Flat wire, stator, electric machine, vehicle for electric machines

Abstract

The application discloses a flat wire, a stator, a motor and a vehicle for the motor, wherein the flat wire has a width direction and a thickness direction in a direction perpendicular to an extension direction of the flat wire, the flat wire comprises a flat wire body, a size of the flat wire body in the thickness direction is δ, a size of the flat wire body in the width direction is ω, and an elastic modulus of the flat wire body is E, and the following conditions are met: wherein μ is 0.5, a unit is Gpa / mm, and η is 0.1, which is a dimensionless quantity. According to the embodiment of the application, the optimal relationship between the width ω, the thickness δ and the elastic modulus E of the flat wire body is determined, so that the flat wire has a small stress in a vibration working condition, and the key technology of balancing mechanical properties and lightweight design is realized, and meanwhile, the space utilization is improved, and the system is more miniaturized.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of electric machines, in particular to a flat wire for an electric machine, a stator, an electric machine and a vehicle. BACKGROUND

[0002] With the rapid development of new energy vehicle technology, the performance requirements of vehicle electric machines are also becoming higher and higher. While constantly pursuing high slot fill factor, high power density and high torque density of electric machines, it is difficult for round wire electric machines to break through the bottleneck of new performance requirements of driving electric machines. Flat wire electric machines can achieve performance requirements that round wire electric machines cannot meet, have high slot fill factor, high power density, and good heat dissipation performance and NVH performance, can greatly reduce the height of the winding end of the electric machine, reduce the amount of copper and reduce the copper loss of the winding, and thus improve the efficiency of the vehicle driving electric machine.

[0003] However, the electric machine 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, and a large stress will appear in the vibrating flat wire body, causing loosening, deformation or even damage. SUMMARY

[0004] The present application aims to at least solve 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 an electric machine, which has high strength and can reduce the problem of stress concentration.

[0005] The flat wire for an electric machine according to the first aspect of the present application has a width direction and a thickness direction in a direction perpendicular to the extension direction of the flat wire, and 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, and the elastic modulus of the flat wire body is E, which satisfies:

[0006] Wherein, μ is 0.5, the unit is Gpa / mm; η is 0.1, which is a dimensionless quantity, ω is mm, δ is mm, and E is Gpa.

[0007] According to the embodiments of the present application, by designing the flat wire body, the optimal relationship between the width ω, the thickness δ and the elastic modulus E is determined, so that the flat wire has a small stress under vibration conditions, balances the key technologies of mechanical properties and lightweight design, and improves the space utilization rate, 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 comprises a first connecting section, a first extending section, a transition section and a second extending section, a second connecting section connected in sequence, the first extending section and the transition section are connected in a radial bending manner along the width direction of the flat wire, the second extending section and the transition section are connected in a radial bending manner along the thickness direction of the flat wire, and the first extending section and the second extending section have an included angle.

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

[0010] According to an embodiment of the present application, the first connecting section and the second connecting section determine a plane, the included angle between the extension line of the first extending section and the extension line of the second extending section in the normal projection of the plane is θ, and 90°≤θ≤150° is satisfied.

[0011] According to an embodiment of the present application, the bending radius of the first extending section and the transition section is R1, and R1≥ω is satisfied.

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

[0013] According to an embodiment of the present application, first and second needle feet are further included, the first needle foot is arranged at one end of the first connecting section away from the first extending section, the second needle foot is arranged at one end of the second connecting section away from the second extending section, the first needle foot and the second needle foot are bent in directions away from each other, or the first needle foot and the second needle foot are bent in the same side.

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

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

[0016] According to an embodiment of the present application, the wrapping layer further comprises an insulating layer, and the insulating layer is wrapped outside the base layer.

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

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

[0019] According to embodiments 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] The second aspect of the present application provides a stator, comprising a stator core and a flat wire winding formed by the flat wire winding for electric machines according to the first aspect of the present application.

[0021] The third aspect of the present application provides an electric machine comprising the stator according to the second aspect of the present application.

[0022] The fourth aspect of the present application provides a vehicle comprising the electric machine according to the second aspect of the present application.

[0023] Additional aspects and advantages of the present application will be in part apparent and in part pointed out hereinafter. BRIEF DESCRIPTION OF DRAWINGS

[0024] The above and / or additional aspects and advantages of the present application will become apparent and be readily appreciated from the following description, including the appended drawings, wherein:

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

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

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

[0028] Figure 4 is a sectional view of a flat wire according to embodiments of the present application;

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

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

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

[0032] REFERENCE NUMERALS:

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

[0034] Flat wire body 10, wrapping layer 20, primer layer 21, coating layer 211, insulation layer 22,

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

[0036] The embodiments of the present application are described below in detail. The embodiments described below are exemplary only, and are not intended to limit the present application.

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

[0038] The endpoints of the ranges and any values disclosed in the present application are not limited to the precise values recited. The ranges or values should be interpreted as being approximate, and include values near the recited values. For numeric values, the endpoints of each range, the endpoints of each range and individual point values, and individual point values can be combined with one another to generate one or more new numeric ranges, which should be considered as being specifically disclosed in the present application.

[0039] In the present application, the term "comprising" or "including" is an open expression, i.e. including the contents indicated in the present application, but not excluding other aspects.

[0040] For the flat wire of the motor, there are many factors affecting its stress performance, and the applicant optimizes on the basis of DOE (Design of Experiments), screens the stress response factors and key factors. Taking the flat wire of the motor as an example, the applicant screens the stress response factors and key factors by DOE, and then optimizes the flat wire of the motor. Figure 1The flat wire body with the shown three-dimensional structure is taken as an experimental object to perform simulation test to obtain a stress nephogram of the flat wire body. Meanwhile, through a large number of test experiments and specific research on the relationship between the influencing factors such as the expansion coefficient, aging temperature, aging time and elastic modulus E and the maximum stress of the flat wire body, part of the experimental result statistics 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 manner: taking each raw material component of the aluminum alloy, performing solid solution treatment and aging treatment to obtain the aluminum alloy. The specific test method of the simulation test is: importing the parameters of the flat wire body and the parameters of the vibration experiment into the finite element analysis element to perform simulation experiment on the flat wire body; wherein the parameters of the vibration experiment include: vibration time 22h, wideband frequency 10HZ-1000HZ, vibration condition RMS (Root Mean Square, vibration speed effective value): 27.8m / s 2 The working condition; it is required that there is no mechanical damage and loosening phenomenon after the test.

[0041] Table 1

[0042]

[0043] Table 2

[0044]

[0045] Table 3

[0046]

[0047] Table 4

[0048]

[0049]

[0050] From Tables 1-4, it can be obtained that the factor and the key factor of the stress response are the elastic modulus, the expansion coefficient factor, the aging temperature factor, the aging time factor have no significant effect on the stress.

[0051] Among them, the elastic modulus is a size used to measure the ability of an object to resist elastic deformation, and from a microscopic point of view, it is a reaction of the bonding strength between atoms, ions or molecules, represented by E. E represents the force borne on the 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 moduli E are used as the flat wire body, the optional range of the flat wire body thickness δ is different. The applicant designs a reasonable relationship between the flat wire body width ω and the flat wire body thickness δ 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) to screen the stress response factors and key factors. At the same time, a large number of test experiments were carried out and verified in detail, such as Figures 1-4 As shown, the present application provides a flat wire 100 for a motor 400 according to an embodiment. The flat wire 100 has a width direction F1 and a thickness direction F2 perpendicular to the extension direction of the flat wire 100. The flat wire 100 includes a flat wire body 10 and a wrapping layer 20. The dimension of the flat wire body 10 in the thickness direction F2 is δ, the dimension 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, satisfying:

[0054]

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

[0056] Here, the unit of δ is mm; the unit of ω is mm; and the unit of E is 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 relationship between the size δ of the flat wire body 10 in the thickness direction F2 and the size ω of the flat wire body 10 in the width direction F1 is not limited. 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 using 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. This can improve the strength of the flat wire body 10 and reduce stress. The structure can meet the requirements of miniaturization and the quality can meet the requirements of lightweight, thereby increasing the power density.

[0059] According to the flat wire 100 for the motor 400 provided by the embodiment of the present application, the optimal relationship among the width omega, the thickness delta and the elastic modulus E is determined through the design of the flat wire body 10, so that the flat wire 100 has small stress in the vibration working condition, and the key technology of balancing the mechanical performance and the lightweight design is achieved. Meanwhile, the flat design can more compactly fill the stator slot, improve the slot fill rate, thereby improving the space utilization, increasing the power density and the efficiency of the motor 400, and facilitating the miniaturization design of the motor 400.

[0060] As shown in Figures 1-4 According to the embodiment of the present application, along the length direction of the flat wire 100, the flat wire 100 includes the first connecting section 1, the first extension section 2, the transition section 3 and the second extension section 4, the second connecting section 5 connected in sequence, the first extension section 2 and the transition section 3 are radially bent and connected in the width direction F1 of the flat wire 100, and the second extension section 4 and the transition section 3 are radially bent and connected in the thickness direction F2 of the flat wire 100, that is, the bending direction of the first extension section 2 relative to the transition section 3 is along the width direction of the flat wire 100, the bending direction of the second extension section 4 relative to the transition section 3 is along the thickness direction of the flat wire 100, and the bending directions of the two extension sections relative to the transition section 3 are different, thereby forming a three-dimensional structure in space, the first extension section 2 and the second extension section 4 have an included angle between the extension lines, thereby forming a model of the flat wire 100, the first connecting section 1 and the second connecting section 5 can be embedded in the stator slot, the extension direction is changed through the first extension section 2 and the second extension section 4, and the plurality of flat wires 100 can be distributed and extended through a plurality of combination modes.

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

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

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

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

[0065] As shown in Figure 3As shown, according to the embodiments of the present application, the first connecting section 1 and the second connecting section 5 determine a plane, the angle between the extension line of the first extending section 2 and the extension line of the second extending section 4 in the plane orthographic projection is θ, which satisfies: 90°≤θ≤150°. When θ is too small, the angle between the first extending section 2 and the second extending section 4 is too small, and under the variable stress condition, stress concentration occurs at the position where the cross-sectional dimension changes suddenly, which is prone to fatigue strength damage. In order to improve the fatigue strength, the stress concentration source is reduced as much as possible and the stress concentration degree is reduced as much as possible.

[0066] Due to the flat design, when θ is too large, the radial distance between the first leg and the second leg of the adjacent flat wire after welding is too large according to the winding method, which cannot be filled more compactly, thereby reducing the 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 be between 90° and 150°, θ can be any value in 90°, 100°, 110°, 120°, 130°, 140°, 150° or a range value between any two of them, thereby reducing the problem of stress concentration and reducing the probability of fatigue cracking of the flat wire 100, while improving the space utilization.

[0068] As shown in Figure 4 , according to the embodiments of the present application, since the first extending section 2 and the transition section 3 are curvedly connected in the width direction F1 of the flat wire 100 as the radial direction, the bending radius of the first extending section 2 and the transition section 3 is R1, which satisfies: R1≥ω, thereby reducing the curvature at the connection between the first extending section 2 and the transition section 3, and reducing the stress concentration degree.

[0069] As shown in Figure 4 , according to the embodiments of the present application, since the second extending section 4 and the transition section 3 are curvedly connected in the thickness direction F2 of the flat wire 100 as the radial direction, the bending radius of the second extending section 4 and the transition section 3 is R2, which satisfies: R1≥δ, thereby reducing the curvature at the connection between the second extending section 4 and the transition section 3, and reducing the stress concentration degree.

[0070] As shown in Figure 2 , according to the embodiments of the present application, the flat wire 100 further comprises a first pin 6 and a second pin 7, the first pin 6 is arranged at one end of the first connecting section 1 away from the first extending section 2, and the second pin 7 is arranged at one end of the second connecting section 5 away from the second extending section 4, the first pin 6 and the second pin 7 are bent 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 first pin 6 and the second pin 7 are provided with chamfers at the ends, and the chamfers at the ends of the pins 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 flat wire 100 line shape 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 legs and second legs of adjacent flat wires 100.

[0072] In the related art, the influence on the surface properties 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. Because a large number of high-speed and continuous projectiles from the surface strengthening spray hit the surface of the material, it is like countless small hammers hammering the material surface. Part of the kinetic energy is absorbed by the surface of the material, forming a crater on the surface of the material. Intense plastic deformation occurs within a certain depth around the crater, forming a plastic deformation layer of a certain thickness. Within the plastic deformation layer, the microstructure of the material changes, and the grain size 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 of the material even changes. This strengthening is called microstructural strengthening. Microstructural strengthening makes it difficult for the crystals in the deformation layer to slip. At the same time, the slip structure 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] During the surface strengthening process, not only is the material's surface structure optimized, but cyclic plastic deformation also introduces a residual compressive stress layer of a certain thickness within the deformed layer. This residual compressive stress layer drives surface cracks from the surface layer to the subsurface layer, effectively reducing the tensile stress generated by external forces or torques in the surface layer. When the depth of the residual stress exceeds the depth of microcracks, it effectively prevents and reduces the rate of fatigue crack propagation. Therefore, for parts with microcracks or notches, the strengthening effect of residual stress is superior to that of structural strengthening. This creates a pre-compressive stress on the surface of the flat wire body 10, improving its fatigue resistance. Since lower surface roughness reduces fatigue strength, surface strengthening treatment also generates compressive stress on the surface, improving fatigue resistance. After the improvement, the surface roughness of the flat wire body 10 reaches Ra = 1.6, and the HV after surface strengthening treatment is greater than 38, thus providing resistance to the effects of fatigue.

[0074] like Figure 4As shown, according to the embodiment of the present application, the wrapping layer 20 comprises a base layer 21 wrapped outside the flat wire body 10, and the base layer 21 is provided with a coating layer 211. The base layer 21 can play a protection function, and the base layer 21 can facilitate the effective combination of the coating layer 211 and the flat wire body 10. The base layer 21 provided with the coating layer 211 is used to strengthen the strength of the flat wire body 10. Spraying the coating layer 211 on the base layer 21 can obtain excellent conductivity, 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 layer 211 is too large, it will affect the conductivity effect and reduce the adhesion strength. If the thickness of the coating layer 211 is too small, the salt spray resistance, humidity resistance and low temperature impact resistance will be reduced, which is not conducive to improving the strength of the flat wire. Therefore, the thickness of the coating layer 211 can be between 0.006mm and 0.012mm. The thickness of the coating layer 211 can be any one value or a range value between any two values of 0.006mm, 0.007mm, 0.008mm, 0.009mm, 0.01mm, 0.011mm and 0.012mm. The main feature of the coating layer 211 is adsorbed on the surface of the base layer 21; and migrates on the surface of the substrate until it is incorporated into the crystal lattice to form the coating layer 211. The coating layer 211 is dense, flat, has good adhesion to the substrate, and has salt spray resistance, 85℃, 85% humidity and-40℃ low temperature impact resistance. Ensure adhesion and avoid falling off. The material of the coating layer 211 can be nickel, silver, etc.

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

[0077] According to the 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 formed piece 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. 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 plurality of stator slots arranged along the circumference of the stator core 310, and is connected and expanded outward.

[0079] According to the embodiment of the present application, the elastic modulus E of the flat wire body 10 is 55Gpa-125Gpa, so that the optimal relationship between the width ω, the thickness δ, and the elastic modulus E is determined, so that the flat wire 100 is small in vibration working condition stress, and the key technology of balancing the mechanical properties and lightweight design is achieved, and at the same time, the flat design can more compactly fill the stator slot, improve the slot fill rate, thereby improving the space utilization, increasing the power density and efficiency of the motor 400, and facilitating the miniaturization design of the motor 400.

[0080] According to the 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 can be added, so as to form an aluminum alloy, and meet the lightweight high-strength design.

[0081] According to the embodiment of the present application, the yield strength of the flat wire body 10 is ≥65MPa, so that 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 ≥110Mpa, so that the flat wire body has a relatively high tensile strength.

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

[0084] The flat wire winding 200 is composed of flat wires 100 arranged in a certain rule, and 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 distributed outwardly by various combination modes, the flat wires 100 form a multi-layer spatial three-dimensional layout in space, the distribution state and size of the flat wires 100 can be adjusted according to the use condition, the connection and transition of the flat wires 100, the forming angle, the connection, the plating layer and the coating layer, the insulation layer 22, and the shielding layer can be adjusted according to the use condition, so as to form a flat wire winding 200 which is compact in structure, high in space utilization, and convenient to produce, use, install, and disassemble.

[0085] The flat wire winding 100 can be assembled in series or in parallel, and the flat wire 100 can be single-layer or multi-layer, and can be applied to different number of connection structures, and can also achieve smaller size and lighter weight while meeting the strength reduction stress.

[0086] The flat wire winding 200 can include a plurality of winding layers, such as Figure 5As shown, each layer-in flat wire 100 is composed of a plurality of layer-in flat wires 100 connected end to end, and each 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 same side end of the second flat wire 100; in the same winding layer, the insertion portions of the first flat wire 100 are arranged in each slot group of the same conductor layer, and the insertion portions of the second flat wire 100 are arranged in each slot group of another conductor layer; each winding layer is provided with layer-in flat wires 100; the flat wire 100 is connected to the external system through the connection, and is extended in multiple angles, shapes and directions, so that the flat wire 100 can be distributed and extended in multiple combination modes.

[0087] The plurality of flat wires 100 form a plurality of flat wire groups, each flat wire group including a plurality of flat wires 100, and the flat wires 100 in different flat wire groups are connected to realize the connection between different flat wire groups, and then realize the three-dimensional layout in space.

[0088] The flat wire winding 200 includes a multi-phase winding, and for a branch of any phase winding in the flat wire winding 200, the flat wire 100 can be a one-piece structure conductor or a conductor welded by a plurality of flat wires 100. The flat wire 100 includes but is not limited to a U-shaped conductor segment.

[0089] As shown, Figure 6 The flat wire winding 200 is formed by winding the flat wire 100 in the stator slot, and the use of the above flat wire 100 can make the slot fill rate of the flat wire winding 200 reach more than 70%, which is beneficial to improve the efficiency of the motor 400. The cross section of the flat wire 100 can be a flat cross section such as a rectangular cross section or a trapezoidal cross section, but is not limited thereto.

[0090] In addition, as shown, Figure 6 Each parallel branch of the flat wire winding 200 can be composed of a group of continuous and complete vertical coils, and the overall motor 400 only has the lead-out wires or neutral points gathered together for welding, and the winding has no redundant welding points, which reduces the complexity of connection and realizes automatic production. The use of vertical winding also greatly reduces the thermal resistance, improves the heat dissipation capacity, and improves the torque density of the motor 400.

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

[0092] According to the motor 400 of the embodiment of the present application, the stator 300 according to the embodiment of the present application is included.

[0093] Specifically, the motor 400 includes a housing, a stator 300 and a rotor accommodated in the housing, 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, a permanent magnet is arranged on the rotor core, and an air gap is left between the stator 300 and the rotor. Here, the motor 400 can be used as an induction motor 400. In the application, the application scenarios of the motor 400 are not specifically limited.

[0094] The position and direction of the flat wire 100 in the motor 400 can be adjusted according to other components. By adjusting the width, thickness and elastic modulus of the flat wire 100, the optimal value is determined after simulation analysis, so that the strength is improved and the stress is reduced, and at the same time, the system of the motor 400 is more integrated, and the quality is more lightweight.

[0095] According to the motor 400 of the embodiment of the application, by adopting the above-mentioned stator 300, the vibration strength of the flat wire 100 can be improved, and the stress concentration is reduced, the flat wire 100 is more compactly filled in the stator slot, the slot fill rate is improved, and the space utilization rate is improved, so that the power density and efficiency of the motor 400 are improved, and the miniaturization design of the motor 400 is facilitated.

[0096] According to the vehicle 500 of the embodiment of the application, the vehicle 500 includes a vehicle body and the motor 400 according to the embodiment of the application, and the motor 400 is located in the vehicle body. By adopting the above-mentioned motor 400, the stress requirement of the vibration working condition can be met, and good strength effect is obtained.

[0097] By adopting the flat wire design model, the width and quality of the flat wire product are greatly improved. The present application 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-thickness ratio.

[0098] The scheme of the present application will be explained below in combination with the embodiments. Those skilled in the art will understand that the following embodiments are only used to illustrate the present application, and should not be regarded as limiting the scope of the present application. If the specific technology or condition is not specified in the embodiments, the technology or condition described in the literature in the art or according to the product manual is used.

[0099] Six groups of flat wire body factor structures are designed by single factor adjustment of DOE (Design of Experiments), 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 1-3 and Comparative Examples 1-3.

[0100] Example 1

[0101] Table 5

[0102] Flat wire body width ω / 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 the present application, which includes most of the structures in Example 1, and the difference is that:

[0108] Table 6

[0109] Flat wire body width ω / 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, satisfies the relationship.

[0113] Example 3

[0114] This embodiment is used to illustrate the flat wire body disclosed in the present application, which includes most of the structures in Example 1, and the difference is that:

[0115] Table 7

[0116] Flat wire body width ω / 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, the relationship is satisfied.

[0120] Comparative Example 1

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

[0122] Table 8

[0123] Flat wire body width ω / 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, the relationship is not satisfied.

[0127] Comparative Example 2

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

[0129] Table 9

[0130] Flat wire body width ω / 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, the relationship is not satisfied.

[0134] Comparative Example 3

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

[0136] Table 10

[0137] Flat wire body width ω / 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∈{2.30 ​​mm, 13.78 mm}, δ=2 mm, which does not satisfy the relationship.

[0141] Performance Testing

[0142] The flat wire body provided above was tested by installing the vibration parameters of the accessories for 22 hours; the frequency was in the broadband frequency of 10-1000HZ, the power density was in the range of [0.2-30[(m / s 2 ) 2 / HZ] range, using vibration conditions RMS: (Root Mean Square, vibration velocity effective value) 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 entered 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] From the test results in Table 11, it can be seen that the flat wire body obtained by using the relationship defined in Examples 1-3 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 the working condition, which can meet the stress requirements of the vibration working condition and has a 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 includes a flat wire body, wherein the dimension of the flat wire body in the thickness direction is δ, the dimension of the flat wire body in the width direction is ω, and the elastic modulus of the flat wire body is E, satisfying: 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 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 radially bent and connected in the width direction of the flat wire, and the second extension section and the transition section are radially bent and connected in the thickness direction of the flat wire. There is an angle between the extension lines of the first extension section and the second extension 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 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.

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 θ between an extension line of the first extending segment and an extension line of the second extending segment on the plane satisfies the following conditions: 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, 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.

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

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 includes an insulating layer, which 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 ≥65 MPa; and / or the tensile strength of the flat wire body is ≥110 MPa.

13. A stator, characterized in that: The stator includes 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 the motor according to claim 14.

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