Stator structure of flat wire motor

Abstract

A flat wire motor stator structure of the present invention comprises a stator core and a winding, the inner wall of the stator core is provided with a plurality of rectangular stator grooves which are distributed in a circumferential array and have the same size, the winding comprises a plurality of conductors, each stator groove is internally provided with at least 2N straight line segments of the conductors, N is a positive integer, and N is a positive integer. One ends of the linear sections of the conductors are connected through a U-shaped hairpin to form a crown end, the other ends of the linear sections of the conductors form a welding end in a torsion head external expansion welding mode, and the linear sections, the crown ends and the welding end of the corresponding conductors form a five-groove-crossing hairpin conductor, a six-groove-crossing hairpin conductor or a seven-groove-crossing hairpin conductor. The two straight line segments of the multiple hairpin conductors are located on different layers respectively, the multiple hairpin conductors are sequentially connected to form single-branch wires, the multiple single-branch wires are connected in parallel or in series to form a complete winding, and the outgoing line of the winding is located on the welding end side. The three-phase line outgoing line and the welding end are arranged on the same side, so that coils at the two ends of the stator core are regular, and the number of line types is small.

Description

Technical Field

[0001] The invention belongs to the technical field of flat wire motor structures, and in particular relates to a flat wire motor stator structure. Background Art

[0002] At present, new energy electric vehicles are developing rapidly. As the key driving component of new energy vehicles, the drive motor is divided into round wire motor and flat wire motor according to the conductor shape of the copper wire. Flat wire motor has many advantages over round wire motor. First, the bare copper slot full rate of flat wire is high, which means that more copper can be stuffed into the same space, thus having a higher power density; secondly, the contact effect between the enameled wires of the flat wire motor is better, which will be more conducive to heat dissipation and NVH; at the same time, the processability of the flat wire motor is more standardized and standardized, and the quality controllability of the production process is higher. Therefore, flat wire motor has gradually become the development trend of new energy vehicles. Flat wire motor is to form the copper flat wire that makes up the winding into the shape of a hairpin, insert it into the iron core slot, and then connect the hairpins together at the other end through twisting and welding process to achieve the required electromagnetic winding.

[0003] In the prior art, some flat wire motors have three-phase stator lead wires and welding ends at both ends of the stator, and the axial length is relatively large, which increases the difficulty of vehicle layout. In addition, some three-phase lead wires in the existing flat wire winding structure are distributed relatively concentratedly, either on the inner diameter side of the wire package or on the outer diameter side of the wire package, and the structural reliability is poor. At the same time, flat wire windings mostly use the same layer span, many types of wire types, irregular wire packages, and poor processability, which causes the wire package to exceed the inner diameter of the core, and the rotor can only be assembled from one end of the shaft, which is inconvenient for production and assembly. Summary of the invention

[0004] In order to solve the above technical problems, the purpose of the present invention is to provide a flat wire motor stator structure, which can realize the twist head end as the lead-out wire interface through a clever winding routing scheme, and the inner and outer rings can lead out at the same time, with strong versatility and expansibility.

[0005] In order to achieve the above-mentioned invention object, the present invention adopts the following technical solutions:

[0006] A flat wire motor stator structure comprises a stator core and a winding, wherein the inner wall of the stator core is provided with a plurality of rectangular stator slots distributed in a circumferential array and having the same size, the winding comprises a plurality of conductors, each stator slot is provided with at least 2N straight line segments of the conductor, N is a positive integer, one end of the straight line segment of the conductor is connected by a U-shaped hairpin to form a crown end, the other end of the straight line segment of the conductor is formed by twisting and expanding the welding end, the straight line segment, the crown end and the welding end of the corresponding conductor form a hairpin conductor spanning 5 slots, a hairpin conductor spanning 6 slots or a hairpin conductor spanning 7 slots, two straight line segments of the plurality of hairpin conductors are respectively located at different layers, the plurality of hairpin conductors are connected in sequence to form a single branch routing, the plurality of single branch routings are connected in parallel or in series to form a complete winding, and the lead wire of the winding is located on the welding end side.

[0007] As a preferred solution, there are 48 stator slots, and the single-branch line A penetrates from the first layer of the 37th stator slot, and is sequentially penetrated into the corresponding stator slots from the inside to the outside by staggered-layer cross-slots hairpin conductors spanning 6 slots, and the conductor of the 1st stator slot and the conductor of the 44th stator slot both adopt the hairpin conductor spanning 5 slots; the conductor of the 2nd stator slot and the conductor of the 43rd stator slot both adopt the hairpin conductor spanning 7 slots.

[0008] As a preferred solution, the stator core includes 2N single-branch wirings A, and the 2N single-branch wirings A are arranged at certain angles in a clockwise direction along the circumference.

[0009] As a preferred solution, there are 48 stator slots, and the single-branch routing B penetrates from the first layer of the 44th stator slot, and is sequentially penetrated into the corresponding stator slots from the inside to the outside by staggered-layer cross-slots hairpin conductors spanning 6 slots, and the conductor of the 7th stator slot and the conductor of the 2nd stator slot both adopt the hairpin conductor spanning 5 slots; the conductor of the 8th stator slot and the conductor of the 1st stator slot both adopt the hairpin conductor spanning 7 slots.

[0010] As a preferred solution, the stator core includes 2N single-branch wirings B, and the 2N single-branch wirings B are arranged at certain angles in a clockwise direction along the circumference.

[0011] As a preferred embodiment, the stator core comprises three single-branch lines A and three single-branch lines B, and the winding consists of a single-branch line A, a single-branch line A array rotated 15° clockwise along a circle, a single-branch line A array rotated 75° clockwise along a circle, a single-branch line B, a single-branch line B array rotated 15° counterclockwise along a circle, and a single-branch line B array rotated 75° counterclockwise along a circle.

[0012] Compared with the prior art, the present invention has the following beneficial effects:

[0013] The three-phase lead wire and the welding end of the present invention are on the same side, so that the wire packages at both ends of the stator core are regular, the number of wire types is small, and both ends can be inserted into the shaft to assemble the rotor; at the same time, the winding structure of the present invention enables the three-phase lead wire interface pin wire to adopt an inner and outer diameter distribution, which has higher reliability. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The drawings in the specification, which constitute a part of the present application, are used to provide a further understanding of the present application. The illustrative embodiments of the present application and their descriptions are used to explain the present application and do not constitute a limitation on the present application.

[0015] Figure 1 It is a schematic diagram of the conductor distribution in the 2n-layer slot of the present invention;

[0016] Figure 2 is an axonometric view of a flat wire stator assembly of the present invention;

[0017] Figure 3 The present invention Figure 2 Schematic diagram of the crown end structure of the stator assembly;

[0018] Figure 4 It is a wiring schematic diagram of a single-branch wiring A of a 2n-layer stator of the present invention;

[0019] Figure 5 It is a wiring schematic diagram of a single branch wiring B of a 2n-layer stator of the present invention;

[0020] Figure 6 It is a schematic diagram of a normal card issuing combination across 6 slots of the present invention;

[0021] Figure 7 It is a schematic diagram of the large and small spans formed by the combination of the card-issuing slots spanning 5 and spanning 7 of the present invention;

[0022] Figure 8 It is a wiring diagram of a single-branch wiring A of a 6-layer stator of the present invention;

[0023] Fig. 9 It is a wiring diagram of a single-branch wiring B of a 6-layer stator of the present invention;

[0024] Fig.10 It is a structural schematic diagram of the six-layer stator branch routing A of the present invention;

[0025] Fig.11 It is a structural schematic diagram of the six-layer stator branch routing B of the present invention;

[0026] Fig.12 It is an axonometric diagram of a 6-layer flat wire stator assembly formed by combining branch wiring A and branch wiring B of the present invention;

[0027] Fig.13It is an axonometric view of a 6-layer flat wire stator assembly formed by a continuous array of only branch wiring A of the present invention.

[0028] The figures are marked as follows: 1. lead wire; 2. welding end; 3. stator core; 4. crown end; 5. hairpin conductor across 6 slots; 6. hairpin conductor across 7 slots; 7. branch wiring A; 8. branch wiring B; 9. hairpin conductor across 5 slots. DETAILED DESCRIPTION

[0029] It should be noted that the following detailed descriptions are illustrative and are intended to provide further explanation of the present application. Unless otherwise specified, all technical and scientific terms used herein have the same meanings as those commonly understood by those skilled in the art to which the present application belongs.

[0030] It should be noted that the terms used herein are only for describing specific embodiments and are not intended to limit the exemplary embodiments according to the present application. As used herein, unless the context clearly indicates otherwise, the singular form is also intended to include the plural form. In addition, it should be understood that when the terms "comprise" and / or "include" are used in this specification, it indicates the presence of features, steps, operations, devices, components and / or combinations thereof.

[0031] In addition, in the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "clockwise", "counterclockwise" and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the referred device or element must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as a limitation on the present invention.

[0032] In addition, 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, a feature defined as "first" or "second" may explicitly or implicitly include one or more of the features. In the description of the present invention, unless otherwise specified, "plurality" means two or more, unless otherwise clearly specified.

[0033] In the present invention, unless otherwise clearly specified and limited, the terms "installed", "connected", "connected", "fixed" and the like should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be an indirect connection through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0034] In the present invention, unless otherwise clearly specified and limited, a first feature being "above" or "below" a second feature may include that the first and second features are in direct contact, or may include that the first and second features are not in direct contact but are in contact through another feature between them. Moreover, a first feature being "above", "above" and "above" a second feature includes that the first feature is directly above and obliquely above the second feature, or simply indicates that the first feature is higher in level than the second feature. A first feature being "below", "below" and "below" a second feature includes that the first feature is directly below and obliquely below the second feature, or simply indicates that the first feature is lower in level than the second feature.

[0035] The present invention will be further described below in conjunction with the accompanying drawings and embodiments:

[0036] like Figures 1 to 7 As shown, a flat wire motor stator structure includes a stator core 3 and a winding, wherein the inner wall of the stator core is provided with a plurality of rectangular stator slots distributed in a circular array and having the same size, and the winding includes a plurality of conductors, characterized in that: each stator slot is provided with at least 2N straight segments of the conductor, N is a positive integer, one end of the straight segment of the conductor is connected by a U-shaped hairpin to form a crown end 4, and the other end of the straight segment of the conductor is formed by twisting and expanding the welding end 2, the straight segment, the crown end and the welding end of the corresponding conductor form a hairpin conductor across 5 slots, a hairpin conductor across 6 slots or a hairpin conductor across 7 slots, two straight segments of the plurality of hairpin conductors are respectively located at different layers, the plurality of hairpin conductors are sequentially connected to form a single branch wiring, the plurality of single branch wirings are mutually connected in parallel or in series to form a complete winding, and the lead wire 1 of the winding is located on the welding end side.

[0037] There are 48 stator slots, and the single-branch routing A7 penetrates from the first layer of the 37th stator slot, and sequentially uses the 6-slot hairpin conductor 5 to be staggered and arranged in the corresponding stator slots from the inside to the outside, and the conductor of the 1st stator slot and the conductor of the 44th stator slot both use the 5-slot hairpin conductor 9; the conductor of the 2nd stator slot and the conductor of the 43rd stator slot both use the 7-slot hairpin conductor 6. The stator core includes 2N single-branch routings A, and the 2N single-branch routings A are arranged clockwise along the circumference at a certain angle.

[0038] There are 48 stator slots, and the single-branch routing B8 penetrates from the first layer of the 44th stator slot, and sequentially uses the 6-slot hairpin conductor to be staggered and arranged in the corresponding stator slots from the inside to the outside, and the conductor of the 7th stator slot and the conductor of the 2nd stator slot both use the 5-slot hairpin conductor; the conductor of the 8th stator slot and the conductor of the 1st stator slot both use the 7-slot hairpin conductor. The stator core includes 2N single-branch routings B, and the 2N single-branch routings B are arranged clockwise along the circumference at a certain angle.

[0039] The stator core comprises three single-branch routings A and three single-branch routings B, and the winding consists of a single-branch routing A, an array of single-branch routing A rotating 15° clockwise along a circle, an array of single-branch routing A rotating 75° clockwise along a circle, a single-branch routing B, an array of single-branch routing B rotating 15° counterclockwise along a circle, and a single-branch routing B rotating 75° counterclockwise along a circle.

[0040] like Figures 8 to 13 , taking 8 poles, 48 ​​slots and 6 layers of conductors in the slots as an example, a specific structural embodiment is described. The symbol "X(i)" is defined to mean "the i-th layer of the X slots", where X is a positive integer from 1 to 48 and i is a positive integer.

[0041] Among them, the branch routing A solution (such as Figure 8 ), the specific implementation is as follows:

[0042] The branch line A of the present invention is as follows: Figure 8 , the routing starts from the first layer of slot 37. The detailed routing logic is as follows:

[0043] Follow the arrow direction and pass Figure 8The inner lead wire enters from the welding end 2 of 37 (1), and enters the 31 (2) conductor at the crown end 4 through a 6-slot hairpin conductor; by twisting the head, 31 (2) and 25 (1) are connected at the welding end, and enter the 19 (2) conductor at the crown end through a 6-slot hairpin conductor; by twisting the head, 19 (2) and 13 (1) are connected at the welding end, and enter the 7 (2) conductor at the crown end through a 6-slot hairpin conductor; by twisting the head, 7 (2) and 1 (1) are connected at the welding end, and enter the 44 (2) conductor at the crown end through a 5-slot hairpin conductor; by twisting the head, 44 (2) and 36 (1) are connected at the welding end. The ends are connected, and at the crown end, a hairpin conductor across 6 slots is passed to the 32(2) conductor; by twisting the head and welding, 32(2) and 26(1) are connected at the welding end, and at the crown end, a hairpin conductor across 6 slots is passed to the 20(2) conductor; then by twisting the head and welding, 20(2) and 14(1) are connected at the welding end, and at the crown end, a hairpin conductor across 6 slots is passed to the 8(2) conductor; then by twisting the head and welding, 8(2) and 2(1) are connected at the welding end, and at the crown end, a hairpin conductor across 7 slots is passed to the 43(2) conductor; by twisting the head and welding, 43(2) and 37(3) are connected at the welding end, and enter the 37(3) conductor;

[0044] Repeat the above process, so that the routing path is from 37(3)→31(4)→25(3)→19(4)→13(3)→7(4)→1(3)→44(4)→36(3)→32(4)→26(3)→20(4)→14(3)→8(4)→2(3)→43(4)→37(5), and reaches 37(5);

[0045] Repeat the above process, so that the routing path is from 37(5)→31(6)→25(5)→19(6)→13(5)→7(6)→1(5)→44(6)→36(5)→32(6)→26(5)→20(6)→14(5)→8(6)→2(5)→43(6), and finally leads out from the 43(6) welding end. The structural diagram of branch routing A is as follows: Fig.10 .

[0046] The branch line B of the present invention is as follows: Fig. 9 , start routing from the first layer of slot 44, the detailed routing logic is as follows:

[0047] Follow the arrow direction and pass Fig. 9The inner lead wire enters from the welding end of 44 (1), and enters the 36 (2) conductor at the crown end through a 6-slot hairpin conductor; by twisting the head, 36 (2) and 32 (1) are connected at the welding end, and enter the 26 (2) conductor at the crown end through a 6-slot hairpin conductor; by twisting the head, 26 (2) and 20 (1) are connected at the welding end, and enter the 14 (2) conductor at the crown end through a 6-slot hairpin conductor; by twisting the head, 14 (2) and 8 (1) are connected at the welding end, and enter the 1 (2) conductor at the crown end through a 7-slot hairpin conductor; by twisting the head, 1 (2) and 43 (1) are connected at the welding end. Connect, at the crown end, through a 6-slot hairpin conductor, enter the 37(2) conductor; by twisting the head and welding, 37(2) and 31(1) are connected at the welding end, and at the crown end, through a 6-slot hairpin conductor, enter the 25(2) conductor; then by twisting the head and welding, 25(2) and 19(1) are connected at the welding end, and at the crown end, through a 6-slot hairpin conductor, enter the 13(2) conductor; then by twisting the head and welding, 13(2) and 7(1) are connected at the welding end, and at the crown end, through a 5-slot hairpin conductor, enter the 2(2) conductor; by twisting the head and welding, 2(2) and 44(3) are connected at the welding end, and enter the 44(3) conductor;

[0048] Repeat the above process, so that the routing path is from 44(3)→36(4)→32(3)→26(4)→20(3)→14(4)→8(3)→1(4)→43(3)→37(4)→31(3)→25(4)→19(3)→13(4)→7(3)→2(4)→44(5), and reaches 44(5);

[0049] Repeat the above process, so that the routing path is from 44(5)→36(6)→32(5)→26(6)→20(5)→14(6)→8(5)→1(6)→43(5)→37(6)→31(5)→25(6)→19(5)→13(6)→7(5)→2(6), and finally leads out from the 2(6) welding end. The structural diagram of branch routing B is as follows: Fig.11 .

[0050] The complete stator winding of the present invention can be a combination of the above-mentioned branch wiring A and branch wiring B, which are embedded in the iron core. Then, the branch wiring A is arrayed once along the circumference clockwise at 15°, and then the branch wiring A is arrayed once along the circumference clockwise at 75°; then, the branch wiring B is arrayed once along the circumference counterclockwise at 15°, and then the branch wiring A is arrayed once along the circumference counterclockwise at 75°, forming a structural schematic diagram of the flat wire stator assembly, as shown in FIG. Fig.12 .

[0051] Alternatively, only the branch wiring A mentioned above is embedded in the iron core, and then six identical branches are continuously arrayed clockwise at intervals of 15° to form a structural schematic diagram of a flat wire stator assembly, as shown in FIG. Fig.13 .

[0052] The purpose of the present invention is to provide a new 8-layer 48-slot flat wire winding solution. Through a clever winding routing solution, the twisting end can be used as a lead-out interface, and the inner and outer circles can lead out at the same time, with strong versatility and expansibility. Compared with the traditional flat wire stator solution, the present invention is aimed at an even-numbered layer flat wire stator winding, which has strong expansibility; the lead-out wire is led out from the welding end, and is led out from the inner and outer circles, with high reliability; the innermost layer of the crown end and the twisting end of the flat wire stator of the present invention does not invade the inner diameter, and can be inserted into the shaft in both directions; the crown end has a regular line shape, which can realize automatic wire insertion; the same-phase slots are evenly distributed, and the windings of different phases are exactly the same, with low circulating current risk.

[0053] In the description of this specification, the description with reference to the terms "one embodiment", "some embodiments", "examples", "specific examples", or "some examples" means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representation of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described may be combined in any one or more embodiments or examples in a suitable manner.

[0054] Although the embodiments of the present invention have been shown and described above, it can be understood that the above embodiments are exemplary and cannot be understood as limiting the present invention. Ordinary technicians in the field can change, modify, replace and modify the above embodiments within the scope of the present invention without departing from the principles and purpose of the present invention. Any simple modifications, equivalent changes and modifications made to the above embodiments based on the technical essence of the present invention are still within the scope of the technical solution of the present invention.

Claims

1. A flat wire motor stator structure, comprising a stator core and a winding, wherein the inner wall of the stator core is provided with a plurality of rectangular stator slots distributed in a circumferential array and having the same size, and the winding comprises a plurality of conductors, characterized in that: At least 2N straight segments of conductors are provided in each stator slot, where N is a positive integer. One end of the straight segment of the conductor is connected by a U-shaped hairpin to form a crown end, and the other end of the straight segment of the conductor is formed by twisting and welding to form a welding end. The straight segment, crown end and welding end of the corresponding conductor form a hairpin conductor spanning 5 slots, a hairpin conductor spanning 6 slots or a hairpin conductor spanning 7 slots. Two straight segments of multiple hairpin conductors are located at different layers respectively. Multiple hairpin conductors are connected in sequence to form a single branch routing. Multiple single branch routings are connected in parallel or in series to form a complete winding, and the lead wire of the winding is located on the welding end side.

2. A flat wire motor stator structure according to claim 1, characterized in that: There are 48 stator slots, and the single-branch routing A penetrates from the first layer of the 37th stator slot, and is sequentially penetrated into the corresponding stator slots from the inside to the outside by staggered-layer cross-slots hairpin conductors spanning 6 slots. The conductor of the 1st stator slot and the conductor of the 44th stator slot both adopt the hairpin conductor spanning 5 slots; the conductor of the 2nd stator slot and the conductor of the 43rd stator slot both adopt the hairpin conductor spanning 7 slots.

3. A flat wire motor stator structure according to claim 2, characterized in that: The stator core includes 2N single-branch wirings A, and the 2N single-branch wirings A are arranged at certain angles in a clockwise direction along the circumference.

4. A flat wire motor stator structure according to claim 2, characterized in that: There are 48 stator slots, and the single-branch routing B penetrates from the first layer of the 44th stator slot, and is sequentially penetrated into the corresponding stator slots from the inside to the outside by staggered-layer cross-slots hairpin conductors across 6 slots, and the conductor of the 7th stator slot and the conductor of the 2nd stator slot both adopt the hairpin conductor across 5 slots; the conductor of the 8th stator slot and the conductor of the 1st stator slot both adopt the hairpin conductor across 7 slots.

5. A flat wire motor stator structure according to claim 4, characterized in that: The stator core includes 2N single-branch wirings B, and the 2N single-branch wirings B are arranged at certain angles in a clockwise direction along the circumference.

6. A flat wire motor stator structure according to claim 4, characterized in that: The stator core comprises three single-branch routings A and three single-branch routings B, and the winding consists of a single-branch routing A, an array of single-branch routing A rotating 15° clockwise along a circle, an array of single-branch routing A rotating 75° clockwise along a circle, a single-branch routing B, an array of single-branch routing B rotating 15° counterclockwise along a circle, and a single-branch routing B rotating 75° counterclockwise along a circle.

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