm and 0.012 mm.

9. The flat wire for a motor according to claim 7, characterized in that: The flat wire further comprises an insulating layer, and the insulating layer is wrapped around the outer side of the base layer.

10. The flat wire for a motor according to claim 1, characterized in that: The elastic modulus E of the flat wire body is 55 Gpa-125 Gpa.

11. The flat wire for a motor according to claim 1, characterized in that: The material of the flat wire body includes aluminum and at least one of the following: silicon, iron, magnesium, boron, copper, manganese, zinc and titanium.

12. The flat wire for a motor according to claim 1, characterized in that: The yield strength of the flat wire body is ≥65MPa; and / or the tensile strength of the flat wire body is ≥110Mpa.

13. A stator, characterized in that: The stator comprises a stator core and a flat wire winding, wherein the flat wire winding is formed by winding the flat wire for a motor according to any one of claims 1 to 12.

14. A motor, characterized in that: Comprising a stator according to claim 13.

15. A vehicle, characterized in that: Comprising an electric machine according to claim 14.

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