Disc type stator winding, preparation method thereof and disc type motor
By using conductor ring molding and epoxy resin filling insulation, the problems of cumbersome manufacturing process and alignment deviation in disc stator windings have been solved, achieving efficient and reliable manufacturing of disc stator windings, reducing power loss and improving motor performance.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- MIDEA GROUP CO LTD
- Filing Date
- 2025-12-24
- Publication Date
- 2026-05-01
AI Technical Summary
In the existing technology, the manufacturing process of disc stator windings is complicated and prone to misalignment, which leads to weakened mechanical connection between conductor bars and poor contact at conductive connection points, increasing power loss.
The conductor ring is formed into a sub-winding disk by molding. The middle area of adjacent conductor bars is spaced apart and the inner and outer ends are connected to each other. The two sub-winding disks are stacked along the axial direction and electrically connected. Finally, the inner and outer rings are cut to form the main winding disk, and epoxy resin is used to fill the insulation.
The manufacturing process was simplified, the manufacturing efficiency and alignment accuracy were improved, the weakening of mechanical connections and poor contact at conductive connection points were reduced, the power loss was reduced, and the energy conversion efficiency and reliability of the motor were improved.
Smart Images
Figure CN121966159A_ABST
Abstract
Description
Disc stator winding and its manufacturing method, disc motor Technical Field
[0001] This application relates to the field of motor technology, specifically to a disc stator winding and its preparation method, and a disc motor. Background Technology
[0002] In related technologies, the fabrication process of disc stator windings typically involves multiple steps: First, multiple conductor bars are bonded and fixed with insulating adhesive to form a sub-winding disc; then, two stacked sub-winding discs are bonded and fixed with insulating adhesive; finally, the corresponding conductor bars in the two sub-winding discs are welded one by one. This fabrication process involves multiple bonding and conductive connections, making it cumbersome and prone to alignment deviations. Summary of the Invention
[0003] In view of the above problems, this application provides a disc stator winding and its preparation method, as well as a disc motor, which can improve the problems of complicated preparation process and easy misalignment of disc stator winding.
[0004] To solve the above-mentioned technical problems, the technical solution adopted in this application is conceived as follows: Firstly, this application provides a method for preparing a disc-type stator winding. The method includes: forming a conductor ring to form a sub-winding disc having multiple conductor bars arranged circumferentially spaced along the conductor ring; wherein the middle regions of adjacent conductor bars are spaced apart, their inner ends are connected to each other, and their outer ends are connected to each other; stacking two sub-winding discs opposite each other along the axial direction of the conductor ring, connecting the inner rings of the two sub-winding discs and making them electrically conductive, and connecting the outer rings of the two sub-winding discs and making them electrically conductive, to form a total winding disc; wherein the middle regions of the two sub-winding discs are insulated; and cutting the inner and outer rings of the total winding disc so that the conductor bars arranged adjacently in the same sub-winding disc are spaced circumferentially.
[0005] The preparation method also includes: filling and curing the main winding disk with epoxy resin.
[0006] The preparation method further includes, before stacking the two sub-winding disks opposite each other along the axial direction of the conductor ring, performing surface insulation treatment on the sub-winding disks to form an insulation layer at least on the outer surface of the conductor bar.
[0007] The forming process of the conductor ring includes: forming multiple through slots spaced circumferentially along the middle region of the conductor ring, and the multiple through slots penetrating the conductor ring axially, so that the middle regions of adjacent conductor bars are spaced apart, the inner ends are connected to each other, and the outer ends are connected to each other, and the middle region of the conductor bar protrudes from the inner and outer ends; wherein, in the circumferential plane of the conductor ring, the conductor bars are arranged in a C-shape; in the two sub-winding disks, the protrusion direction of the middle region of the conductor bar of one sub-winding disk is opposite to the protrusion direction of the middle region of the conductor bar of the other sub-winding disk.
[0008] The through slot extends to the outer and inner rings at both ends of the conductor ring radially, respectively; the inner and outer rings of the main winding disk are cut so that the adjacent conductor bars in the same sub-winding disk are spaced apart circumferentially, including: cutting the inner ring into a circle; cutting the outer ring into a circle and forming lead ends on the outer ring.
[0009] The process of connecting the inner rings of the two sub-winding disks and making them electrically conductive, and connecting the outer rings of the two sub-winding disks and making them electrically conductive, includes: welding the inner rings of the two sub-winding disks using resistance welding, and welding the outer rings of the two sub-winding disks using resistance welding.
[0010] Secondly, this application provides a disc-type stator winding, which includes two sub-winding discs, each sub-winding disc including a plurality of conductor bars arranged at intervals along the circumference of the disc-type stator winding; wherein the two sub-winding discs are stacked opposite each other along the axial direction of the disc-type stator winding, and the conductor bars arranged along the axial direction are connected.
[0011] The disc stator winding also includes an epoxy resin layer, which is disposed at least between two sub-winding discs and between adjacent conductor bars on the same sub-winding disc.
[0012] Among them, the dimension of the end of the conductor bar near the inner ring of the sub-winding disc along the circumference of the disc stator winding is smaller than the dimension of the end near the outer ring of the sub-winding disc along the circumference of the disc stator winding.
[0013] In the circumferential plane of the disc stator winding, the conductor bars are arranged in a C-shape, and in the two sub-winding discs, the protruding direction of the middle area of the conductor bars of one sub-winding disc is opposite to the protruding direction of the middle area of the conductor bars of the other sub-winding disc.
[0014] Among them, the winding disk is a copper disk.
[0015] Thirdly, this application provides a disc motor, which includes: the aforementioned disc stator winding; and a rotor assembly disposed on one side of the disc stator winding along its axial direction.
[0016] The advantages of this application's implementation method, which differs from existing technologies, are as follows: This application provides a disc-type stator winding and its preparation method, as well as a disc-type motor. By molding the conductor ring as a whole, a sub-winding disc can be obtained. Then, two sub-winding discs are stacked relative to each other along the axial direction of the conductor ring. The inner and outer rings of the two sub-winding discs are electrically connected to obtain the main winding disc. Finally, the inner and outer rings of the main winding disc are cut to obtain the disc-type stator winding. On the one hand, the sub-winding disc is obtained through a molding process. Compared to the method of bonding multiple conductor strips with insulating adhesive, this not only shortens the preparation time of the sub-winding disc and improves its preparation efficiency, but also, because the inner and outer rings of the sub-winding disc are... The outer ring is continuous, enabling direct conductive connection between the two stacked sub-winding discs. This means that the mechanical connection and electrical conduction of the two sub-winding discs are completed in one step, which simplifies the manufacturing process of the disc stator winding and shortens the manufacturing time, thereby improving the manufacturing efficiency of the disc stator winding. On the other hand, the sub-winding discs are obtained through a molding process, eliminating the need for one-to-one alignment of multiple conductor bars. This helps improve the alignment accuracy when the two sub-winding discs are stacked relative to each other, eliminating alignment deviations. This reduces or avoids weakening of the mechanical connection between conductor bars and poor contact at conductive connection points, thereby reducing the power loss of the disc motor (not shown in the figure) and improving the energy conversion efficiency and reliability of the disc motor. Attached Figure Description
[0017] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort. Among them: Figure 1 is a schematic diagram of the preparation process of the disc stator winding provided in this application; Figure 2 is a schematic diagram of the structure of the conductor ring; Figure 3 is a schematic diagram of the preparation structure of the disc stator winding provided in this application; Figure 4 is a schematic diagram of the structure of one winding disc in the disc stator winding provided in this application; Figure 5 is a schematic diagram of the structure of another winding disc in the disc stator winding provided in this application; Figure 6 is a schematic diagram of the structure of the disc stator winding provided in this application; Figure 7 is a schematic diagram of the electrical conduction structure of the two disc stator windings provided in this application. Detailed Implementation
[0018] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. It is understood that the specific embodiments described herein are only for explaining this application and not for limiting it. Furthermore, it should be noted that, for ease of description, only the parts related to this application are shown in the accompanying drawings, not all structures. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application.
[0019] In the description of this application, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise," etc., indicating orientation or positional relationships based on the orientation or positional relationships shown in the accompanying drawings, are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, features defined with "first" and "second" may explicitly or implicitly include one or more of the stated features. In the description of this application, "a plurality of" means two or more, unless otherwise explicitly specified.
[0020] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection, an electrical connection, or a connection that allows communication between them; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication between two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.
[0021] In this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature being directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.
[0022] In this document, the term "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.
[0023] In related technologies, the fabrication process of disc stator windings typically involves multiple steps: First, multiple conductor bars are bonded and fixed with insulating adhesive to form a sub-winding disc; then, two stacked sub-winding discs are bonded and fixed with insulating adhesive; finally, the corresponding conductor bars in the two sub-winding discs are welded one by one. This fabrication process involves multiple bonding and welding operations, making it cumbersome and complex, which affects the production efficiency of disc stator windings. In addition, due to the large number of conductor bars, it is difficult to achieve precise alignment during fabrication, easily leading to alignment deviations. This not only weakens the mechanical connection between the conductor bars, increasing the risk of deformation or loosening of the disc stator winding during operation, but also causes poor contact at the conductive connection points of the conductor bars, resulting in increased energy loss in the disc motor.
[0024] This application provides a method for preparing a disc-type stator winding 100. As shown in Figures 1 to 3, Figure 1 is a schematic diagram of the preparation process of the disc-type stator winding provided in this application; Figure 2 is a schematic diagram of the structure of the conductor ring; Figure 3 is a schematic diagram of the preparation structure of the disc-type stator winding provided in this application. The method for preparing the disc-type stator winding 100 includes the following steps: Step S10: The conductor ring 200 is shaped to form a winding disc 20 having multiple conductor bars 21 arranged at circumferential intervals along the conductor ring 200; wherein, the middle regions 21c of adjacent conductor bars 21 are spaced apart, the inner ends 21a are connected to each other, and the outer ends 21b are connected to each other.
[0025] The conductor ring 200 can be a ring-shaped disk structure, and its material can be copper, copper alloy, or silver, but is not limited to these. Multiple through-grooves 20a, spaced circumferentially along the conductor ring 200, can be formed in the central region of the conductor ring 200 by electro-erosion or stamping. These through-grooves 20a extend axially through the conductor ring 200, forming multiple guide bars 21 arranged circumferentially along the central region of the conductor ring 200. Adjacent guide bars 21 are separated by through-grooves 20a. Since the through-grooves 20a are only formed in the central region of the winding disk 20, the inner ends 21a of adjacent guide bars 21 are interconnected, and the outer ends 21b of adjacent guide bars 21 are also interconnected. This ensures that the inner circumferential region of the winding disk 20 near its axis and the outer circumferential region away from its axis are consistent with the state of the conductor ring 200 before forming.
[0026] The sub-winding disk 20 can be obtained by molding the conductor ring 200 as a whole. The multiple conductor strips 21 of the sub-winding disk 20 obtained after molding have high consistency in size and dimensions, and the spacing between two adjacent conductor strips 21 is consistent, which helps to improve the alignment accuracy of the subsequent two sub-winding disks 20. In addition, the molding speed is fast, which can simplify the preparation steps of the sub-winding disk 20, shorten the preparation time, and improve the preparation efficiency of the sub-winding disk 20.
[0027] Step S20: Two sub-winding disks 20 are stacked opposite each other along the axial direction of the conductor ring 200. The inner rings of the two sub-winding disks 20 are connected and electrically connected, and the outer rings of the two sub-winding disks 20 are connected and electrically connected to form a total winding disk 10. The middle area of the two sub-winding disks 20 is insulated.
[0028] The two sub-winding disks 20 can be of the same size and shape. Assuming one surface of the sub-winding disk 20 along its axial direction is the front and the other surface is the back, when stacking the two sub-winding disks 20, the front surface of one sub-winding disk 20 can be placed opposite the front surface of the other sub-winding disk 20, or the back surface of one sub-winding disk 20 can be placed opposite the back surface of the other sub-winding disk 20. Furthermore, the portion of the middle region 21c of the plurality of guide bars 21 of one sub-winding disk 20 (i.e., the region where the sub-winding disk 20 has the through slot 20a) near the inner end 21a is respectively connected to the other sub-winding disk 20. The middle region 21c of the corresponding guide bar 21 in the sub-winding disk 20 is aligned with the part near the inner end 21a. The middle region 21c of multiple guide bars 21 in one sub-winding disk 20 (i.e., the area of the sub-winding disk 20 with the through slot 20a) near the outer end 21b is respectively aligned with the middle region 21c of the corresponding guide bar 21 in another sub-winding disk 20 near the outer end 21b. This process can be achieved in one step of alignment, which can improve the alignment accuracy and eliminate alignment deviation.
[0029] After the step of stacking the two sub-winding disks 20 relative to each other along the axial direction of the conductor ring 200 is completed, the inner rings of the two sub-winding disks 20 can be connected together by resistance welding to achieve electrical conduction of the inner rings. At the same time, the outer rings of the two sub-winding disks 20 can be connected together by resistance welding to achieve electrical conduction of the outer rings. Here, the inner ring of the sub-winding disk 20 refers to the part of the inner end 21a region of the adjacent conductor bars 21 that is connected to each other and the middle region 21c of the conductor bars 21 (i.e., the region of the sub-winding disk 20 with through slots 20a) along the radial direction of the sub-winding disk 20 near the inner end 21a of the conductor bars 21. The outer ring of the sub-winding disk 20 refers to the part of the outer end 21b region of the adjacent conductor bars 21 that is connected to each other and the middle region 21c of the conductor bars 21 (i.e., the region of the sub-winding disk 20 with through slots 20a) along the radial direction of the sub-winding disk 20 near the outer end 21b of the conductor bars 21.
[0030] Specifically, the area where the two sub-winding disks 20 are connected and electrically conductive extends a predetermined distance from the inner edge of the two sub-winding disks 20 along the radial direction of the sub-winding disks 20 toward the outer edge, and also extends a predetermined distance from the outer edge of the two sub-winding disks 20 along the radial direction of the sub-winding disks 20 toward the inner edge. This allows the middle region 21c of the conductor bar 21 to be connected and electrically conductive along the radial direction of the sub-winding disks 20 near the inner end 21a of the conductor bar 21, and the middle region 21c of the conductor bar 21 to be connected and electrically conductive along the radial direction of the sub-winding disks 20 near the outer end 21b of the conductor bar 21. That is, the two sub-winding disks 20... The inner end 21a region and the outer end 21b region of the adjacent conductors 21 are connected and electrically conductive. In the middle region 21c of the conductors 21, the conductor 21 of one winding disk 20 is connected and electrically conductive along the radial direction of the winding disk 20 near the inner end 21a to the corresponding conductor 21 of another winding disk 20 along the radial direction of the winding disk 20 near the inner end 21a. The conductor 21 of one winding disk 20 is connected and electrically conductive along the radial direction of the winding disk 20 near the outer end 21b to the corresponding conductor 21 of another winding disk 20 along the radial direction of the winding disk 20 near the outer end 21b.
[0031] Step S30: Cut the inner and outer rings of the main winding disk 10 respectively so that the adjacent conductor bars 21 in the same sub-winding disk 20 are spaced apart along the circumference of the conductor ring 200.
[0032] Specifically, the inner and outer rings of the main winding disk 10 are cut, that is, the inner end 21a region and the outer end 21b region where adjacent conductors 21 connect are cut. Laser cutting, plasma cutting, or electrical discharge machining can be used to cut the inner and outer rings of the main winding disk 10. After cutting, adjacent conductors 21 in the same sub-winding disk 20 are spaced apart circumferentially along the sub-winding disk 20.
[0033] Because the middle region 21c of the conductor 21 is connected and electrically conductive along the radial direction of the sub-winding disk 20 near the inner end 21a of the conductor 21, and the middle region 21c of the conductor 21 is connected and electrically conductive along the radial direction of the sub-winding disk 20 near the outer end 21b of the conductor 21, after cutting, the two ends of the conductor 21 in one sub-winding disk 20 are connected and electrically conductive to the corresponding conductor 21 in another sub-winding disk 20 along the radial direction of the sub-winding disk 20, thus preventing the main winding disk 10 from becoming loose or split.
[0034] This application obtains the sub-winding disks 20 by molding the conductor ring 200 as a whole. Then, two sub-winding disks 20 are stacked opposite each other along the axial direction of the conductor ring 200. The inner and outer rings of the two sub-winding disks 20 are electrically connected to obtain the main winding disk 10. Finally, the inner and outer rings of the main winding disk 10 are cut to obtain the disc-type stator winding 100. On the one hand, the sub-winding disks 20 are obtained through a molding process. Compared to bonding multiple conductor strips 21 with insulating adhesive, this not only shortens the preparation time of the sub-winding disks 20 and improves the preparation efficiency, but also, because the inner and outer rings of the sub-winding disks 20 are continuous, the two stacked... The two sub-winding disks 20 are electrically connected, meaning that the mechanical connection and electrical conduction of the two sub-winding disks 20 are completed in one step. This simplifies the manufacturing process of the disc stator winding 100, shortens the manufacturing time, and thus improves the manufacturing efficiency of the disc stator winding 100. On the other hand, the sub-winding disks 20 are obtained through a molding process, eliminating the need for one-to-one alignment of multiple conductor bars 21. This helps improve the alignment accuracy when the two sub-winding disks 20 are stacked relative to each other, eliminates alignment deviations, and reduces or avoids weakening of the mechanical connection between conductor bars 21 and poor contact at conductive connection points. This, in turn, reduces the power loss of the disc motor (not shown in the figure) and improves the energy conversion efficiency and reliability of the disc motor.
[0035] In some embodiments, as shown in FIG1, the method for preparing the disc stator winding 100 further includes step S40: filling and curing the total winding disc 10 with epoxy resin.
[0036] The epoxy resin can be filled into the main winding disk 10 by manual dispensing / coating, automatic dispensing with an electric glue machine, automatic coating with a coating machine, or pouring. After filling, the main winding disk 10 can be placed in a greenhouse for a first preset time, or it can be placed in an oven or curing oven for a second preset time to allow the epoxy resin to fully cure, thereby forming an epoxy resin layer (not shown) on the outer surface of the main winding disk 10.
[0037] By filling and curing the main winding disk 10 with epoxy resin, an epoxy resin layer can be formed on the outer surface of the main winding disk 10. The epoxy resin layer is distributed at least between the two sub-winding disks 20 and between adjacent conductor bars 21 on the same sub-winding disk 20. On the one hand, the epoxy resin layer is a high-resistance insulating layer, which can form a uniform and reliable insulating barrier between the two sub-winding disks 20 and between adjacent conductor bars 21 on the same sub-winding disk 20, preventing short circuits. On the other hand, the epoxy resin layer can firmly bond the two sub-winding disks 20 together. By connecting them into a robust integral structure, not only can the overall structural strength of the main winding disk 10 be improved, reducing the risk of deformation, bending, or relative displacement of the main winding disk 10 under vibration or impact, but the epoxy resin layer can also disperse local stress, alleviating or avoiding the risk of deformation or cracking of the main winding disk 10 due to stress concentration. On the other hand, the epoxy resin layer can improve the overall heat dissipation effect and high temperature resistance of the main winding disk 10, reduce heat accumulation, and help extend the service life of the disc stator winding 100.
[0038] In some embodiments, after filling the main winding disk 10 with epoxy resin and before curing, the main winding disk 10 can be subjected to degassing and pressurization treatment in sequence. That is, the epoxy resin-filled main winding disk 10 is placed in a vacuum chamber so that the gap between the epoxy resin and the main winding disk 10 and the air inside the epoxy resin expand and are extracted, thereby effectively removing air bubbles and achieving degassing; after the degassing process is completed, a preset pressure can be applied to one or two planes along its axial direction of the main winding disk 10 so that the epoxy resin can be evenly distributed between the two sub-winding disks 20.
[0039] In some embodiments, before the two sub-winding disks 20 are stacked opposite each other along the axial direction of the conductor ring 200, the method of preparing the disk stator winding 100 further includes: performing a surface insulation treatment on the sub-winding disks 20 to form an insulating layer (not shown) at least on the outer surface of the conductor bar 21.
[0040] The sub-winding disk 20, obtained by molding the conductor ring 200, can be completely immersed in the insulating varnish. After the insulating varnish completely covers the sub-winding disk 20, the sub-winding disk 20 is removed from the insulating varnish and the insulating varnish is cured by heating or other means, so that a thin and strong insulating layer is formed on the surface of the sub-winding disk 20.
[0041] By performing surface insulation treatment on the sub-winding disk 20, on the one hand, eddy current losses can be prevented from occurring when the two sub-winding disks 20 are stacked opposite each other along the axial direction of the conductor ring 200, which can further reduce the power loss of the disk motor; on the other hand, the insulation layer can isolate the surface of the sub-winding disk 20 from corrosive media such as air, liquid, and dust, which can reduce the risk of oxidation and corrosion of the sub-winding disk 20.
[0042] In some embodiments, as shown in Figures 3 to 5, Figure 4 is a structural schematic diagram of one winding disc in the disc-type stator winding provided in this application; Figure 5 is a structural schematic diagram of another winding disc in the disc-type stator winding provided in this application. The conductor ring 200 is formed by: forming a plurality of through slots 20a spaced circumferentially along the middle region of the conductor ring 200, and the plurality of through slots 20a penetrating the conductor ring 200 axially, so that the middle regions 21c of adjacent conductor bars 21 are spaced apart, the inner ends 21a are connected to each other, and the outer ends 21b are connected to each other, and the middle regions 21c of the conductor bars 21 protrude beyond the inner ends 21a and the outer ends 21b.
[0043] Multiple through-grooves 20a, spaced circumferentially along the conductor ring 200, can be formed in the central region of the conductor ring 200 by methods such as electro-erosion or stamping. These through-grooves 20a extend axially through the conductor ring 200, forming multiple guide bars 21 arranged circumferentially along the central region of the conductor ring 200. Adjacent guide bars 21 are separated by the through-grooves 20a. Since the through-grooves 20a are only formed in the central region of the winding disk 20, the inner ends 21a and outer ends 21b of adjacent guide bars 21 are interconnected. This ensures that the inner circumferential region of the winding disk 20 near its axis and the outer circumferential region away from its axis are consistent with the state before the conductor ring 200 is formed. The winding disk 20 is obtained by forming the entire conductor ring 200. The multiple guide bars 21 of the sub-winding disk 20 obtained after molding have high consistency in size and dimensions, and the spacing between two adjacent guide bars 21 is consistent, which helps to improve the alignment accuracy when the two sub-winding disks 20 are stacked relative to each other. In addition, the molding speed is fast, which can simplify the preparation steps of the sub-winding disk 20, shorten the preparation time, and improve the preparation efficiency of the sub-winding disk 20.
[0044] Within the circumferential plane of the conductor ring 200, the conductor strips 21 are arranged in a C-shape. In the two sub-winding disks 20, the convex direction of the middle region 21c of the conductor strips 21 of one sub-winding disk 20 is opposite to the convex direction of the middle region 21c of the conductor strips 21 of the other sub-winding disk 20.
[0045] The shape and size of the conductor strips 21 of the same sub-winding disk 20 are identical, and the shape and size of the conductor strips 21 of the two sub-winding disks 20 are also identical. After one of the two sub-winding disks 20 is flipped 180°, the two sub-winding disks 20 can completely overlap, and the protruding direction of the middle region 21c of the conductor strip 21 of one sub-winding disk 20 corresponds to the protruding direction of the middle region 21c of the conductor strip 21 of the other sub-winding disk 20.
[0046] As shown in Figures 6 and 7, Figure 6 is a structural schematic diagram of the disc-type stator winding provided in this application; Figure 7 is a schematic diagram of the electrical conduction structure of the two disc-type stator windings provided in this application. The conductor bar 21 includes an inner conductor section 211, a connecting section 212, and an outer conductor section 213 connected sequentially from the inner ring to the outer ring of the sub-winding disc 20. The connecting section 212 can extend radially along the sub-winding disc 20. The inner conductor section 211 extends obliquely from the connecting section 212 toward the inner ring of the sub-winding disc 20, and the outer conductor section 213 extends obliquely from the connecting section 212 toward the outer ring of the sub-winding disc 20. The inner conductor section 211 and the outer conductor section 213 extend in the same direction along the circumference of the sub-winding disc 20. The inner conductor section 211 and the outer conductor section 213 are flared from the connecting section 212 to the inner end 21a and the outer end 21b.
[0047] The inner conductor section 211 and outer conductor section 213 of the two sub-winding discs 20 extend in different directions along the circumference of the sub-winding discs 20, so that multiple sets of windings 11 on the disc stator winding 100 can be arranged sequentially along the circumference of the disc stator winding 100. Each set of windings 11 is formed by connecting corresponding conductor bars 21 in the two sub-winding discs 20 in series. Among the multiple conductor bars 21 connected in series, every two connected conductor bars 21 constitute one turn of winding 11. Each set of windings 11 has two free ends. One of the two free ends is connected to the free end of the adjacent set of windings 11, and the other has a lead end 22 for connecting to the three-phase power supply. The lead ends 22 of two adjacent sets of windings 11 can be stacked along the axial direction of the disc stator winding 100 and are interconnected and electrically conductive. For example, the disc stator winding 100 may include 3P groups of windings 11, where P is a positive integer; each group of windings 11 has a lead end 22 at one of its free ends, and the number of lead ends 22 is 3P; the number of turns in each group of windings 11 is N, and the total number of turns in the entire disc stator winding 100 is N*3P. In some embodiments, P can be 3, N can be 6, that is, the disc stator winding 100 may include 9 groups of windings 11, the number of lead ends 22 is 9, the number of turns in each group of windings 11 is 6, and the total number of turns in the entire disc stator winding 100 is 54.
[0048] In some embodiments, as shown in FIG6, along the radial direction of the winding disk 20, the inner guide segment 211 gradually increases in size from the inner ring to the outer ring of the winding disk 20, the outer guide segment 213 gradually increases in size from the inner ring to the outer ring of the winding disk 20, and the connecting segment 212 gradually increases in size from the inner ring to the outer ring of the winding disk 20, or the connecting segment 212 has the same size everywhere along the circumference of the winding disk 20. Specifically, the circumferential size of the inner guide segment 211 near the inner ring of the winding disk 20 is smaller than the circumferential size of the outer guide segment 213 near the inner ring of the winding disk 20, and the circumferential size of the inner guide segment 211 near the outer ring of the winding disk 20 is smaller than the circumferential size of the outer guide segment 213 near the outer ring of the winding disk 20. This allows full utilization of the circumferential dimensions of the winding disc 20 and maximizes the average cross-sectional area of the conductor bar 21, thereby reducing the resistance of the conductor bar 21, improving its overcurrent and overload capacity, and ultimately reducing energy loss, thus enhancing the energy conversion efficiency and reliability of the disc motor.
[0049] In some embodiments, the through slot 20a extends to the outer ring and the inner ring at both ends of the conductor ring 200 in the radial direction, respectively. The inner ring and the outer ring of the main winding disk 10 are cut so that the adjacent conductor bars 21 in the same sub-winding disk 20 are spaced apart in the circumferential direction of the conductor ring 200, including: cutting the inner ring into a circle; cutting the outer ring into a circle, and forming a lead end 22 on the outer ring.
[0050] The inner and outer rings of the main winding disk 10 can be rounded using laser cutting, plasma cutting, or electrical discharge machining to remove the inner end 21a and outer end 21b regions of the interconnecting conductors 21 in the same sub-winding disk 20, thereby ensuring that adjacent conductors 21 in the same sub-winding disk 20 are spaced apart circumferentially. Specifically, the inner ring of the main winding disk 10 can be cut in one step along the circumference of the main winding disk 10; the outer ring of the main winding disk 10 can also be cut in one step along the circumference of the main winding disk 10, with independent lead ends 22 located at one free end of each winding group 11. The lead ends 22 of two adjacent winding groups 11 can be stacked along the axial direction of the main winding disk 10, interconnected, and electrically conductive; alternatively, the outer ring of the main winding disk 10 can be cut in an arc shape to reserve the lead ends 22.
[0051] In some embodiments, connecting the inner rings of the two sub-winding disks 20 and making them electrically conductive, and connecting the outer rings of the two sub-winding disks 20 and making them electrically conductive, includes: welding the inner rings of the two sub-winding disks 20 using resistance welding, and welding the outer rings of the two sub-winding disks 20 using resistance welding.
[0052] After the two sub-winding disks 20 are stacked opposite each other along the axial direction of the conductor ring 200, pressure can be applied to the sub-winding disks 20 to ensure that the contact points of the inner and outer rings of the two sub-winding disks 20 are tightly fitted, reducing contact resistance and providing forging force for the subsequent welding process, compacting the molten metal and avoiding the formation of pores and cracks. When the inner and outer rings of the two sub-winding disks 20 are welded separately using resistance welding, the current generated will generate concentrated heat in a very short time when passing through the high resistance area, instantly melting the insulation layer at the contact points of the inner and outer rings of the two sub-winding disks 20, thereby connecting and electrically conducting the inner rings of the two sub-winding disks 20, and connecting and electrically conducting the outer rings of the two sub-winding disks 20, thus forming the total winding disk 10 from the two sub-winding disks 20. The mechanical connection and electrical conduction of the two sub-winding discs 20 are completed in one step, thus eliminating the need to bond and fix the two sub-winding discs 20 together. This shortens the processing time required to achieve conductive connection between the two sub-winding discs 20, simplifies the manufacturing process of the disc stator winding 100, and improves the manufacturing efficiency of the disc stator winding 100.
[0053] As shown in Figures 4 to 7, this application also provides a disc-type stator winding 100. The disc-type stator winding 100 includes two sub-winding discs 20. Each sub-winding disc 20 includes a plurality of conductor bars 21 arranged at intervals along the circumference of the disc-type stator winding 100. The two sub-winding discs 20 are stacked opposite each other along the axial direction of the disc-type stator winding 100, and the conductor bars 21 arranged along the axial direction are connected.
[0054] In the winding disk 20, a through groove 20a is provided between two adjacent guide bars 21. The through groove 20a penetrates the winding disk 20 radially and axially, and the shape of the through groove 20a matches the shape of the guide bar 21. Assuming that one surface of the winding disk 20 along its axial direction is the front and the other surface is the back, when the two winding disks 20 are stacked opposite each other along the axial direction of the disc stator winding 100, the opposite side of the two winding disks 20 is either the front or the opposite side of the two winding disks 20 is either the back.
[0055] The two sub-winding disks 20 can be of the same size and have the same shape. That is, the shape and size of the conductor strips 21 of the same sub-winding disk 20 are the same, and the shape and size of the conductor strips 21 of the two sub-winding disks 20 are also the same. After one of the two sub-winding disks 20 is flipped 180°, the two sub-winding disks 20 can completely overlap, and the convex direction of the middle region 21c of the conductor strip 21 of one sub-winding disk 20 corresponds to the convex direction of the middle region 21c of the conductor strip 21 of the other sub-winding disk 20.
[0056] The conductor bars 21 of the two sub-winding disks 20 are connected along the axial direction. That is, the end of the conductor bar 21 of one sub-winding disk 20 near the inner ring is connected to the end of the corresponding conductor bar 21 of the other sub-winding disk 20 near the inner ring, and the end of the conductor bar 21 of one sub-winding disk 20 near the outer ring is connected to the end of the corresponding conductor bar 21 of the other sub-winding disk 20 near the outer ring, to form a total sub-winding disk 20. The cross-sectional area of the conductor bar 21 is not limited by the process. The circumferential dimension of the conductor bar 21 along the disk stator winding 100 can be designed according to actual needs to maximize the average cross-sectional area of the conductor bar 21. This reduces the resistance of the conductor bar 21, improves the overcurrent and overload capacity of the conductor bar 21, and thus reduces power loss, improving the energy conversion efficiency and reliability of the disk motor.
[0057] As shown in Figures 6 and 7, the disc-type stator winding 100 includes multiple sets of windings 11 arranged sequentially along its circumference. Each set of windings 11 is formed by connecting corresponding conductor bars 21 in two sub-winding discs 20 in series. Each pair of conductor bars 21 connected in series constitutes one turn of winding 11, meaning each set of windings 11 consists of multiple turns of winding 11. Each set of windings 11 has two free ends. One of these free ends is connected to the free end of an adjacent set of windings 11, and the other end has a lead end 22 for connecting to a three-phase power supply. The lead ends 22 of two adjacent sets of windings 11 can be stacked along the axial direction of the disc-type stator winding 100, and are interconnected and electrically conductive. For example, the disc stator winding 100 may include 3P groups of windings 11, where P is a positive integer; each group of windings 11 has a lead end 22 at one of its free ends, and the number of lead ends 22 is 3P; the number of turns in each group of windings 11 is N, and the total number of turns in the entire disc stator winding 100 is N*3P. In some embodiments, P can be 3, N can be 6, that is, the disc stator winding 100 may include 9 groups of windings 11, the number of lead ends 22 is 9, the number of turns in each group of windings 11 is 6, and the total number of turns in the entire disc stator winding 100 is 54.
[0058] In some embodiments, the disc stator winding 100 further includes an epoxy resin layer, which is disposed at least between the two sub-winding discs 20 and between adjacent conductor bars 21 on the same sub-winding disc 20. This arrangement serves several purposes: firstly, the epoxy resin layer, being a high-resistance insulating layer, forms a uniform and reliable insulating barrier between the two sub-winding discs 20 and between adjacent conductor bars 21 on the same sub-winding disc 20, preventing short circuits; secondly, the epoxy resin layer firmly bonds the two sub-winding discs 20 into a robust integral structure, not only improving the overall structural strength of the main winding disc 10 and reducing the risk of deformation, bending, or relative displacement of the main winding disc 10 under vibration or impact, but also dispersing local stress, mitigating or preventing deformation or cracking of the main winding disc 10 due to stress concentration; and thirdly, the epoxy resin layer enhances the overall heat dissipation and high-temperature resistance of the main winding disc 10, reduces heat accumulation, and helps extend the service life of the disc stator winding 100.
[0059] In some embodiments, the circumferential dimension of the conductor bar 21 at the end near the inner ring of the winding disc 20 along the disc stator winding 100 is smaller than the circumferential dimension of the end near the outer ring of the winding disc 20 along the disc stator winding 100. This fully utilizes the circumferential dimension of the winding disc 20, maximizing the average cross-sectional area of the conductor bar 21, thereby reducing the resistance of the conductor bar 21, improving its overcurrent and overload capacity, and ultimately reducing energy loss, thus enhancing the energy conversion efficiency and reliability of the disc motor.
[0060] In some embodiments, as shown in Figures 4, 5, and 7, the conductor bars 21 are arranged in a C-shape within the circumferential plane of the disc stator winding 100. In the two sub-winding discs 20, the protruding direction of the middle region 21c of the conductor bars 21 of one sub-winding disc 20 is opposite to the protruding direction of the middle region 21c of the conductor bars 21 of the other sub-winding disc 20.
[0061] The shape and size of the conductor strips 21 of the same sub-winding disk 20 are identical, and the shape and size of the conductor strips 21 of the two sub-winding disks 20 are also identical. After one of the two sub-winding disks 20 is flipped 180°, the two sub-winding disks 20 can completely overlap, and the protruding direction of the middle region 21c of the conductor strip 21 of one sub-winding disk 20 corresponds to the protruding direction of the middle region 21c of the conductor strip 21 of the other sub-winding disk 20.
[0062] The conductor 21 includes an inner conductor section 211, a connecting section 212, and an outer conductor section 213 connected sequentially from the inner ring to the outer ring of the winding disk 20. The connecting section 212 can extend radially along the winding disk 20. The inner conductor section 211 extends obliquely from the connecting section 212 toward the inner ring of the winding disk 20, and the outer conductor section 213 extends obliquely from the connecting section 212 toward the outer ring of the winding disk 20. The inner conductor section 211 and the outer conductor section 213 extend in the same direction along the circumference of the winding disk 20. The inner conductor section 211 and the outer conductor section 213 are flared from the connecting section 212 to the inner end 21a and the outer end 21b.
[0063] The inner conductor 211 and outer conductor 213 of the two sub-winding disks 20 extend in different directions along the circumference of the sub-winding disks 20, so that multiple sets of windings 11 on the disc stator winding 100 can be arranged sequentially along the circumference of the disc stator winding 100, and each set of windings 11 is formed by the corresponding conductor bars 21 in the two sub-winding disks 20 in series. Among the multiple conductor bars 21 connected in series, every two connected conductor bars 21 constitute a turn of winding 11.
[0064] In some embodiments, along the radial direction of the winding disk 20, the inner guide segment 211 gradually increases in size from the inner ring to the outer ring of the winding disk 20, the outer guide segment 213 gradually increases in size from the inner ring to the outer ring of the winding disk 20, and the connecting segment 212 gradually increases in size from the inner ring to the outer ring of the winding disk 20, or the connecting segment 212 has the same size everywhere along the circumference of the winding disk 20. Specifically, the circumferential size of the inner guide segment 211 near the inner ring of the winding disk 20 is smaller than the circumferential size of the outer guide segment 213 near the inner ring of the winding disk 20, and the circumferential size of the inner guide segment 211 near the outer ring of the winding disk 20 is smaller than the circumferential size of the outer guide segment 213 near the outer ring of the winding disk 20. This allows full utilization of the circumferential dimensions of the winding disc 20 and maximizes the average cross-sectional area of the conductor bar 21, thereby reducing the resistance of the conductor bar 21, improving its overcurrent and overload capacity, and ultimately reducing energy loss, thus enhancing the energy conversion efficiency and reliability of the disc motor.
[0065] In some embodiments, the winding disk 20 can be a copper disk.
[0066] In some embodiments, the winding disk 20 may be a copper alloy disk or a silver disk, but is not limited thereto.
[0067] This application also provides a disc motor. The disc motor includes the disc stator winding 100 and rotor assembly (not shown) of any of the above embodiments. The rotor assembly is located on one side of the disc stator winding 100 along the axial direction.
[0068] In this embodiment, the specific structure of the disc stator winding 100 is the same as described in the above embodiments. Since the disc motor adopts all the technical solutions of all the above embodiments of the disc stator winding 100, it has at least all the beneficial effects brought about by the technical solutions of the above embodiments, which will not be described in detail here.
[0069] The above description is merely an embodiment of this application and does not limit the patent scope of this application. Any equivalent structural or procedural transformations made using the content of this application's specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of this application.
Claims
1. A method for preparing a disc-type stator winding, characterized in that, The preparation method includes: shaping a conductor ring to form a winding disk having multiple conductor bars arranged circumferentially along the conductor ring; wherein the middle regions of adjacent conductor bars are spaced apart, their inner ends are connected to each other, and their outer ends are connected to each other; stacking two winding disks opposite each other along the axial direction of the conductor ring, connecting the inner rings of the two winding disks and making them electrically conductive, and connecting the outer rings of the two winding disks and making them electrically conductive, to form a total winding disk; wherein the middle regions of the two winding disks are insulated; and cutting the inner and outer rings of the total winding disk so that the conductor bars arranged adjacently in the same winding disk are spaced apart circumferentially.
2. The preparation method according to claim 1, characterized in that, The preparation method further includes: filling and curing the total winding disk with epoxy resin.
3. The preparation method according to claim 1, characterized in that, Before stacking the two sub-winding disks opposite each other along the axial direction of the conductor ring, the preparation method further includes: performing surface insulation treatment on the sub-winding disks to form an insulating layer at least on the outer surface of the conductor bar.
4. The preparation method according to claim 1, characterized in that, The forming process of the conductor ring includes: forming a plurality of through slots spaced circumferentially along the middle region of the conductor ring, and the plurality of through slots penetrating the conductor ring axially, so that the middle regions of adjacent conductor bars are spaced apart, their inner ends are connected to each other, and their outer ends are connected to each other, and the middle region of the conductor bar protrudes beyond the inner and outer ends; wherein, in the circumferential plane of the conductor ring, the conductor bar is C-shaped; in the two sub-winding disks, the protrusion direction of the middle region of the conductor bar of one sub-winding disk is opposite to the protrusion direction of the middle region of the conductor bar of the other sub-winding disk.
5. The preparation method according to claim 4, characterized in that, The through slot extends to the outer ring and the inner ring respectively at both ends of the conductor ring in the radial direction; the cutting process of the inner and outer rings of the main winding disk so that the adjacent conductor bars in the same sub-winding disk are spaced apart along the circumferential direction includes: cutting the inner ring into a circle; cutting the outer ring into a circle and forming a lead end on the outer ring.
6. The preparation method according to claim 1, characterized in that, The step of connecting and electrically connecting the inner rings of the two sub-winding disks and connecting and electrically connecting the outer rings of the two sub-winding disks includes: welding the inner rings of the two sub-winding disks using resistance welding, and welding the outer rings of the two sub-winding disks using resistance welding.
7. A disc-type stator winding, characterized in that, The disc stator winding includes two sub-winding discs, each sub-winding disc including a plurality of guide bars arranged at intervals along the circumference of the disc stator winding; wherein the two sub-winding discs are stacked opposite each other along the axial direction of the disc stator winding, and the guide bars arranged along the axial direction are connected.
8. The disc stator winding according to claim 7, characterized in that, The disc-type stator winding also includes an epoxy resin layer, which is disposed at least between two of the sub-winding discs and between the conductor bars disposed adjacently on the same sub-winding disc.
9. The disc stator winding according to claim 7, characterized in that, The dimension of the conductor bar at the end near the inner ring of the sub-winding disc along the circumference of the disc stator winding is smaller than the dimension of the end near the outer ring of the sub-winding disc along the circumference of the disc stator winding.
10. The disc stator winding according to claim 7, characterized in that, In the circumferential plane of the disc stator winding, the guide bar is arranged in a C-shape, and in the two sub-winding discs, the protrusion direction of the middle region of the guide bar of one sub-winding disc is opposite to the protrusion direction of the middle region of the guide bar of the other sub-winding disc.
11. The disc stator winding according to claim 7, characterized in that, The winding disk is a copper disk.
12. A disc motor, characterized in that, The disc motor includes: a disc stator winding as described in any one of claims 7 to 11; and a rotor assembly disposed on one side of the disc stator winding along its axial direction.