A motor flat wire winding arrangement structure

Abstract

The present 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, a wire slot, insulating paper, a flat wire, a phase copper bar and a star point bar, the star point bar is arranged inside and outside the coil, the phase copper bar is designed to be universal, reducing costs, the welding end of the coil is on the same side as the phase copper bar and the star point bar, and there is no I‑pin, which can shorten the axial length of the motor, save welding time, the number of tooling and costs, and when the flat wire is bent, the downward pressure deformation effect is utilized to drive the extrusion block to approach the surface of the flat wire in the wire slot, and with the approach of the extrusion block and the cooperation of the fixing block, the flat wire can be constrained and limited, so as to prevent the bent part of the flat wire from falling to the top of the wire slot during the arrangement process, affecting the uniformity of the subsequent wiring height, and the receiving block includes a deformation block and a fixing part, when the deformation block is pressed, the power is cut off, and the deformation covers the side of the flat wire and solidifies, thereby maintaining the bent state of the flat wire and then maintaining the clamping state.

Description

Technical Field

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

[0002] Flat wire motor windings are motor coils wound with flat conductors (flat wire). Unlike traditional round wire windings, flat wire has a rectangular or nearly rectangular cross-section. This shape allows the windings to be arranged more tightly within the motor slots. Due to the high fill factor and excellent heat dissipation, flat wire winding motors significantly improve efficiency.

[0003] The specification of Chinese invention patent CN117318359B discloses a multi-phase flat wire motor winding output structure, which adopts the above-mentioned multi-layer busbar winding structure to shorten the axial distance of the motor, so that the space at the end of the motor is fully utilized, reducing space waste, and ultimately achieving a shortened size in the length direction of the motor, which is conducive to the miniaturization of the motor. In addition, the specification of CN117997010B discloses a heat transfer structure of a concentrated winding flat wire stator and its manufacturing method, 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. The device is easy to assemble, does not require welding, and is firmly fixed.

[0004] When the existing flat wire arrangement structure is working, the neutral point and lead wire of the parallel branch are scattered and have a large span, requiring many transfer copper bars to connect them, which increases material consumption and cost. In addition, the welding points of the hairpin winding and the phase copper bars and star point bars are arranged on both sides of the stator core, increasing the axial length and welding tooling costs. As a result, the welding points are scattered, which is not conducive to centralized welding and has low production efficiency. Summary of the Invention

[0005] In view of 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 flat wire windings, thereby achieving cost control and improving production efficiency.

[0006] To solve the above problems, the present invention provides a motor flat wire winding arrangement structure, including an iron core, a plurality of wire slots are provided inside the iron core, the inner wall of the wire slot is arranged with insulating paper, and a flat wire is inserted into the inner side of the insulating paper, and the flat wire is inserted in a U-shape in the wire slot. A plurality of flat wires form a coil, and a star point row is arranged on the inner and outer sides of the coil, wherein the surface of the inner star point row is arranged with three adjacent phase copper bars, and a constraint member with a U-shaped cross-section is glued to the top of the wire slot by glue, and side plates and a constraint unit located in the middle of the side plates are installed on the top ends of both sides of the constraint member, and two adjacent constraint units are point-symmetrically arranged along the axis direction of the constraint member, and the constraint unit includes an extrusion block that slides in contact with the top surface of the constraint member, and the top of the constraint member is connected to a receiving block through a vertically arranged No. 1 spring member, and the surface of the extrusion block is connected to the surface of the side plate through a No. 2 spring member. The constraint unit also includes a fixed block fixedly installed on the top of the constraint member, and the fixed block and the receiving block are arranged symmetrically about the constraint member axis.

[0007] In the above-mentioned motor flat wire winding arrangement structure, the flat wire winding can solve the problems of large winding span and scattered welding points during the arrangement process, and can also achieve cost control and improvement of production efficiency.

[0008] As a further improvement of the present application, the extrusion block and the receiving block are both wedge-shaped blocks, and the oblique sides of the extrusion block and the receiving block are parallel and fit together.

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

[0010] As a further improvement of the present application, when the flat wire is arranged, both end portions extending out of a single wire trough are bent, wherein the first bent portion located above the wire trough is located above the receiving block.

[0011] As a further improvement of the present application, the glue is a peelable glue, and the insulating paper is glued to the inner wall of the cable duct by a thermally conductive insulating glue.

[0012] As a further improvement of the present application, the cross-sectional length of the receiving block is the same as the cross-sectional width of the flat wire, and the vertical projection of one end of the restraint close to the center of the core is located within the vertical projection of the wire slot.

[0013] As another improvement of the present application, the receiving block includes a deformable block, the bottom of the deformable block is connected to a fixing part, and the bottom of the fixing part is connected to a movable magnetic rod that slides through the top of the restraining part, and an electromagnetic ring matching the movable magnetic rod is installed inside the restraining part.

[0014] As another improved supplement to the present application, the deformation block includes an elastic bag made of memory rubber, conductive wire 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 wire is connected to the pressure sensor signal.

[0015] As another improved supplement of the present application, the deformation block is in an energized 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] To summarize, the winding arrangement structure includes an iron core, a wire slot, insulating paper, a flat wire, a phase copper bar and a star point bar. The star point bar is arranged inside and outside the coil. The phase copper bar is universally designed to reduce costs. The welding end of the coil is on the same side as the phase copper bar and the star point bar. There is no I-pin, which can shorten the axial length of the motor, save welding time, the number of tooling and costs, and when the flat wire is bent, the downward pressure deformation effect is used to drive the extrusion block to approach the surface of the flat wire in the wire slot. As the extrusion block approaches and the fixing block cooperates, the flat wire can be constrained and limited to prevent the bent part of the flat wire from falling to the top of the wire slot during the arrangement process, affecting the uniformity of the subsequent wiring height. In addition, the receiving block includes a deformation block and a fixing part. When the deformation block is under pressure, it is powered off, deformed to cover the side of the flat wire and then solidified, maintaining the bent state of the flat wire, and then maintaining the clamping state. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 This is an installation diagram of the iron core, flat wire, phase copper busbar, and star point busbar of the first embodiment of the present application;

[0018] Figure 2 This is the installation diagram of the core and wire slot of the first embodiment of this application;

[0019] Figure 3 This is a schematic diagram of the arrangement of the flat wires according to the first embodiment of the present application;

[0020] Figure 4 This is a state diagram of the insulating paper and multiple flat wires in the same wire trough according to the first embodiment of the present application;

[0021] Figure 5 This is a diagram of the phase copper busbar structure of the first embodiment of this application;

[0022] Figure 6 This is a star point array structure diagram of the first embodiment of this application;

[0023] Figure 7 This is a top view of the insulating paper in the wire slot according to the first embodiment of the present application;

[0024] Figure 8 This is a schematic diagram of the installation of the restraining member and the flat wire according to the first embodiment of the present application;

[0025] Figure 9 This is a structural diagram of a restraining member according to a first embodiment of the present application;

[0026] Figure 10 For the first embodiment of this application Figure 9 A magnified view of point A in the figure;

[0027] Figure 11 This is a schematic diagram of the working state of the restraint member of the second embodiment of the present application;

[0028] Figure 12 This is an installation diagram of the deformation block, movable magnetic rod and electromagnetic ring according to the second embodiment of the present application;

[0029] Figure 13 This is a diagram showing the process of the deformation block covering the side of the flat wire to maintain the bent state according to the second embodiment of the present application.

[0030] Description of the numbers in the figure:

[0031] 1. Iron core; 101. Wire duct; 2. Flat wire; 3. Phase copper busbar; 4. Star point busbar; 5. Insulation paper; 6. Restraint; 7. Adapter block; 8. Side plate; 9. Extrusion block; 10. Spring member No. 1; 11. Spring member No. 2; 12. Fixing block; 71. Deformation block; 72. Fixing member; 73. Movable magnetic rod; 74. Electromagnetic ring. DETAILED DESCRIPTION

[0032] Two implementation modes of the present application are described in detail below with reference to the accompanying drawings.

[0033] The first implementation method:

[0034] Figure 1-Figure 7 A motor flat wire winding arrangement structure is shown, including an iron core 1, with several wire slots 101 provided inside the iron core 1. Insulation paper 5 is arranged on the inner wall of the wire slot 101, and flat wires 2 are inserted into the inner side of the insulating paper 5. The flat wires 2 are inserted into the wire slot 101 in a U-shape. Multiple flat wires 2 form a coil, and star point rows 4 are arranged on the inner and outer sides of the coil, wherein three adjacent phase copper bars 3 are arranged on the surface of the inner star point row 4.

[0035] Specifically, in the present application, the lead wires of multiple parallel branches of each phase in the multi-phase winding are arranged relatively centrally, reducing material usage and cost;

[0036] The neutral points of multiple parallel branches of the multi-phase winding, that is, the star point row 4, are centrally arranged, which allows for centralized welding and improves production efficiency;

[0037] The multi-phase lead copper bar, also known as phase copper bar 3, is designed into a universal structure, and the branch lead ends distributed on the inner and outer diameters of the winding are welded in a phase-by-phase bridge-type manner, which reduces the overall height of the winding end, reduces the amount of transfer copper bar, and reduces mold and product costs;

[0038] 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 composed entirely 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.

[0039] Figures 8-10 It is shown that a restraint member 6 with a U-shaped cross-section is glued to the top of the wire trough 101 by glue, and side panels 8 and a restraint unit located in the middle of the side panels 8 are installed on the top of both sides of the restraint member 6, and two adjacent restraint units are point-symmetrically arranged along the axial direction of the restraint member 6. The restraint unit includes an extrusion block 9 that slides in contact with the top surface of the restraint member 6, and the top of the restraint member 6 is connected to the receiving block 7 through a vertically arranged No. 1 spring member 10. The surface of the extrusion block 9 is connected to the surface of the side panel 8 through a No. 2 spring member 11. The restraint unit also includes a fixed block 12 fixedly installed on the top of the restraint member 6, and the fixed block 12 and the receiving block 7 are arranged symmetrically about the axis of the restraint member 6.

[0040] The extrusion block 9 and the receiving block 7 are both wedge-shaped blocks, and the oblique sides of the extrusion block 9 and the receiving block 7 are parallel to and fit together.

[0041] The inner cross-sectional width of the restraining member 6 is the same as the cross-sectional width of the flat wire 2 , and the surface 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 .

[0042] When the flat wire 2 is arranged, both end portions extending out of a single wire groove 101 are bent, wherein the first bent portion located above the wire groove 101 is located above the receiving block 7 .

[0043] The cross-sectional length of the receiving block 7 is the same as the cross-sectional width of the flat wire 2 , and the vertical projection of the end of the restraining member 6 close to the center of the core 1 is located within the vertical projection of the wire slot 101 .

[0044] Specifically, in the present application, the first bending portion of the flat wire 2 located above the wire slot 101 is at a certain height distance from the top of the wire slot 101. When the winding is arranged, the flat wire 2 extends out of a single wire slot 101 and continues to be bent upwards for the first time. If there is no restraining structure, the flat wire 2 will fall to the top of the wire slot 101 under the action of gravity (because the wire slot 101 can accommodate six flat wires 2, but the flat wires 2 need to be inserted into the wire slot 101 one by one, so when a single flat wire 2 enters the wire slot 101, After being extended, if there is no restraining and limiting structure, the flat wire 2 will fall, resulting in the loss of the height difference between the first bent portion and the top of the wire groove 101). Due to the existence of the restraining member 6, when the first bending portion above the wire groove 101 is bent at the end of the flat wire 2, the receiving block 7 will be lowered due to the extrusion effect, thereby driving the extrusion block 9 to approach the surface of the flat wire 2 in the wire groove 101. As the extrusion block 9 approaches and the fixing block 12 cooperates, the flat wire 2 can be restrained and limited (such as Figure 11 as shown), to avoid the subsequent flat wire 2 from falling.

[0045] The fixing block 12 and the receiving block 7 on the same side are arranged at intervals, which is suitable for arranging the bending directions of the odd-numbered and even-numbered flat wires 2 in the same wire slot 101 in opposite directions, such as Figure 4 As shown, the point-symmetrical arrangement of the constraint units can adapt to this state.

[0046] Furthermore, since the restraining member 6 and the top of the core 1 are bonded in a removable manner, the restraining member 6 can be pulled out and separated from the surface of the core 1 after all the flat wires 2 are subsequently arranged.

[0047] 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 thermally conductive insulating glue.

[0048] Specifically, the insulating paper 5 is made of a thermally conductive insulating material, which takes into account both insulation protection and thermal conductivity treatment. The thermally conductive insulating glue can strengthen the connection between the insulating paper 5 and the inner wall of the wire groove 101. It can also continue to play the role of insulation and heat conduction after the insulating paper 5 ages and fails, and transfer the heat of the flat wire 2 in the wire groove 101 to the end of the iron core 1 to facilitate heat dissipation.

[0049] Second implementation method:

[0050] Figure 12 It is shown that the receiving block 7 includes a deformable block 71, the bottom of the deformable block 71 is connected to a fixing part 72, and the bottom of the fixing part 72 is connected to a movable magnetic rod 73 that slides through the top of the restraining part 6, and an electromagnetic ring 74 matching the movable magnetic rod 73 is installed inside the restraining part 6.

[0051] The deformation block 71 includes an elastic bag made of memory rubber, with conductive wires and electrorheological fluid 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 connected to the pressure sensor signal.

[0052] The deformable block 71 is in an energized state in the initial state, and the cross-sectional lengths of the deformable block 71 and the fixing member 72 in the initial state are both greater than the cross-sectional width of the flat wire 2 .

[0053] Specifically, the flat wire 2 is usually an enameled wire, which will not recover in the normal state after being bent by an external force. However, in the first embodiment, under the action of the No. 1 spring member 10, the bending of the flat wire 2 will be damaged to a certain extent. In order to prevent it from recovering, it is necessary to maintain the bent state for a period of time, which can ensure the clamping effect on the flat wire 2 (the bent state is maintained, and the extrusion effect on the receiving block 7 is maintained, so that the extrusion effect of the extrusion block 9 and the fixed block 12 can be maintained).

[0054] To ensure that the bending state is maintained, when the flat wire 2 is bent and squeezed against the deformation block 71, the deformation block 71 is subjected to pressure. At this time, the conductive wire in the deformation block 71 is de-energized, thus becoming a non-solid state. As the bending action continues, the end of the deformation block 71 stretches and partially covers the side of the flat wire 2, forming a U-shaped structure. Thereafter, the conductive wire is energized and solidified. The bending state of the flat wire 2 is maintained by the friction and covering effect between the elastic bag and the surface of the flat wire 2. At this time, as the bending operation causes the fixing member 72 and the movable magnetic rod 73 to descend, driving the squeezing block 9 to squeeze, the electromagnetic ring 74 is started, and the falling movable magnetic rod 73 is attracted to the electromagnetic ring 74, so that the descending state of the receiving block 7 is maintained and the bending state of the flat wire 2 is maintained by the deformation block 71 (such as Figure 13 shown).

[0055] In summary, the winding arrangement structure includes an iron core 1, a wire slot 101, insulating paper 5, a flat wire 2, a phase copper bar 3 and a star point bar 4. The star point bar 4 is arranged inside and outside the coil. The phase copper bar 3 is of universal design to reduce costs. The welding end of the coil is on the same side as the phase copper bar 3 and the star point bar 4. There is no I-pin, which can shorten the axial length of the motor, save welding time, the number of tooling and costs, and when the flat wire 2 is bent, the downward pressure deformation effect is used to drive the extrusion block 9 to approach the surface of the flat wire 2 in the wire slot 101. As the extrusion block 9 approaches and the fixing block 12 cooperates, 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 slot 101 during the arrangement process, affecting the uniformity of the subsequent wiring 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, deformed to cover the side of the flat wire 2 and then solidified, maintaining the bent state of the flat wire 2, and then maintaining the clamping state.

[0056] In view of current actual needs, the protection scope of the above-mentioned implementation mode adopted in this application is not limited to this. Various changes made within the knowledge scope of technical personnel in this field 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 slots (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 inserted in a U-shaped manner in the wire slot (101), and a plurality of the flat wires (2) form a coil. A star point row (4) is arranged on the inner and outer sides of the coil, 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. The top ends of both sides of the restraining member (6) are both installed with side plates (8) and a restraining unit located in the middle of the side plates (8), and the restraining members (6) are adjacent to each other in the axial direction of the restraining member (6). The two constraint units are arranged point-symmetrically, the constraint unit comprising an extrusion block (9) slidingly fitted with the top surface of the constraint member (6), the top of the constraint member (6) being connected to a receiving block (7) via a vertically arranged No. 1 spring member (10), the surface of the extrusion block (9) being 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) being 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 sides of the extrusion block (9) and the receiving block (7) are parallel to and fit together.

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 the 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 trough (101) are bent, wherein the first bent portion located above the wire trough (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 wire duct (101) through the heat-conducting 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 vertical projection of one end of the restraining member (6) close to the center of the iron core (1) is located within the vertical projection 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), and 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 pressure sensor signal.

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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