A motor winding installation structure

Abstract

The present application relates to a kind of motor winding installation structure, including stator core, stator core includes a plurality of stator teeth, also including several groups of flat wire coil group, flat wire coil group includes several flat wire coils formed by a continuous wire winding, flat wire coil group is set on stator tooth after winding is completed, and all flat wire coil group is connected to form winding;End of stator tooth is equipped with pole shoe;The end of stator tooth is equipped with mounting lug, and the side of pole shoe is made with corresponding mounting recess, and mounting lug is clamped into mounting recess.The present application adopts the installation mode that flat wire coil group pre-wound into shape is set on stator tooth, substantially reduces winding cross-slot difficulty, makes the formation of winding more simple and convenient fast, simplifies installation process, reduces cost, improves material utilization rate;Pole shoe and stator core are set in split mode, it is convenient for the setting of winding formation flat wire coil group, and the installation of pole shoe reduces the opening of stator slot, reduces torque fluctuation, reduces tooth slot torque.

Description

Technical Field

[0001] This invention relates to a motor winding mounting structure, belonging to the field of motor technology. Background Technology

[0002] Motor windings can be classified into round wire windings and flat wire windings based on the type of copper wire used. When current flows through these coils, the resulting magnetic field causes the motor rotor to rotate. Round wire winding motors use traditional circular cross-section wires to construct the motor coils. The construction method typically involves winding the round wire into the slots of the stator core. Due to the simplicity of the round wire winding method, round wire windings are widely used in motors. However, the natural gaps between the round wires result in a low slot fill factor, leading to low efficiency and power density, making it difficult to meet the demands for high-performance motors.

[0003] Flat wire winding motors use flat-shaped wires (also known as rectangular or flat wires) to construct the coils. This design allows the coils to be arranged more closely, increasing slot fill factor and improving the motor's power density. However, the current installation process for flat wire windings is cumbersome. Typically, the flat wires are first stamped into hairpins, then rows of hairpins are inserted axially into the stator slots according to a preset order and position. Next, twisting and welding are performed to fuse multiple wire ends together, completing the installation of the flat wire windings. The overall installation process is complex, costly, and involves numerous welding points. Summary of the Invention

[0004] The purpose of this invention is to address the shortcomings of existing technologies by providing a simple and convenient motor winding installation structure.

[0005] To achieve the objective, the technical solution adopted by this invention is:

[0006] An electric motor winding mounting structure includes a stator core, the stator core including multiple stator teeth, and several groups of flat wire coils, each flat wire coil group including several flat wire coils formed by winding a continuous conductor. After the flat wire coil groups are wound, they are sleeved on the stator teeth, and all the flat wire coil groups are connected to form a winding.

[0007] As a further optimization of the above technical solution: pole shoes are installed at the ends of the stator teeth.

[0008] As a further optimization of the above technical solution: the end of the stator tooth is provided with a mounting protrusion, and the side of the pole shoe is provided with a corresponding mounting groove, and the mounting protrusion is inserted into the mounting groove.

[0009] As a further optimization of the above technical solution, it also includes multiple insulating baffles, which are inserted into the gap between the inner circumferential surface of the flat wire coil and the side surface of the stator tooth. Each stator tooth has an insulating baffle on both sides, and the insulating baffle is in contact with the pole shoe.

[0010] As a further optimization of the above technical solution: the insulating baffle includes an insertion part and a blocking part, the width of the blocking part is greater than the width of the insertion part, and the insertion part is provided with several guide slopes. After the insulating baffle is inserted, the blocking part presses down on the pole shoe.

[0011] As a further optimization of the above technical solution: the insulating baffle is also provided with a number of protrusions, the side of the protrusion near the insertion part is an insertion slope, and the side of the protrusion near the baffle is a positioning baffle.

[0012] As a further optimization of the above technical solution: the guide slope includes a first guide slope located on both sides of the insertion part, a second guide slope located on the upper surface of the insertion part, and a third guide slope located at the head of the insertion part.

[0013] As a further optimization of the above technical solution: the insulating baffle also includes an intermediate portion located between the insertion portion and the baffle portion, and the protrusion is located on the upper surface of the intermediate portion.

[0014] As a further optimization of the above technical solution, it also includes insulating paper, with a stator slot formed between two adjacent stator teeth, the insulating paper closely adhering to and covering the inner wall of the stator slot, and the inner circumferential surface of the flat wire coil group in contact with the insulating paper.

[0015] As a further optimization of the above technical solution: the stator core also includes a connecting ring, which is composed of multiple arc-shaped core segments. Each core segment has a fixing groove and a fixing block at both ends. Both the fixing groove and the fixing block are dovetail-shaped. All the core segments are connected end to end so that the fixing groove and the fixing block of two adjacent core segments are interlocked and fixed to form an annular stator core. The stator teeth are integrally formed on the outer circumferential surface of the connecting ring.

[0016] As a further optimization of the above technical solution: each group of flat wire coils includes four flat wire coils formed by winding a continuous conductor, and the height of the cross-slot line between two adjacent flat wire coils is higher than the height of the flat wire coil.

[0017] As a further optimization of the above technical solution: the flat wire coil group is made of aluminum wire.

[0018] Compared with existing technologies, this invention uses flat wire coils to increase slot fill factor, thereby improving the power density of the motor. Furthermore, the installation method of mounting pre-wound flat wire coil assemblies onto the stator teeth significantly reduces the difficulty of winding across slots, making winding formation simpler, more convenient, and faster, simplifying the installation process, reducing costs, and improving material utilization. The separate design of the pole shoes and stator core facilitates the mounting of the pre-wound flat wire coil assemblies. Simultaneously, the installation of the pole shoes reduces the opening of the stator slots, decreasing torque fluctuations, cogging torque, and radial force fluctuations, thus improving the motor's NVH performance. The insulation scheme using a combination of insulating paper and insulating baffles enhances the motor's withstand voltage. Higher accuracy, higher slot fill rate, and lower cost; the simple and inexpensive insulating bamboo sticks ensure the flat wire coils are firmly wound, fill gaps, and increase insulation reliability, while preventing the pole shoes from slipping due to motor vibration; the positioning facets on the protrusions prevent the insulating baffles from accidentally moving outwards, and the insulating paint adheres the insulating baffles to the stator core, further reducing the risk of the insulating baffles falling off; the stator core is segmented and spliced, improving material utilization and reducing costs; the height of the slot-crossing line between two adjacent flat wire coils is higher than the height of the flat wire coils, shortening the distance between the slot-crossing lines at both ends of the flat wire coil located in the middle, preventing the flat wire coils from being too wide and colliding with the pole shoes. Attached Figure Description

[0019] Figure 1 This is an exploded structural diagram of the present invention.

[0020] Figure 2 yes Figure 1 A magnified structural diagram of point A in the middle.

[0021] Figure 3 This is a three-dimensional structural diagram of the insulating baffle in this invention. Detailed Implementation

[0022] The present invention will be further described below with reference to the accompanying drawings and specific embodiments. For example... Figure 1-3 As shown, a motor winding mounting structure includes a stator core 1 and several sets of flat wire coil groups 2. Each flat wire coil group 2 comprises several flat wire coils wound from a single continuous conductor. The stator core 1 includes a connecting ring 11 and multiple stator teeth 12 located on the connecting ring 11. A stator slot is formed between two adjacent stator teeth 12. After the flat wire coil groups 2 are wound, they are fitted onto the stator teeth 12. All flat wire coil groups 2 are connected to form a winding. The use of flat wire coils increases the slot fill factor, thereby increasing the power density of the motor. Furthermore, the installation method of fitting pre-wound flat wire coil groups 2 onto the stator teeth 12 significantly reduces the difficulty of winding slot crossing, making winding formation simpler, more convenient, and faster, simplifying the installation process, reducing costs, and improving material utilization.

[0023] In the above technical solution: a pole shoe 3 is detachably installed at the end of the stator tooth 12. The end of the stator tooth 12 is provided with a mounting protrusion 121, and the side of the pole shoe 3 is provided with a corresponding mounting groove 31. Both the mounting protrusion 121 and the mounting groove 31 are dovetail-shaped. The mounting protrusion 121 is inserted into the mounting groove 31, allowing the pole shoe 3 to be installed at the end of the stator tooth 12. The pole shoe 3 and the stator core 1 are separately configured, facilitating the installation of the wound flat wire coil group 1. Simultaneously, the installation of the pole shoe 3 reduces the opening of the stator slot, decreasing torque fluctuation, reducing cogging torque, and lowering radial force fluctuation, thereby improving the motor's NVH (noise, vibration, and harshness) performance.

[0024] The above technical solution also includes insulating paper 4, which is closely attached to and covers the inner wall of the stator slot. After the flat wire coil group 2 is sleeved on the stator tooth 12, the inner circumferential surface of the flat wire coil group 2 is in contact with the insulating paper 4 to provide insulation and prevent the flat wire coil group 2 from conducting electricity.

[0025] The above technical solution also includes multiple insulating baffles 5, which are inserted into the gap between the inner circumference of the flat wire coil and the side of the stator tooth 12. Each stator tooth 12 has an insulating baffle 5 on both sides, and the insulating baffles 5 contact the pole shoe 3. Compared to an integrated insulating frame (where the insulating paper 4 and insulating baffles 5 are integrally formed to create the insulating frame, and the flat wire coil is wound on the insulating frame), this insulation solution, using insulating paper 4 and insulating baffles 5, results in higher motor withstand voltage, higher slot fill factor, and lower cost.

[0026] In the above technical solution: the insulating baffle 5 includes an insertion part 51, a stop part 52, and an intermediate part 53 located between the insertion part 51 and the stop part 52. The width of the stop part 52 is greater than the width of the insertion part 51 and also greater than the width of the intermediate part 53, making the insulating baffle 5 approximately T-shaped. Several guide slopes are formed on the insertion part 51. After the insulating baffle 5 is inserted, the stop part 52 presses down on the pole shoe 3. The guide slopes include a first guide slope 59 located on both sides of the insertion part 51, a second guide slope 54 located on the upper surface of the insertion part 51, and a third guide slope 55 located at the head of the insertion part 51.

[0027] In the above technical solution: the insulating baffle 5 is also provided with several protrusions 56. The side of the protrusion 56 near the insertion part 51 is the insertion slope 57, and the side of the protrusion 56 near the stop part 52 is the positioning stop 58. The protrusion 56 is located on the upper surface of the middle part 53. The first guide slope 59, the second guide slope 54, the third guide slope 55 and the insertion slope 57 guide the insertion process of the insulating baffle 5, making the insertion process smoother. After the insulating baffle 5 is inserted, the stop part 52 presses down on the mounting protrusion 121 and the pole shoe 3 to prevent the installation between the pole shoe 3 and the stator tooth 12 from sliding and to prevent the pole shoe 3 from falling out; at the same time, the positioning stop 58 on the protrusion 56 prevents the insulating baffle 5 from accidentally moving outward and to prevent the insulating baffle 5 from falling out. The simple-shaped and low-cost insulating bamboo sticks can make the flat wire coils tightly wound, fill gaps and increase insulation reliability, while preventing the pole shoe 3 from slipping due to motor vibration.

[0028] In the above technical solution: the connecting ring 11 of the stator core 1 is composed of multiple arc-shaped core segments. Each core segment has a fixing groove 13 and a fixing block 14 at both ends, both being dovetail-shaped. All core segments are connected end-to-end, allowing the fixing grooves 13 and fixing blocks 14 of adjacent segments to interlock and fix each other, forming a ring-shaped stator core. The stator teeth 12 are integrally formed on the outer circumferential surface of the connecting ring 11. The motor in this invention is a hub motor, and each core segment has a total of eight stator teeth 12. The stator core 1 is assembled in segments, improving material utilization and reducing costs.

[0029] In the above technical solution: each flat wire coil group 2 includes four flat wire coils formed by winding a continuous conductor, that is, the flat wire coil group 2 of the present invention is specifically a four-slot continuous-wound flat wire coil group. At the same time, the height of the cross-slot line 21 between two adjacent flat wire coils is higher than the height of the flat wire coil, thus shortening the distance between the cross-slot lines 21 at both ends of the middle flat wire coil (i.e., Figure 2 The distance between the two slot lines 21 marked in the figure is used to prevent the width of the flat wire coil from being too wide and interfering with the pole shoe 3. Of course, two-strand flat wire coils or six-strand flat wire coils can also be set, but two-strand flat wire coils have more welding points, while six-strand flat wire coils are more difficult to wind and have a slower winding speed. Therefore, the four-slot flat wire coil group of the present invention ensures the winding speed and reduces the number of welding points.

[0030] In the above technical solution: the flat wire coil group 2 is made of aluminum wire, which greatly reduces the material cost of the flat wire coil group 2 while meeting the lightweight requirements of the motor. Multiple flat wire coil groups 2 are laser welded together. When aluminum wire cannot meet the actual motor power requirements, copper wire can be replaced with the same mounting structure to further increase the motor power.

[0031] The installation process of this invention is as follows: First, insulating paper 4 is placed in the stator slot; then, the pre-wound flat wire coil group 2 is sleeved on the stator tooth 12, so that the inner circumferential surface of the flat wire coil group 2 is in contact with the insulating paper 4; then, the pole shoe 3 is installed at the end of the stator tooth 12; next, the insulating baffle 5 is inserted into the gap between the flat wire coil and the side of the stator tooth 12; finally, varnish is applied to allow the insulating varnish to fully penetrate into every gap of the winding. The insulating varnish makes the insulating baffle 5 adhere to the stator core 1, further reducing the risk of the insulating baffle 5 falling off.

[0032] The preferred embodiments of the present invention have been described in detail above. It should be understood that those skilled in the art can make numerous modifications and variations based on the concept of the present invention without creative effort. Therefore, all technical solutions that can be obtained by those skilled in the art based on the concept of the present invention through logical analysis, reasoning, or limited experimentation on the basis of existing technology should fall within the protection scope of the present invention.

Claims

1. A motor winding mounting structure, comprising a stator core (1), wherein the stator core (1) includes a plurality of stator teeth (12), characterized in that... It also includes several sets of flat wire coil groups (2), each set of flat wire coil groups (2) includes several flat wire coils formed by winding a continuous wire. After the flat wire coil group (2) is wound, it is sleeved on the stator tooth (12). All the flat wire coil groups (2) are connected to form a winding. The end of the stator tooth (12) is equipped with a pole shoe (3). It also includes multiple insulating baffles (5), which are inserted into the gap between the inner circumferential surface of the flat wire coil and the side surface of the stator tooth (12). Each stator tooth (12) has an insulating baffle (5) on both sides, and the insulating baffle (5) is in contact with the pole shoe (3). The insulating baffle (5) includes an insertion part (51) and a blocking part (52). The width of the blocking part (52) is greater than the width of the insertion part (51). The insertion part (51) has several guide slopes. After the insulating baffle (5) is inserted, the blocking part (52) presses down on the pole shoe (3). The insulating baffle (5) is also provided with a number of protrusions (56). The side of the protrusion (56) near the insertion part (51) is an insertion slope (57), and the side of the protrusion (56) near the baffle (52) is a positioning baffle (58).

2. The motor winding mounting structure according to claim 1, characterized in that... The stator tooth (12) has a mounting protrusion (121) at its end, and the pole shoe (3) has a corresponding mounting groove (31) on its side. The mounting protrusion (121) is inserted into the mounting groove (31).

3. The motor winding mounting structure according to claim 1, characterized in that... The guide slope includes a first guide slope (59) located on both sides of the insertion part (51), a second guide slope (54) located on the upper surface of the insertion part (51), and a third guide slope (55) located at the head of the insertion part (51).

4. The motor winding mounting structure according to claim 1, characterized in that... The insulating baffle (5) also includes an intermediate portion (53) located between the insertion portion (51) and the baffle portion (52), and the protrusion (56) is located on the upper surface of the intermediate portion (53).

5. The motor winding mounting structure according to claim 1, characterized in that... It also includes insulating paper (4), a stator slot is formed between two adjacent stator teeth (12), the insulating paper (4) is close to and covers the inner wall of the stator slot, and the inner circumferential surface of the flat wire coil group (2) is in contact with the insulating paper (4).

6. The motor winding mounting structure according to claim 1, characterized in that... The stator core (1) also includes a connecting ring (11), which is composed of multiple arc-shaped core segments. Each core segment has a fixing groove (13) and a fixing block (14) at both ends. The fixing groove (13) and the fixing block (14) are both dovetail-shaped. All the core segments are connected end to end so that the fixing groove (13) and the fixing block (14) of two adjacent core segments are locked together to form an annular stator core (1). The stator teeth (12) are integrally formed on the outer circumferential surface of the connecting ring (11).

7. The motor winding mounting structure according to claim 1, characterized in that... Each of the flat wire coil groups (2) includes four flat wire coils formed by winding a continuous conductor, and the height of the cross groove line (21) between two adjacent flat wire coils is higher than the height of the flat wire coil.

8. The motor winding mounting structure according to claim 1, characterized in that... The flat wire coil group (2) is made of aluminum wire.

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