Motor flat wire winding arrangement structure

Abstract

The invention relates to a motor flat wire winding arrangement structure applied to the field of flat wire motors, the winding arrangement structure comprises an iron core, wire grooves, insulation paper, flat wires, phase copper bars and star point bars, the star point bars are arranged on the inner side and the outer side of a coil, the phase copper bars are universal in design, the cost is reduced, the welding end of the coil, the phase copper bars and the star point bars are arranged on the same side, no I-pin exists, and the winding arrangement structure is simple in structure and convenient to use. The axial length of the motor can be shortened, the welding time, the number of tools and the cost can be saved, when the flat wire is bent, the extrusion block is driven to approach the surface of the flat wire in the wire slot under the action of downward pressing deformation, and the flat wire can be restrained and limited along with approaching of the extrusion block and cooperation of the fixing block; in this way, it is avoided that the bent part of the flat wire falls to the top end of the wire groove in the arranging process, the uniformity of the follow-up wire arranging height is affected, in addition, the bearing block comprises a deformation block and a fixing piece, when the deformation block is pressed, power is cut off, the deformation block deforms to wrap the side edge of the flat wire and then is cured, the bent state of the flat wire is maintained, and then the clamping state is maintained.

Description

Technical Field

[0001] The present invention relates to a winding arrangement structure of an electric motor, and particularly to a flat wire winding arrangement structure of an electric motor applied to the field of flat wire motors. Background Art

[0002] The flat wire winding of an electric motor is an electric motor coil wound with flat wires (flat wires). Different from the traditional round wire winding, the shape of the flat wire is a rectangular or approximately rectangular cross-section. This shape enables the windings to be arranged more closely in the motor slots. Due to the high filling factor and good heat dissipation performance, the efficiency of the flat wire winding motor is significantly improved.

[0003] The specification of Chinese invention patent CN117318359B discloses a multi-phase flat wire motor winding lead-out structure, which adopts the above-mentioned winding method structure of a multi-layer busbar to shorten the axial distance of the motor, so that the end space of the motor is fully utilized, reducing the phenomenon of space waste, and finally realizing the shortening of the size in the length direction of the motor, which is beneficial to the miniaturization of the motor. In addition, the specification of CN117997010B discloses a heat transfer structure and its manufacturing method of a concentrated winding flat wire stator, which transfers the heat of the flat wire winding to the stator yoke through a segmented iron core and a heat conducting wedge block for heat dissipation, thereby improving its heat dissipation effect, and the device is convenient to assemble, does not require welding, and is firmly fixed.

[0004] When the existing flat wire arrangement structure is working, the neutral points and lead-out positions of the parallel branches are scattered and have a large span, and a lot of transition copper bars are required for connection, increasing the material consumption and cost. Moreover, the solder joints of the hairpin winding, the phase copper bar, and the star point row are arranged on both sides of the stator core, increasing the axial length and the cost of the welding tooling. Therefore, the solder joints are scattered, which is not conducive to centralized welding and the production efficiency is low. Summary of the Invention

[0005] Aiming at the above-mentioned prior art, the technical problem to be solved by the present invention is to solve the problems of large winding span and scattered solder joints during the arrangement of the flat wire winding, and to achieve cost control and production efficiency improvement.

[0006] To solve the above problems, the present invention provides a flat wire winding arrangement structure for an electric motor, which includes an iron core. Inside the iron core, there are several wire grooves. The inner wall of the wire groove is arranged with insulating paper, and flat wires are inserted inside the insulating paper. The flat wires are U-shaped inserted in the wire groove, and multiple flat wires form a coil. Star point rows are arranged on both the inner side and the outer side of the coil. Among them, on the surface of the inner star point row, three phase copper bars arranged adjacent to each other are arranged. The top of the wire groove is adhesively bonded with a restraint member having a U-shaped cross-section. On both top ends of the restraint member, side plates and a restraint unit located in the middle of the side plates are installed, and two adjacent restraint units are symmetrically arranged along the axial direction of the restraint member. The restraint unit includes a pressing block that slidably fits on the top surface of the restraint member. The top of the restraint member is connected with a receiving block through a vertically arranged first spring member. The surface of the pressing block and the surface of the side plate are connected through a second spring member. The restraint unit further includes a fixing block fixedly installed on the top of the restraint member, and the fixing block and the receiving block are axially symmetrically arranged with respect to the restraint member.

[0007] In the above flat wire winding arrangement structure of the electric motor, during the arrangement process of the flat wire winding, the problems of large winding span and scattered solder joints can be solved, and cost control and production efficiency improvement can also be achieved.

[0008] As a further improvement of the present application, both the pressing block and the receiving block are wedge-shaped blocks, and the hypotenuse parts of the pressing block and the receiving block are parallel and fitted to each other.

[0009] As a further improvement of the present application, the inner cross-sectional width of the restraint member is the same as the cross-sectional width value of the flat wire, and the surface of the side of the fixing block close to the receiving block is on the same vertical line as the inner cross-section of the restraint member.

[0010] As a further improvement of the present application, when the flat wire is arranged, both end parts extending out of a single wire groove are bent, and the first bending part located above the wire groove is above the receiving block.

[0011] As a further improvement of the present application, the glue is a peelable glue, and the insulating paper is adhesively bonded to the inner wall of the wire groove through a thermally conductive insulating glue.

[0012] As a further improvement of the present application, the cross-sectional length value of the receiving block is the same as the cross-sectional width value of the flat wire, and the projection of the end part of the restraint member close to the center of the iron core in the vertical direction is within the vertical projection of the wire groove.

[0013] As another improvement of the present application, the receiving block includes a deformable block. The bottom of the deformable block is connected with a fixing member, and the bottom of the fixing member is connected with a movable magnetic rod that slidably penetrates the top of the restraint member. An electromagnetic ring matching the movable magnetic rod is installed inside the restraint member.

[0014] As another supplementary improvement of the present application, the deformation block includes an elastic bag made of memory rubber. A conductive wire and an electrorheological fluid are arranged inside the elastic bag. A pressure sensor is installed on the surface of the elastic bag, and the power supply of the conductive wire is signal-connected to the pressure sensor.

[0015] As another supplementary improvement of the present application, the deformation block is in a powered-on state in the initial state, and the cross-sectional length values of the deformation block and the fixing member in the initial state are both greater than the cross-sectional width value of the flat wire.

[0016] In summary, the winding arrangement structure of the present application includes an iron core, a wire groove, insulating paper, flat wires, phase copper bars, and a star point row. The star point row is arranged on the inner and outer sides of the coil. The phase copper bars are designed in a general way, reducing costs. The welding ends of the coils are on the same side as the phase copper bars and the star point row, without I-pins, which can shorten the axial length of the motor, save welding time, the number of toolings, and costs. When the flat wires are bent, the pressing deformation drives the extrusion block to approach the surface of the flat wires in the wire groove. With the approach of the extrusion block and the cooperation of the fixing block, the flat wires can be constrained and limited, so as to prevent the bent parts of the flat wires from falling to the top of the wire groove during the arrangement process, affecting the unity of the subsequent wire arrangement height. In addition, the receiving block includes a deformation block and a fixing member. When the deformation block is pressed, the power is cut off, and after deforming and wrapping the side of the flat wire, it is cured to maintain the bent state of the flat wire, and then maintain the clamping state. Description of the Drawings

[0017] Figure 1 Installation diagram of the iron core, flat wires, phase copper bars, and star point row of the first embodiment of the present application; Figure 2 Installation diagram of the iron core and wire groove of the first embodiment of the present application; Figure 3 Schematic diagram of the arrangement state of the flat wires of the first embodiment of the present application; Figure 4 State diagram of the insulating paper and multiple flat wires in the same wire groove of the first embodiment of the present application; Figure 5 Structure diagram of the phase copper bar of the first embodiment of the present application; Figure 6 Structure diagram of the star point row of the first embodiment of the present application; Figure 7 Top view of the insulating paper in the wire groove of the first embodiment of the present application; Figure 8 Installation schematic diagram of the constraint member and the flat wire of the first embodiment of the present application; Figure 9 Structure diagram of the constraint member of the first embodiment of the present application; Figure 10 Of the first embodiment of the present application Figure 9A in the enlarged view; Figure 11 This is a schematic diagram of the working state of the restraining member of the second embodiment of the present application; Figure 12 This is an installation diagram of a deformation block, a movable magnetic rod and an electromagnetic ring according to a second embodiment of the present application; Figure 13 This is a process diagram of the second embodiment of the present application where the deformation block covers the side of the flat wire to maintain the bending state.

[0018] Description of the numbers in the figure: 1. Iron core; 101. Wire trough; 2. Flat wire; 3. Phase copper bar; 4. Star point bar; 5. Insulating paper; 6. Restraint; 7. Acceptor block; 8. Side plate; 9. Extrusion block; 10. Spring part No. 1; 11. Spring part No. 2; 12. Fixed block; 71. Deformation block; 72. Fixed part; 73. Movable magnetic rod; 74. Electromagnetic ring. DETAILED DESCRIPTION

[0019] Two implementation modes of the present application are described in detail below with reference to the accompanying drawings.

[0020] The first implementation method: Figures 1-7 A motor flat wire winding arrangement structure is shown, including an iron core 1, a plurality of wire slots 101 are provided inside the iron core 1, the inner wall of the wire slots 101 is arranged with insulating paper 5, a flat wire 2 is inserted into the inner side of the insulating paper 5, the flat wire 2 is inserted into the wire slots 101 in a U-shape, a plurality of flat wires 2 form a coil, star point rows 4 are arranged on the inner and outer sides of the coil, wherein three adjacently arranged phase copper bars 3 are arranged on the surface of the inner star point row 4.

[0021] Specifically, in the present application, the lead-out wires of multiple parallel branches of each phase in the multi-phase winding are arranged relatively concentratedly, which reduces the material usage and cost; The neutral points of multiple parallel branches of the multi-phase winding, that is, the star point row 4, are centrally arranged, so that welding can be centralized to improve production efficiency; The multi-phase lead-out copper bar, i.e., the phase copper bar 3, is designed into a universal structure, and the lead-out ends of each branch distributed on the inner and outer diameters of the winding are welded in phase-bridge manner, which reduces the overall height of the winding end, reduces the amount of transfer copper bars, and reduces the mold and product costs; In addition, the welding ends of the windings are arranged on the same side as the phase copper bar 3 and the star point bar 4. The windings are all composed of U-pins without I-pins. At the same time, the axial length of the motor can be shortened, saving welding time, tooling quantity and cost.

[0022] Figures 8-10It is shown that a U-shaped constraint member 6 is adhesively bonded to the top of the wire groove 101 with glue. Side plates 8 and a constraint unit located in the middle of the side plates 8 are installed at both top ends of the constraint member 6, and two adjacent constraint units are symmetrically arranged along the axial direction of the constraint member 6. The constraint unit includes an extrusion block 9 that slidably fits on the top surface of the constraint member 6. A receiving block 7 is connected to the top of the constraint member 6 through a vertically arranged first spring member 10. The surface of the extrusion block 9 and the surface of the side plate 8 are connected through a second spring member 11. The constraint unit further includes a fixed block 12 fixedly installed on the top of the constraint member 6, and the fixed block 12 and the receiving block 7 are axially symmetrically arranged with respect to the constraint member 6.

[0023] Both the extrusion block 9 and the receiving block 7 are wedge-shaped blocks, and the inclined sides of the extrusion block 9 and the receiving block 7 are parallel and in contact with each other.

[0024] The inner cross-sectional width of the constraint member 6 is the same as the cross-sectional width value of the flat wire 2, and the surface of the side of the fixed block 12 close to the receiving block 7 is on the same vertical line as the inner cross-section of the constraint member 6.

[0025] When the flat wire 2 is arranged, both end portions extending out of a single wire groove 101 are bent. The first bent portion located above the wire groove 101 is above the receiving block 7.

[0026] The cross-sectional length value of the receiving block 7 is the same as the cross-sectional width value of the flat wire 2, and the projection of one end of the constraint member 6 close to the center of the iron core 1 in the vertical direction is within the vertical projection of the wire groove 101.

[0027] Specifically, in this application, there is a certain height distance between the first bent portion of the flat wire 2 located above the wire groove 101 and the top end of the wire groove 101. When arranging the windings, when the flat wire 2 extends out of a single wire groove 101 and continues to make the first bending treatment upward, without a constraint structure, the flat wire 2 will fall to the top end of the wire groove 101 under the action of gravity (because the wire groove 101 can accommodate six flat wires 2, but the flat wires 2 need to be inserted into the wire groove 101 one by one. Therefore, after a single flat wire 2 enters and extends out of the wire groove 101, without a constraint and limiting structure, the flat wire 2 will fall, resulting in the lack of height difference between the first bent portion and the top end of the wire groove 101). Due to the existence of the constraint member 6, when bending the first bent portion above the wire groove 101 at the end of the flat wire 2, due to the extrusion effect, the receiving block 7 will descend, and then drive the extrusion block 9 to approach the surface of the flat wire 2 in the wire groove 101. With the approach of the extrusion block 9 and the cooperation of the fixed block 12, the flat wire 2 can be constrained and limited (as Figure 11 shown) to prevent the subsequent falling of the flat wire 2.

[0028] The fixing block 12 and the receiving block 7 on the same side are arranged at intervals, which is suitable for the bending directions of the flat wires 2 at odd and even positions in the same wire groove 101 to be arranged in opposite directions. As Figure 4 shown, therefore, the symmetric arrangement of the constraint unit points can adapt to this state.

[0029] Moreover, since the tops of the constraint member 6 and the iron core 1 are for peelable bonding operation, after all the subsequent flat wires 2 are arranged, the constraint member 6 can be pulled out and separated from the surface of the iron core 1.

[0030] The glue is peelable glue, and the insulating paper 5 is adhesively bonded to the inner wall of the wire groove 101 through heat-conducting insulating glue.

[0031] Specifically, the insulating paper 5 is made of a heat-conducting and insulating material, taking into account both insulation protection and heat-conducting treatment. The heat-conducting insulating glue can strengthen the connection between the insulating paper 5 and the inner wall of the wire groove 101, and can also continue to play the role of insulation and heat conduction after the insulating paper 5 ages and fails, transferring the heat of the flat wires 2 in the wire groove 101 to the end of the iron core 1 for easy heat dissipation.

[0032] The second implementation method: Figure 12 It is shown that the receiving block 7 includes a deformation block 71. The bottom of the deformation block 71 is connected to a fixing member 72, and the bottom of the fixing member 72 is connected to a movable magnetic rod 73 that slidably penetrates the top of the constraint member 6. An electromagnetic ring 74 matching the movable magnetic rod 73 is installed inside the constraint member 6.

[0033] The deformation block 71 includes an elastic bag made of memory rubber. Conductive wires and electrorheological fluid are arranged inside the elastic bag. A pressure sensor is installed on the surface of the elastic bag, and the power supply of the conductive wires is signal-connected to the pressure sensor.

[0034] The deformation block 71 is in an energized state in the initial state, and the cross-sectional length values of the deformation block 71 and the fixing member 72 in the initial state are both greater than the cross-sectional width value of the flat wire 2.

[0035] Specifically, the flat wire 2 is usually an enameled wire, and generally will not recover after being bent by an external force. However, in the first implementation method, under the action of the first spring member 10, the bending of the flat wire 2 will be damaged to a certain extent. To prevent it from recovering, it is necessary to maintain the bent state for a period of time, which can not only ensure the clamping effect on the flat wire 2 (the bent state is maintained, the extrusion effect on the receiving block 7 is maintained, so that the extrusion effect between the extrusion block 9 and the fixing block 12 can be maintained).

[0036] To ensure the maintenance of the bent state, when the flat wire 2 bends and presses the deformation block 71, the deformation block 71 is under pressure. At this time, the conductive wire inside the deformation block 71 is powered off and thus becomes a non-solid state. As the bending action continues, the end of the deformation block 71 elongates and partially wraps the side of the flat wire 2, forming a structure similar to a U shape. Then, the conductive wire is powered on and solidified. Through the friction and wrapping action between the elastic bag and the surface of the flat wire 2, the bent state of the flat wire 2 is maintained. And at this time, as the bending operation causes the fixing part 72 and the movable magnetic rod 73 to descend, while driving the extrusion block 9 to perform extrusion, the electromagnetic ring 74 is activated, and the falling movable magnetic rod 73 is adsorbed by the electromagnetic ring 74, so that the descending state of the receiving block 7 is maintained and the bent state of the flat wire 2 is maintained by the deformation block 71 (as Figure 13 shown).

[0037] In summary, the winding arrangement structure of the present invention includes an iron core 1, a wire groove 101, an insulating paper 5, a flat wire 2, a phase copper row 3, and a star point row 4. The star point row 4 is arranged on the inner and outer sides of the coil. The phase copper row 3 is designed to be universal, reducing costs. The welding ends of the coil are on the same side as the phase copper row 3 and the star point row 4, without I-pins, which can shorten the axial length of the motor, save welding time, the number of toolings, and costs. When the flat wire 2 bends, the downward pressing deformation drives the extrusion block 9 to approach the surface of the flat wire 2 in the wire groove 101. With the approach of the extrusion block 9 and the cooperation of the fixing block 12, the flat wire 2 can be constrained and limited, so as to prevent the bent part of the flat wire 2 from falling to the top of the wire groove 101 during the arrangement process, affecting the unity of the subsequent wire arrangement height. In addition, the receiving block 7 includes a deformation block 71 and a fixing part 72. When the deformation block 71 is under pressure, it is powered off, deforms and wraps the side of the flat wire 2 and then solidifies, maintaining the bent state of the flat wire 2 and thus maintaining the clamping state.

[0038] Combined with the current actual requirements, the above-mentioned implementation manner adopted in this application, the scope of protection is not limited to this. Within the knowledge possessed by those skilled in the art, various changes made without departing from the concept of this application still fall within the protection scope of the present invention.

Claims

1. A motor flat wire winding arrangement structure, comprising an iron core (1), wherein a plurality of wire slots (101) are provided inside the iron core (1), an inner wall of the wire slot (101) is provided with insulating paper (5), and a flat wire (2) is inserted into the inner side of the insulating paper (5), characterized in that: The flat wire (2) is plugged into the wire slot (101) in a U-shape, and a plurality of the flat wires (2) form a coil. The inner and outer sides of the coil are both arranged with star point rows (4), wherein the surface of the inner star point row (4) is arranged with three adjacently arranged phase copper bars (3). The top of the wire slot (101) is glued with a restraining member (6) with a U-shaped cross section, and the top ends of both sides of the restraining member (6) are both installed with side plates (8) and restraining units located in the middle of the side plates (8), and the restraining members (6) are adjacently connected along the axis direction of the restraining member (6). The two constraint units are arranged point-symmetrically, the constraint unit comprising an extrusion block (9) slidably fitted with the top surface of the constraint member (6), the top of the constraint member (6) is connected to a receiving block (7) via a vertically arranged No. 1 spring member (10), the surface of the extrusion block (9) is connected to the surface of the side plate (8) via a No. 2 spring member (11), the constraint unit further comprising a fixed block (12) fixedly mounted on the top of the constraint member (6), and the fixed block (12) and the receiving block (7) are arranged symmetrically about the axis of the constraint member (6).

2. The motor flat wire winding arrangement structure according to claim 1, characterized in that: The extrusion block (9) and the receiving block (7) are both wedge-shaped blocks, and the oblique edges of the extrusion block (9) and the receiving block (7) are parallel to and fit with each other.

3. The motor flat wire winding arrangement structure according to claim 1, characterized in that: The inner cross-sectional width of the restraining member (6) is the same as the cross-sectional width of the flat wire (2), and a surface of one side of the fixing block (12) close to the receiving block (7) is on the same vertical line as the inner cross-sectional width of the restraining member (6).

4. The motor flat wire winding arrangement structure according to claim 1, characterized in that: When the flat wire (2) is arranged, both end portions extending out of a single wire slot (101) are bent, wherein the first bent portion located above the wire slot (101) is located above the receiving block (7).

5. The motor flat wire winding arrangement structure according to claim 1, characterized in that: The glue is a peelable glue, and the insulating paper (5) is glued to the inner wall of the cable duct (101) by means of the heat-conductive insulating glue.

6. The motor flat wire winding arrangement structure according to claim 1, characterized in that: The cross-sectional length of the receiving block (7) is the same as the cross-sectional width of the flat wire (2), and the projection in the vertical direction of an end of the restraining member (6) close to the center of the iron core (1) is located within the projection in the vertical direction of the wire slot (101).

7. The motor flat wire winding arrangement structure according to claim 1, characterized in that: The receiving block (7) comprises a deformable block (71), the bottom of the deformable block (71) is connected to a fixing member (72), the bottom of the fixing member (72) is connected to a movable magnetic rod (73) that slides through the top of the restraining member (6), and an electromagnetic ring (74) that matches the movable magnetic rod (73) is installed inside the restraining member (6).

8. The motor flat wire winding arrangement structure according to claim 7, characterized in that: The deformation block (71) comprises an elastic bag made of memory rubber, a conductive wire and an electrorheological fluid are arranged inside the elastic bag, a pressure sensor is installed on the surface of the elastic bag, and a power supply of the conductive wire is connected to a signal of the pressure sensor.

9. The motor flat wire winding arrangement structure according to claim 8, characterized in that: The deformation block (71) is in an energized state in an initial state, and the cross-sectional length values ​​of the deformation block (71) and the fixing member (72) in the initial state are both greater than the cross-sectional width value of the flat wire (2).

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