Stator winding insulation structure for improving slot space factor of flat wire motor

Abstract

The invention discloses a stator winding insulation structure for improving the slot fullness rate of a flat wire motor, which comprises a stator core, a plurality of stator slots are arranged on the inner circumferential wall surface of the stator core, a plurality of turns of conducting copper wire groups are placed in each stator slot, and each turn of conducting copper wire group is formed by connecting at least two copper wires in parallel. The copper wire comprises a copper wire layer and an insulating material layer, the insulating material layer is tubular, wraps the copper wire layer and comprises a first section layer, a second section layer, a third section layer and a fourth section layer, and the radial wall thickness of the first section layer, the radial wall thickness of the second section layer and the radial wall thickness of the third section layer are all larger than the radial wall thickness of the fourth section layer. And the outer peripheral surfaces of the fourth section layers of the insulating material layers of the two copper wires are connected. The method can improve the full slot rate of the motor stator, reduce the AC loss of the copper wire of the motor stator, and improve the power density and efficiency of the motor.

Description

Technical Field

[0001] The present invention relates to the technical field of new energy automobile motors, and in particular to a stator winding insulation structure for improving a slot fill rate of a flat wire motor. Background Art

[0002] As new energy vehicle power systems have higher and higher requirements for motor speed, the problem of high AC loss in the stator winding of traditional flat wire motors has become increasingly prominent. In the prior art, increasing the number of winding layers and reducing the conductor thickness in the same slot is an effective way to solve the problem of winding AC loss. However, the increase in the number of winding layers will increase the insulation proportion of copper wires, which not only reduces the slot fill rate of the motor, but also excessive electrical load will cause severe heating of the winding, accelerating the aging and shedding of the winding insulation layer. Summary of the invention

[0003] In view of the above problems, the present invention provides a stator winding insulation structure for improving the slot fill rate of a flat wire motor.

[0004] The technical solutions to the above technical problems are as follows: A stator winding insulation structure for improving the slot fill rate of a flat wire motor comprises a stator core, a plurality of stator slots are arranged on the inner circumferential wall surface of the stator core, a plurality of copper wire turns are placed in each stator slot, each copper wire turn group is formed by at least two copper wires connected in parallel, the copper wire comprises a copper wire layer and an insulating material layer, the insulating material layer is tubular, the insulating material layer is wrapped on the copper wire layer, the insulating material layer comprises a first cross-sectional layer, a second cross-sectional layer, a third cross-sectional layer, and a fourth cross-sectional layer, the radial wall thickness of the first cross-sectional layer, the second cross-sectional layer, and the third cross-sectional layer are all greater than the fourth cross-sectional layer, and the outer circumferential surfaces of the fourth cross-sectional layers of the insulating material layers of the two copper wires are connected.

[0005] Furthermore, it also includes insulating paper, which is inserted into the stator slot of the stator core. The insulating paper is rectangular, and a plurality of turns of copper wire groups are placed in the insulating paper rectangular frame.

[0006] Furthermore, a wire connection portion is provided on the outer circumference of the fourth cross-sectional layer of the insulating material layer, and the cross-section of the wire connection portion is triangular or circular. The upper and lower copper wires of each turn of the copper wire group are connected through the wire connection portion on the outer circumference of the fourth cross-sectional layer of the insulating material layer.

[0007] Furthermore, a gap is provided between two adjacent insulating material layers, the width of the gap is smaller than the radial thickness of the fourth cross-sectional layer, an adhesive material layer is coated in the gap, and the upper and lower insulating material layers are connected by the adhesive material layer.

[0008] The beneficial effects of the present invention are as follows: the present invention provides a stator winding insulation structure for improving the slot full rate of a flat wire motor, by thinning the fourth cross-section layer of the insulating material layer of the two copper wires of each turn of the copper wire group, so as to achieve the purpose of improving the slot full rate. Compared with the traditional insulating material layer with uniform thickness, the two copper wires of the present invention have a larger available copper material area when connected in parallel, which can not only improve the slot full rate of the motor stator, but also effectively reduce the AC loss of the copper wires of the motor stator, thereby improving the power density and efficiency of the motor. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 It is a partially enlarged stereoscopic view of the copper conductor group and the stator core of the present invention; Figure 2 It is a partial enlarged view of the insulating paper, the copper conductor group, and the stator core of the present invention; Figure 3 It is a schematic diagram of the cross-sectional structure of the copper conductor of the present invention; Figure 4 It is a schematic diagram of the cross-sectional structure of the copper wire when the wire connecting portion of the present invention adopts a cylindrical shape; Figure 5 It is a schematic diagram of the cross-sectional structure of any one turn of the copper wire group in the present invention; Figure 6 It is a schematic diagram of the cooperation between the adhesive material layer and the insulating material layer of the present invention.

[0010] Markings in the drawings: stator core 1, stator slot 1-1, copper wire layer 2, insulating material layer 3, first cross-sectional layer 3-1, second cross-sectional layer 3-2, third cross-sectional layer 3-3, fourth cross-sectional layer 3-4, insulating paper 4, wire connecting part 5, gap L1, adhesive material layer 6. DETAILED DESCRIPTION

[0011] The present invention will be further described below in conjunction with the accompanying drawings and specific implementation methods.

[0012] like Figures 1 to 6 As shown, a stator winding insulation structure for improving the slot fill rate of a flat wire motor comprises a stator core 1, a plurality of stator slots 1-1 are arranged on the inner circumferential wall surface of the stator core 1, a plurality of copper wire turns are placed in each stator slot 1-1, each copper wire turn group is formed by at least two copper wires connected in parallel, the copper wire comprises a copper wire layer 2 and an insulating material layer 3, the insulating material layer 3 is tubular, the insulating material layer 3 is wrapped on the copper wire layer 2, the insulating material layer 3 comprises a first cross-sectional layer 3-1, a second cross-sectional layer 3-2, a third cross-sectional layer 3-3, and a fourth cross-sectional layer 3-4, the radial wall thickness of the first cross-sectional layer 3-1, the second cross-sectional layer 3-2, and the third cross-sectional layer 3-3 are all greater than the fourth cross-sectional layer 3-4, and the outer circumferential surfaces of the fourth cross-sectional layers 3-4 of the insulating material layers 3 of the two copper wires are connected.

[0013] It also includes insulating paper 4, which is inserted into the stator slot 1-1 of the stator core 1. The insulating paper 4 is rectangular, and a plurality of turns of copper wire groups are placed in the rectangular frame of the insulating paper 4.

[0014] Specifically, in this embodiment, the copper wire layer 2 is a conductor layer, the insulating material layer 3 is an insulating layer, the copper wire layer 2 is oxygen-free copper, and the insulating material layer 3 preferably uses insulating materials such as PEEK, PAI, PI, PEI, and AI; the fourth cross-sectional layer 3-4 of the insulating material layer 3 of each copper conductor is thinner than the first cross-sectional layer 3-1, the second cross-sectional layer 3-2, and the third cross-sectional layer 3-3. When the fourth cross-sectional layer 3-4 (i.e., the contact surface direction of the copper conductor) of the insulating material layer 3 of two copper conductors is connected, its thickness is thinned. Compared with the insulating material layer 3 of the prior art with the same radial wall thickness, the copper wire layer 2 that can be accommodated in the prior art is thinner. In the stator slot 1-1 of the same space, the structure of the present invention can accommodate a thicker (i.e., more) copper wire layer 2, which can not only improve the slot fill rate of the motor, but also effectively reduce the AC loss of the copper conductor, and improve the power density and efficiency of the motor. In this way, the motor can withstand a larger current, its magnetic field is larger, the torque output by the motor is larger, and the performance is better.

[0015] In this embodiment, the radial wall thicknesses of the first cross-sectional layer 3-1, the second cross-sectional layer 3-2, the third cross-sectional layer 3-3, and the fourth cross-sectional layer 3-4 of the insulating material layer 3 vary according to the actual maximum voltage level of the motor.

[0016] A wire connecting portion 5 is provided on the outer peripheral surface of the fourth cross-sectional layer 3-4 of the insulating material layer 3 , and the cross-section of the wire connecting portion 5 is triangular or circular. The upper and lower copper wires of each turn of the copper wire group are connected through the wire connecting portion 5 on the outer peripheral surface of the fourth cross-sectional layer 3-4 of the insulating material layer 3 .

[0017] Specifically, in this embodiment, the two copper wires are preferably welded, and a wire connecting portion 5 is provided on the outer peripheral surface of the fourth cross-sectional layer 3-4 of the insulating material layer 3 (i.e., the contact surface of the insulating material layer 3 of the two copper wires), and the two copper wires are welded together through the wire connecting portion 5. There are various welding methods, such as ultrasonic welding.

[0018] A gap L1 is provided between two adjacent insulating material layers 3 , the width of the gap L1 is smaller than the radial thickness of the fourth cross-sectional layer 3 - 4 , an adhesive material layer 6 is coated in the gap L1 , and the upper and lower insulating material layers 3 are connected by the adhesive material layer 6 .

[0019] Specifically, in this embodiment, the gap L1 between two adjacent insulating material layers 3 is a reserved gap. When the insulating material layers 3 are not connected by the above-mentioned welding method, an adhesive material can be applied in the gap L1 to form an adhesive material layer 6 between the insulating material layers 3 of the two copper wires. The adhesive material layer 6 may be insulating or non-insulating. The adhesive material layer 6 preferably uses epoxy resin, silicone, polyurethane and other adhesive materials.

[0020] Finally, it should be noted that the above-described implementation mode is only a preferred embodiment of the present invention to illustrate the technical solution of the present invention, and does not limit it, let alone limit the protection scope of the present invention; although the invention is described in detail with reference to the aforementioned embodiments, ordinary technicians in this field should understand that they can still modify the technical solutions recorded in the aforementioned embodiments, or replace some or all of the technical features therein with equivalents; and these modifications or replacements do not make the essence of the corresponding technical solution deviate from the protection scope of the claims.

Claims

1. A stator winding insulation structure for improving slot fill rate of a flat wire motor, comprising a stator core (1), wherein a plurality of stator slots (1-1) are arranged on the inner circumferential wall surface of the stator core (1), characterized in that: A plurality of copper wire groups are placed in each stator slot (1-1), each copper wire group being composed of at least two copper wires connected in parallel, the copper wire comprising a copper wire layer (2) and an insulating material layer (3), the insulating material layer (3) being tubular, the insulating material layer (3) being wrapped on the copper wire layer (2), the insulating material layer (3) comprising a first cross-sectional layer (3-1), a second cross-sectional layer (3-2), a third cross-sectional layer (3-3), and a fourth cross-sectional layer (3-4), the radial wall thickness of the first cross-sectional layer (3-1), the second cross-sectional layer (3-2), and the third cross-sectional layer (3-3) being greater than the fourth cross-sectional layer (3-4), and the outer circumferential surfaces of the fourth cross-sectional layers (3-4) of the insulating material layers (3) of the two copper wires are connected.

2. A stator winding insulation structure for improving slot filling rate of a flat wire motor according to claim 1, characterized in that: It also comprises insulating paper (4), wherein the insulating paper (4) is inserted into the stator slot (1-1) of the stator core (1), the insulating paper (4) is rectangular, and a plurality of turns of copper wire groups are placed in the rectangular frame of the insulating paper (4).

3. The stator winding insulation structure for improving slot filling rate of a flat wire motor according to claim 1, characterized in that: A wire connection portion (5) is provided on the outer circumference of the fourth cross-sectional layer (3-4) of the insulating material layer (3); the cross-section of the wire connection portion (5) is triangular or circular; and the upper and lower copper wires of each turn of the copper wire group are connected via the wire connection portion (5) on the outer circumference of the fourth cross-sectional layer (3-4) of the insulating material layer (3).

4. The stator winding insulation structure for improving slot filling rate of a flat wire motor according to claim 1, characterized in that: A gap (L1) is provided between two adjacent insulating material layers (3); the width of the gap (L1) is smaller than the radial wall thickness of the fourth cross-section layer (3-4); an adhesive material layer (6) is coated in the gap (L1); and the upper and lower insulating material layers (3) are connected via the adhesive material layer (6).

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