Wire connecting structure of flat wire stator

Abstract

The invention discloses a wire connecting structure of a flat wire stator, and belongs to the technical field of energy-saving motors, the wire connecting structure comprises a stator core and a stator slot, a winding is arranged in the stator slot, the stator core and the winding form a stator, the stator is a concentrated winding type stator, the longitudinal section of the winding is of an octagonal structure, and the winding is arranged in the stator slot. And the left and right sides of the windings can be broken to reduce the number of used molds and reduce the winding difficulty of the windings, and one end of each of two outgoing lines of each group of windings is on the outer diameter side of the stator while the other end is on the inner diameter side of the stator. According to the wire connecting structure of the flat wire stator, the cross section of the winding is of an octagonal structure, folding can be carried out on the two sides, the number of molds can be reduced, the winding difficulty of the winding can be reduced, compared with a traditional winding with a rectangular cross section, the slot fullness rate can be increased by 4%-8%, the end space is small, the number of opened molds is reduced, the winding difficulty of the winding is reduced, the cost is reduced, and the slot fullness rate, the power density and the efficiency are high.

Description

Technical Field

[0001] This invention relates to the field of energy-saving motor technology, specifically to a wiring structure for a flat wire stator. Background Technology

[0002] In fields such as new energy vehicles, industrial drives, and high-efficiency home appliances, higher performance requirements have been placed on drive motors, which are the core power source. High power density, high efficiency, and compactness have become the mainstream trends in motor technology development.

[0003] The announcement number is CN213782996U, which describes a flat wire stator output terminal structure and a flat wire motor. The flat wire stator output terminal structure includes flat wire stator windings and an output connection structure. The flat wire stator windings include a star-connected U-phase winding, V-phase windings, and W-phase windings. The output connection structure includes a U-phase copper busbar connected to the U-phase winding, a V-phase copper busbar connected to the V-phase winding, a W-phase copper busbar connected to the W-phase winding, and a neutral point copper busbar connected to each phase winding. The U-phase, V-phase, W-phase, and neutral point copper busbars are spatially staggered and located on the same side of the flat wire stator windings. Each phase winding includes 2n branch leads and 2n neutral point leads. The 2n branch leads are connected to both sides of the phase copper busbar, and the 2n neutral point leads are connected to both sides of the neutral point copper busbar; n is a positive integer greater than or equal to 1.

[0004] The existing technologies mentioned above have the following technical problems: the existing stator windings are usually rectangular in cross-section. However, the rectangular cross-section windings have a large end space, which increases the number of molds required and greatly increases the difficulty of winding, reducing the slot fill factor, power density and efficiency.

[0005] Therefore, we propose a connection structure for a flat wire stator to solve the problems mentioned above. Summary of the Invention

[0006] The purpose of this invention is to provide a connection structure for a flat wire stator, in order to solve the problems mentioned in the background art. Currently, the stator windings on the market are usually rectangular in cross-section. However, the winding ends of the rectangular cross-section windings have large space, which leads to an increase in the number of molds required. At the same time, it also greatly increases the difficulty of winding and reduces its slot fill factor, power density and efficiency.

[0007] To achieve the above object, the present invention provides the following technical solution: A connection structure for a flat wire stator, including a stator core and stator slots. Windings are arranged inside the stator slots. The stator core and the windings form a stator. The stator is a concentrated winding type stator. The longitudinal cross-sectional shape of the winding is an octagonal structure, and the left and right sides of the winding can be folded to reduce the number of molds used and the winding difficulty. The two leads of each group of windings are one at the outer diameter side of the stator and the other at the inner diameter side of the stator.

[0008] Preferably, for the rectangular winding with the triangle at the uncut corner, the length is L2, the width is h1, the fillet radius is R, the length of the cut triangle is x, the width is y, the length of the octagonal longitudinal cross-section winding with the triangles cut at both sides of the corner is L3, and the width is h2.

[0009] Preferably, for the rectangular winding with a triangle cut at one side of the corner, the winding forms a winding with a wide side and a narrow side cross-section. The length of the winding with a wide side and a narrow side cross-section is L4, the width is h3, the length of the cut triangle is x1, and the width is y1; It satisfies: 2(L2 + h1) - 8 R + 2 π R < 2 (L3 - 2 X) + 2(h2 - 2 Y) + 4 <2 L4 + 2 h3 - X1 - Y1 + 2 , 0 < X < L3 / 2, 0 < Y < h2 / 2, 0 < X1 < L4, 0 < Y1 < h3, 0.2 < R < 0.8.

[0010] Preferably, for a single formed winding, the length of the horizontal straight side is L0, the length of the vertical straight side of the winding is L1, the fillet radius of the winding is R, the total width of the winding is L5, the perimeter of the winding is C, and the area is S. It satisfies: C = 2(L1 + L0) + 2 π R, S = L1 L0 + π R², L0 >​​​​​​​​​Preferably, each phase winding consists of N sets of W groups of flat wire coils, where N ranges from 2 to 6 and W ranges from 2 to 4.

[0013] Preferably, the winding has ten connecting wires at the output end, one of which is a star wire and nine of which are phase wires. The connecting wires are located close to the inner diameter side of the stator, and the phase wires are connected from the inner diameter side of the stator to the outer diameter side of the stator.

[0014] Preferably, the winding is connected in parallel with two paths. All the outgoing lines on the inner diameter side of the stator are connected together with star connectors, and the outgoing lines on the outer diameter side of the stator are connected in pairs and welded together. Finally, the two outgoing lines are welded together to form a parallel connection.

[0015] Preferably, the winding with a cross-sectional shape that is wide on one side and narrow on the other can only be broken on the narrow side.

[0016] Compared with the prior art, the beneficial effects of the present invention are: 1. The winding cross-section is octagonal, which can be folded on both sides, reducing the number of molds and the difficulty of winding. Compared with traditional rectangular cross-section windings, the slot fill factor can be increased by 4% to 8%, the end space is small, the number of molds is reduced, the winding difficulty is reduced, the cost is reduced, the slot fill factor is high, the power density is high, and the efficiency is high. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the octagonal cuboid cross-section winding structure of the present invention; Figure 2 This is a schematic diagram of the winding structure with one side wider than the other side of the present invention; Figure 3 This is a schematic diagram comparing the octagonal cross-section winding with the rectangular cross-section winding after the broken line of the present invention; Figure 4 This is a schematic diagram comparing the structure of the winding with a cross-section that is wider on one side and narrower on the other with that of a rectangular cross-section winding according to the present invention. Figure 5 This is a schematic diagram of the structure of the octagonal cross-section winding after the left side is broken. Figure 6 This is a schematic diagram of the structure of the octagonal cross-section winding after the right-side bend line of the present invention; Figure 7 This is a schematic diagram of the structure of the winding with a cross-section that is wide on one side and narrow on the other after being broken along a zigzag line. Figure 8 This is a schematic diagram of the rectangular cross-section winding structure of the present invention; Figure 9 This is a schematic diagram of the isometric side view of the three-dimensional structure of the stator connection lines of the present invention; Figure 10 This is a schematic cross-sectional view of the stator core and winding structure of the present invention; Figure 11 This is a schematic diagram of the winding connection structure of the present invention; Figure 12 This is a schematic diagram of a single winding structure of the present invention; Figure 13 This is a schematic diagram of the three-dimensional structure of a single winding of the present invention; Figure 14 This is a schematic diagram of the three-dimensional structure of the single-phase winding of the present invention; Figure 15 This is a schematic diagram of the isometric side view of the three-dimensional structure of the winding connection lines of the present invention; Figure 16 This is a schematic diagram of the stator core structure of the present invention; Figure 17 This is a schematic diagram of the staircase structure with two parallel windings connected by an equiaxial side view according to the present invention. Figure 18 This is a schematic diagram of the single-phase winding structure of the two parallel windings of the present invention; Figure 19 This is a schematic diagram showing the effect of current on efficiency in octagonal and rectangular cross-sections of the present invention; Figure 20 This is a schematic diagram showing the influence of current on torque on a cross-section with one side wide and the other side narrow, and a rectangular cross-section, as presented in this invention.

[0018] In the diagram: 1. Stator core; 2. Stator slot; 3. Winding. Detailed Implementation

[0019] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0020] Please see Figures 1-20 Existing stator windings are typically rectangular in cross-section. However, the large end space of rectangular windings leads to an increased number of molds required, significantly increasing the difficulty of winding and reducing slot fill factor, power density, and efficiency. To address this technical problem, this invention discloses the following technical content: a connection structure for a flat wire stator, comprising a stator core 1 and a stator slot 2. A winding 3 is disposed inside the stator slot 2. The stator core 1 and the winding 3 together form a stator, which is a concentrated winding type stator. The longitudinal cross-section of the winding 3 is octagonal, and the left and right sides of the winding 3 can be bent to reduce the number of molds required and the difficulty of winding the winding 3. The two leads of each winding 3 are located with one end on the outer diameter side of the stator and the other end on the inner diameter side of the stator.

[0021] The cross-sectional shape of the winding 3 is an octagonal structure, which can be folded on both sides, reducing the number of molds and the difficulty of winding the winding. Compared with the traditional rectangular cross-sectional winding, the slot fill factor can be increased by 4% - 8%.

[0022] For the rectangular winding 3 without the triangular corners cut off, its length is L2, width is h1, fillet radius is R, the length of the cut-off triangle is x, width is y, and for the octagonal longitudinal section winding 3 with the triangular corners cut off on both sides, its length is L3 and width is h2.

[0023] The cross-sectional line type of the winding can also be a shape with one side wide and one side narrow. Compared with the traditional rectangular winding cross-section, the slot fill factor can be increased by 6% - 10%.

[0024] The rectangular winding 3 with a triangle cut off at one side corner forms a winding 3 with a cross-section of one side wide and one side narrow. The length of the winding 3 with a cross-section of one side wide and one side narrow is L4, width is h3, the length of the cut-off triangle is x1, width is y1, and it satisfies: 2(L2 + h1) - 8 R + 2 π R < 2 [[ID=ID=17]](L3 - 2 X) + 2(h2 - 2 Y) + 4 <2 L4 + 2 h3 - X1 - Y1 + 2 , 0 < X < L3 / 2, 0 < Y < h2 / 2, 0 < X1 < L4, 0 < Y1 < h3, 0.2 < R < 0.8.

[0025] For a single formed winding 3, the length of the horizontal straight side is L0, the length of the vertical straight side of the winding is L1, the fillet radius of the winding is R, the total width of the winding is L5, the perimeter of the winding is C, and the area is S, and they satisfy: C = 2(L1 + L0) + 2 π R, S = L1 L0 + π R², L0 > 0.5mm, 0.5 L5 < R < 0.8 L5.

[0026] The outgoing wire of a single set of formed windings of the single set of windings 3 near the inner diameter side of the stator is bent towards the outer diameter side of the stator, which can reduce the large wire distance caused by different layer cross-wires and the connection difficulty increased by different layer cross-wires, and avoid interference.

[0027] Each phase winding 3 is composed of N sets of W groups of flat wire coils, where the value range of N is: N = 2 - 6, and the value range of W is W = 2 - 4.

[0028] There are ten connecting wires at the output end of winding 3, one of which is a star connection and nine are phase connection wires. The connecting wires are located close to the inner diameter side of the stator, and the phase connection wires are connected from the inner diameter side of the stator to the outer diameter side of the stator.

[0029] The winding 3 is connected in two parallel paths. All the outgoing wires on the inner diameter side of the stator are connected together with star connectors, and the outgoing wires on the outer diameter side of the stator are connected in pairs and welded together. Finally, the two outgoing wires are welded together to form two parallel paths.

[0030] Winding 3, with a cross-sectional shape that is wide on one side and narrow on the other, can only be broken on the narrow side.

[0031] The contents not described in detail in this specification are existing technologies known to those skilled in the art.

[0032] Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A flat wire stator connecting structure, comprising a stator core (1) and a stator slot (2), the inside of the stator slot (2) being provided with a winding (3), the stator core (1) and the winding (3) constituting a stator, characterized in that: The stator is a concentrated winding type stator, the longitudinal section shape of the winding (3) is an octagon structure, and the left and right sides of the winding (3) can be folded lines, for reducing the number of molds used and reducing the winding difficulty of the winding (3), and the two outgoing lines of each winding (3) are one end on the outer diameter side of the stator and one end on the inner diameter side of the stator.

2. The connection structure of a flat stator according to claim 1, wherein: The rectangular winding (3) with the triangular corners not cut off has a length L2, a width h1, and a round corner radius R, the cut-off triangular shape has a length x and a width y, the length of the octagonal longitudinal section winding (3) with the triangular corners cut off on both sides is L3, and the width is h2.

3. The connection structure of a flat stator according to claim 2, wherein: The winding (3) formed by the rectangle with a triangle cut off at one side corner forms a winding (3) with a wide-narrow cross section, and the length of the winding (3) with a wide-narrow cross section is L4, the width is h3, the length of the cut-off triangle is x1, and the width is y1, which satisfy: 2(L2+h1)-8 R+2 π R < 2 (L3-2 X)+2(h2-2 Y) + 4 <2 L4+2 h3-X1-Y1+2 ,0<X<L3 / 2,0<Y<h2 / 2,0<X1<L4,0<Y1<h3,0.2<R<0.8。 4. The connection structure of a flat stator according to claim 3, wherein: The length of the transverse straight edge of the single winding (3) after winding forming is L0, the longitudinal straight edge of the winding (3) is L1, the rounding radius of the winding (3) is R, the total width of the winding is L5, the circumference of the winding is C, the area is S, which satisfies: C=2(L1+L0)+2 π R, S=L1 L0+π R², L0>0.5mm, 0.5 L5<R<0.8 L5.

5. The connection structure of a flat stator according to claim 4, wherein: The outgoing line of the single set of the winding (3) near the inner diameter side of the stator is bent towards the outer diameter side of the stator after being wound and formed, which can reduce the large wire spacing caused by different layer cross lines and the increased connection difficulty of different layer cross lines, and avoid interference.

6. The connection structure of a flat stator according to claim 5, wherein: The winding (3) of each phase is composed of N sets of W flat wire coils, wherein the value range of N is N=2-6, and the value range of W is W=2-4.

7. The connection structure of a flat stator according to claim 6, wherein: The outgoing line end of the winding (3) has ten connection lines, one is a star connection line, and nine are phase line connection lines, the position of the connection line is close to the inner diameter side of the stator, and the phase line connection line is connected from the inner diameter side end of the stator to the outer diameter side end of the stator.

8. The connection structure of a flat stator according to claim 7, wherein: The connection mode of the winding (3) is two-way parallel connection, the outgoing lines on the inner diameter side of the stator are all connected together by the star connection line, the outgoing lines on the outer diameter side of the stator are connected together two by two and welded together, and finally the two-way outgoing lines are welded together to form two-way parallel connection.

9. The connecting structure of a flat stator according to claim 3, wherein: The winding (3) with the one-side-wide one-side-narrow cross-sectional shape can only be folded on the narrow side.

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