Fully-immersed oil-cooled winding stator assembly

Abstract

The invention relates to the technical field of motor cooling structures, in particular to a fully-immersed oil-cooled winding stator assembly, which comprises a shell, an end cover, a stator iron core, a winding and an oil collecting ring component, an oil inlet and a shell oil outlet are formed in the shell, the end cover is positioned at the side part of the shell, the stator iron core is assembled in the shell, and the oil collecting ring component is arranged in the shell. An oil channel is arranged in the stator core and is communicated with the oil inlet. Cooling oil is guided into the oil duct through the oil inlet, and is conveyed through the oil duct and enters the oil collecting ring assembly through the stator core oil outlet, so that the winding in the oil collecting ring assembly is immersed in the cooling oil, and the cooling oil can flow to the joint of the stator core and the winding in the oil collecting ring assembly, namely the area in the winding groove. Therefore, global cooling oil immersion of the winding is achieved, the heat dissipation uniformity of the winding is improved, the heat dissipation efficiency is also improved, local hot spots are effectively prevented from being formed, and the heat management problem under the high-load working condition is solved.

Description

Technical Field

[0001] The present invention relates to the field of motor cooling structures, and in particular to a fully immersed oil-cooled winding stator assembly. Background Art

[0002] The drive motors currently used in automobiles have high requirements for motor performance. In order to improve motor performance and increase motor power density to meet the growing market demand, it is necessary to continuously optimize the motor's heat dissipation performance to increase the peak power and rated power of the motor during operation.

[0003] In related technologies, different cooling solutions are required for motors in different usage scenarios and with different performance requirements, such as natural cooling, air cooling, water cooling, and oil cooling. Automotive-grade drive motors and generators are usually cooled by oil cooling. This is because oil-cooled motors can exchange internal heat in a timely manner, greatly improving the cooling efficiency compared to air-cooled and natural-cooled motors. However, in high-power-density motors, especially those used in commercial vehicle scenarios, the heat generated by the stator windings during motor operation is concentrated and difficult to dissipate effectively. This is because traditional oil cooling methods have limited heat dissipation efficiency and are mostly localized spraying or end-to-end oil immersion. This makes it difficult to meet the thermal management requirements under continuous high-load conditions. The cooling effect on the winding area in the slot is poor, and local hot spots are easily formed, which will affect the overall performance and life of the motor.

[0004] Based on the above background, a fully immersed oil-cooled winding stator assembly is proposed to solve the problems raised. Summary of the Invention

[0005] Other features and advantages of the present invention will be described in the following description, and in part will become apparent from the description, or will be understood by practicing the present invention. The purpose and other advantages of the present invention can be realized and obtained through the structures particularly pointed out in the description and other drawings.

[0006] The purpose of the present invention is to overcome the above-mentioned shortcomings and provide a fully immersed oil-cooled winding stator assembly.

[0007] To achieve the above objectives, the technical solution of the present invention is: a fully immersed oil-cooled winding stator assembly, including: a shell, an end cover, a stator core, a winding, and an oil collecting ring assembly. The shell is provided with an oil inlet and a shell oil outlet. The end cover is located on the side of the shell. The stator core is fitted into the shell. An oil channel is arranged in the stator core and is connected to the oil inlet. Oil collecting ring assemblies are provided on the front and back sides of the shell and are located on both sides of the stator core. The winding is installed in the stator core and passes through both sides to enter the oil collecting ring assemblies respectively. Both sides of the oil channel are provided with stator core oil outlets and face the oil collecting ring assemblies.

[0008] In some embodiments, the oil passages in the stator core are labyrinth-type oil passages.

[0009] In some embodiments, the oil collecting ring assembly includes an inner ring, an outer ring, a baffle, an oil collecting ring oil outlet, and an immersion chamber. One side of the baffle is connected to the inner ring and the other side is connected to the outer ring. Several oil collecting ring oil outlets are opened on the baffle. The gap between the inner ring and the outer ring forms an immersion chamber. The side of the winding is located in the immersion chamber, and the oil in the immersion chamber is introduced through the iron core oil outlet.

[0010] In some embodiments, a plurality of oil guide grooves are provided on the inner ring and located inside the winding, the oil guide grooves are directed toward the teeth of the stator core, and slot wedges are installed outside the teeth of the stator core.

[0011] In some embodiments, a plurality of buckles are installed on the outer ring, and buckle grooves for the buckles to be snapped into are provided inside the shell.

[0012] In some embodiments, a sealing ring groove is provided on the outer side of the outer ring, and a sealing ring that cooperates with the sealing ring groove is installed in the housing.

[0013] In some embodiments, an oil collecting ring groove is provided on the outer ring of the oil collecting ring assembly on the front side of the housing, and a housing boss is installed at the front end of the housing to enter the oil collecting ring groove.

[0014] In some embodiments, an oil collecting ring boss is installed on the outer ring of the oil collecting ring assembly on the rear side of the shell, and a shell boss for the oil collecting ring boss to enter is opened at the rear end of the shell.

[0015] In some embodiments, a waist-shaped hole is provided on the outer ring of the oil collecting ring assembly on the rear side of the shell, and the waist-shaped hole is sealed by a sealing gasket, and a wire hole is provided on the sealing gasket.

[0016] In some embodiments, an end cover on the side of the housing is close to a side where the rear oil collecting ring assembly is provided, and a junction box is installed on the end cover.

[0017] By adopting the above technical solution, the beneficial effects of the present invention are as follows: the cooling oil of the present invention is introduced into the oil channel through the oil inlet, and is transported through the oil channel and enters the oil collecting ring assembly through the oil outlet of the stator core, so that the winding in the oil collecting ring assembly is immersed in the cooling oil. The cooling oil can flow to the junction of the stator core and the winding in the oil collecting ring assembly, that is, the area inside the winding slot, thereby realizing the full-area cooling oil immersion of the winding, improving the heat dissipation uniformity of the winding, and the heat dissipation efficiency will also be improved, effectively preventing the formation of local hot spots, thereby solving the thermal management problem under high load conditions.

[0018] It is to be understood that the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the disclosure.

[0019] Undoubtedly, these and other objects of the present invention will become more apparent after the following detailed description of the preferred embodiment is described with reference to the various figures and drawings.

[0020] In order to make the above-mentioned beneficial effects and other purposes, features and advantages of the present invention more obvious and easy to understand, one or several preferred embodiments are given below and described in detail with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] The accompanying drawings are used to provide further understanding of the present invention and constitute a part of the specification. Together with the embodiments of the present invention, they are used to explain the present invention but do not constitute a limitation of the present invention.

[0022] In the drawings, like components are given like reference numerals, and the drawings are schematic and not necessarily drawn to scale.

[0023] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only one or several embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on such drawings without paying any creative work.

[0024] Description of main reference numerals: Figure 1 This is a schematic structural diagram of a fully immersed oil-cooled winding stator assembly from a first perspective of the present invention; Figure 2 This is a schematic structural diagram of a fully immersed oil-cooled winding stator assembly from a second perspective of the present invention; Figure 3 This is a schematic diagram of a half-section planar structure of a fully immersed oil-cooled winding stator assembly of the present invention; Figure 4 This is a schematic diagram of a half-section three-dimensional structure of a fully immersed oil-cooled winding stator assembly of the present invention; Figure 5 For the present invention Figure 5 Schematic diagram of the partially enlarged structure of A in FIG; Figure 6 This is a schematic diagram of the structure of the present invention without the winding; Figure 7 This is a schematic diagram of the structure of the present invention without the winding and oil collecting ring assembly; Figure 8 For the present invention Figure 8 Schematic diagram of the local enlarged structure of B in FIG; Figure 9 It is a structural schematic diagram of the slot wedge of the present invention; Figure 10This is a schematic structural diagram of the front oil collecting ring assembly of the present invention; Figure 11 This is a schematic structural diagram of the rear oil collecting ring assembly of the present invention; Figure 12 Schematic diagram of the structure of the stator core of the present invention; Figure 13 Schematic diagram of the structure of the end cover of the present invention.

[0025] Explanation of the main figure marks: housing-1, end cover-2, stator core-3, winding-4, oil collecting ring assembly-5, oil inlet-6, housing oil outlet-7, oil channel-8, stator core oil outlet-9, slot wedge-10, buckle groove-11, sealing ring-12, housing boss-13, housing boss-14, terminal box-15, inner ring-51, outer ring-52, baffle-53, oil collecting ring oil outlet-54, immersion chamber-55, oil guide groove-56, buckle-57, sealing ring groove-58, oil collecting ring groove-59, oil collecting ring boss-510, waist-shaped hole-511, sealing gasket-512. DETAILED DESCRIPTION

[0026] The following describes the embodiments of the present invention in detail with reference to the accompanying drawings and examples, so that the present invention can fully understand how to apply technical means to solve technical problems and achieve technical effects, and thus implement the invention accordingly. It should be noted that, as long as no conflict exists, the various embodiments of the present invention and the various features of the embodiments can be combined with each other, and the resulting technical solutions are all within the scope of protection of the present invention.

[0027] Meanwhile, in the following description, many specific details are set forth for the purpose of explanation to provide a thorough understanding of the embodiments of the present invention. However, it will be apparent to those skilled in the art that the present invention may be implemented without the specific details herein or the particular manner described.

[0028] See also Figure 1-12 The present invention provides a fully immersed oil-cooled winding stator assembly, comprising: a housing 1, an end cover 2, a stator core 3, a winding 4, and an oil collecting ring assembly 5. The housing 1 is provided with an oil inlet 6 and a housing oil outlet 7. The end cover 2 is located on the side of the housing 1. The stator core 3 is fitted into the housing 1. An oil passage 8 is arranged in the stator core 3 and is connected to the oil inlet 6. Oil collecting ring assemblies 5 are provided on the front and rear sides of the housing 1 and are located on both sides of the stator core 3. The winding 4 is installed in the stator core 3 and passes through both sides to enter the oil collecting ring assembly 5 respectively. Both sides of the oil passage 8 are provided with stator core oil outlets 9 and face the oil collecting ring assembly 5.

[0029] When in use, the oil collecting ring assembly 5 is installed on the front and rear sides of the shell 1. During cooling, the cooling oil is introduced into the oil channel 8 through the oil inlet 6, and is transported through the oil channel 8 and enters the oil collecting ring assembly 5 through the stator core oil outlet 9, so that the winding 4 in the oil collecting ring assembly 5 is immersed in the cooling oil. The cooling oil can flow in the oil collecting ring assembly 5 to the junction of the stator core 3 and the winding 4, that is, the area inside the winding slot, so that the winding can be fully exposed to the cooling oil, thereby improving the heat dissipation uniformity of the winding and the heat dissipation efficiency will also be improved.

[0030] See also Figure 12 The oil passage 8 is a labyrinth oil passage in the stator core 3. The labyrinth oil passage has the function of guiding the oil to flow efficiently and enhancing the heat exchange efficiency.

[0031] According to some embodiments of the present application, optionally, oil channel branches of different shapes or numbers are used in the maze-type oil channel, such as a spiral or grid design, to optimize the oil flow path and adapt to motors with different power densities.

[0032] See also Figure 1 and Figure 2 Two housing oil outlets 7 are provided on the lower sides of housing 1. The oil inlet 6 and housing oil outlets 7 communicate with the vehicle's oil circuit. Oil is introduced through the oil inlet 6 and then returned to the vehicle's oil circuit via the housing oil outlets 7 on both sides. This not only creates a closed cooling oil circulation system, but also allows the cooling oil in the front and rear oil collecting ring assemblies 5 to be discharged through different housing oil outlets 7, enhancing oil conduction efficiency.

[0033] Please refer to 3-11. The oil collecting ring assembly 5 includes an inner ring 51, an outer ring 52, a baffle 53, an oil collecting ring outlet 54, and an immersion chamber 55. One side of the baffle 53 is connected to the inner ring 51 and the other side is connected to the outer ring 52. The baffle 53 is provided with a plurality of oil collecting ring outlets 54. The space between the inner ring 51 and the outer ring 52 forms an immersion chamber 55. The side of the winding 4 is located in the immersion chamber 55. The oil in the immersion chamber 55 is introduced through the iron core oil outlet 9. The cooling oil enters the immersion chamber 55 of the oil collecting ring assembly 5 through the stator iron core oil outlet 9. The oil in the immersion chamber 55 is blocked by the baffle 53, so that the oil in the immersion chamber 55 will immerse and cool the side of the winding. When the oil is immersed in the oil collecting ring outlet 54, the oil flows out of the immersion chamber 55.

[0034] See also Figure 7-9Several oil guide grooves 56 are formed on the inner ring 51 and are located inside the winding 4. The grooves of the oil guide grooves 56 point toward the teeth of the stator core 3. Slot wedges 10 are installed outside the teeth of the stator core 3. An oil flow cavity is formed between the slot wedges 10 and the teeth of the stator core 3. The oil guide grooves 56 are connected to the teeth of the stator core 3, so that the oil in the immersion chamber 55 will flow into the oil flow cavity through the oil guide grooves 56. The teeth of the stator core 3 intersect with the middle part of the winding, that is, the area inside the winding slot. The oil flowing into the oil flow cavity will contact the middle part of the winding and cool it, thereby achieving full cooling of the winding. This can solve the problem of local hot spots easily forming in the winding, thereby improving the uniformity and efficiency of heat dissipation of the winding and solving the thermal management problem under high load conditions.

[0035] According to some embodiments of the present application, the number and distribution of the slot wedges 10 are optionally adjusted, for example, to 72, 48, or 96, etc., and the aperture of the internal channel of the slot wedge 10 is changed to match specific cooling requirements.

[0036] According to some embodiments of the present application, the slot wedge 10 and the teeth of the stator core 3 are optionally bonded by cofferdam glue to achieve chamber sealing and provide multiple seals to prevent oil leakage, thereby meeting the high power density motor requirements of commercial vehicles.

[0037] According to some embodiments of the present application, the oil collecting ring assembly 5 can be optionally made of different materials, such as lightweight alloys or high-temperature resistant polymers, to improve corrosion resistance and thermal stability and be suitable for applications in extreme environments.

[0038] According to some embodiments of the present application, a plurality of clips 57 are optionally mounted on the outer ring 52, and a clip groove 11 is provided in the housing 1 for the clips 57 to snap into. During assembly, the clips 57 snap into the clip grooves 11, thereby preventing axial movement of the oil collecting ring assembly 5 and increasing the connection stability of the structure.

[0039] According to some embodiments of the present application, a sealing ring groove 58 is optionally formed on the outer side of the outer ring 52, and a sealing ring 12 is installed in the housing 1 to cooperate with the sealing ring groove 58. This has the effect of increasing the sealing between the oil collecting ring assembly 5 and the housing 1, thereby ensuring that the oil is sealed without leakage.

[0040] According to some embodiments of the present application, an oil collecting ring groove 59 is optionally formed on the outer ring 52 of the front oil collecting ring assembly 5 in the housing 1, and a housing boss 13 is installed at the front end of the housing 1 to enter the oil collecting ring groove 59. This has the effect of limiting the radial displacement of the front oil collecting ring assembly 5 and increasing the connection stability of the structure.

[0041] According to some embodiments of the present application, an oil collecting ring boss 510 is optionally mounted on the outer ring 52 of the rear oil collecting ring assembly 5 in the housing 1, and a housing boss 14 is provided at the rear end of the housing 1 for the oil collecting ring boss 510 to enter. This serves to limit radial displacement of the rear oil collecting ring assembly 5 and increase structural connection stability.

[0042] See also Figure 11 The outer ring 52 of the oil collecting ring assembly 5 on the rear side of the housing 1 has a waist-shaped hole 511. The waist-shaped hole 511 is sealed by a sealing gasket 512, and the sealing gasket 512 has a wiring hole. The wiring of the present invention enters through the wiring hole, and the sealing gasket 512 seals the waist-shaped hole 511, further improving the sealing performance and effectively preventing oil leakage from this point.

[0043] See also Figure 13 The end cover 2 on the side of the housing 1 is close to the side where the rear oil collecting ring assembly 5 is set, and a junction box 15 is installed on the end cover 2. It has the effect of facilitating the access of the line on the junction box 15 from the wire hole.

[0044] According to some embodiments of the present application, the present invention may optionally be applied to other types of motors, such as industrial drive motors or electric ship motors, by modifying the size of the housing 1 and the position of the oil port to achieve cross-domain adaptation.

[0045] According to some embodiments of the present application, optionally, an intelligent temperature control system is integrated, and sensors and valves are added to the oil inlet 6 to automatically adjust the oil flow according to the temperature to enhance energy efficiency management.

[0046] It should be understood that the embodiments disclosed herein are not limited to the specific processing steps or materials disclosed herein, but should extend to equivalent substitutions of such features understood by those skilled in the relevant art. It should also be understood that the terminology used herein is for the purpose of describing specific embodiments only and is not intended to be limiting.

[0047] The "embodiment" mentioned in the specification means that a particular feature or characteristic described in conjunction with the embodiment is included in at least one embodiment of the present invention. Therefore, the phrase or "embodiment" appearing in various places throughout the specification does not necessarily refer to the same embodiment.

[0048] Furthermore, the described features or characteristics may be combined in any other suitable manner into one or more embodiments. In the above description, some specific details, such as thickness, quantity, etc., are provided to provide a comprehensive understanding of the embodiments of the present invention. However, those skilled in the relevant art will appreciate that the present invention may be implemented without one or more of the above specific details or may be implemented using other methods, components, materials, etc.

Claims

1. A fully immersed oil-cooled winding stator assembly, characterized in that: include: A housing (1), an end cover (2), a stator core (3), a winding (4), and an oil collecting ring assembly (5); an oil inlet (6) and a housing oil outlet (7) are provided on the housing (1); the end cover (2) is located on the side of the housing (1); the stator core (3) is fitted into the housing (1); an oil passage (8) is arranged in the stator core (3) and is connected to the oil inlet (6); oil collecting ring assemblies (5) are provided on the front and rear sides of the housing (1) and are located on both sides of the stator core (3); the winding (4) is installed in the stator core (3) and passes through both sides to enter the oil collecting ring assembly (5); both sides of the oil passage (8) are provided with stator core oil outlets (9) and face the oil collecting ring assembly (5).

2. The fully immersed oil-cooled winding stator assembly according to claim 1, characterized in that: The oil passage (8) is a labyrinth oil passage in the stator core (3).

3. The fully immersed oil-cooled winding stator assembly according to claim 1, characterized in that: The oil collecting ring assembly (5) comprises an inner ring (51), an outer ring (52), a baffle (53), an oil collecting ring oil outlet (54), and an immersion chamber (55). One side of the baffle (53) is connected to the inner ring (51) and the other side is connected to the outer ring (52). A plurality of oil collecting ring oil outlets (54) are provided on the baffle (53). The interval between the inner ring (51) and the outer ring (52) forms an immersion chamber (55). The side of the winding (4) is located in the immersion chamber (55). The oil in the immersion chamber (55) is introduced through the iron core oil outlet (9).

4. The fully immersed oil-cooled winding stator assembly according to claim 3, characterized in that: A plurality of oil guide grooves (56) are formed on the inner ring (51) and are located inside the winding (4). The groove directions of the oil guide grooves (56) are directed toward the teeth of the stator core (3). Slot wedges (10) are installed outside the teeth of the stator core (3).

5. The fully immersed oil-cooled winding stator assembly according to claim 3, characterized in that: A plurality of buckles (57) are mounted on the outer ring (52), and buckle grooves (11) for the buckles (57) to be snapped into are provided on the housing (1).

6. The fully immersed oil-cooled winding stator assembly according to claim 3, characterized in that: A sealing ring groove (58) is provided on the outer side of the outer ring (52), and a sealing ring (12) that matches the sealing ring groove (58) is installed in the housing (1).

7. The fully immersed oil-cooled winding stator assembly according to claim 3, characterized in that: An oil collecting ring groove (59) is formed on the outer ring (52) of the oil collecting ring assembly (5) on the inner front side of the housing (1), and a housing boss (13) is installed at the inner front end of the housing (1) and enters the oil collecting ring groove (59).

8. The fully immersed oil-cooled winding stator assembly according to claim 3, characterized in that: An oil collecting ring boss (510) is mounted on the outer ring (52) on the oil collecting ring assembly (5) at the inner rear side of the housing (1), and a housing boss (14) for the oil collecting ring boss (510) to enter is provided at the inner rear end of the housing (1).

9. The fully immersed oil-cooled winding stator assembly according to claim 8, characterized in that: A waist-shaped hole (511) is provided on the outer ring (52) of the oil collecting ring assembly (5) on the inner rear side of the housing (1). The waist-shaped hole (511) is sealed by a sealing gasket (512), and a wire hole is provided on the sealing gasket (512).

10. The fully immersed oil-cooled winding stator assembly according to claim 9, characterized in that: The end cover (2) on the side of the housing (1) is close to the side where the rear oil collecting ring assembly (5) is provided, and a junction box (15) is installed on the end cover (2).

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