Stator assembly and electric machine

Abstract

This invention relates to the field of motor technology, and more particularly to a stator assembly and a motor. The stator assembly includes: a stator core, which is annular and has multiple stator slots evenly spaced circumferentially on its inner surface; a three-phase winding, formed by multiple sets of flat wire conductor coils wound in multiple layers within the stator slots, the three-phase winding having terminals, each terminal including a first terminal located radially close to the axis within the stator slot and a second terminal located radially away from the axis within the stator slot, the first and second terminals being continuously numbered in the slots circumferentially of the stator core; and a busbar assembly electrically connected to the first and second terminals respectively. By continuously arranging the terminals of the three-phase winding within the stator slots, the distribution of the stator winding leads is concentrated, thereby reducing the structural complexity and size of the busbar.

Description

Technical Field

[0001] This invention relates to the field of motor technology, and more particularly to a stator assembly and a motor. Background Technology

[0002] The stator winding leads of conventional motors are scattered and cover a fan angle of more than 2 / 3 of a circle. Therefore, large-area busbars or multiple busbars are required to ensure stable electrical connection, resulting in a complex busbar topology and large size, which limits the size and cost of the busbars.

[0003] The above content is only used to help understand the technical solution of the present invention and does not represent an admission that the above content is prior art. Summary of the Invention

[0004] The main objective of this invention is to provide a stator assembly and a motor that solves the technical problem in the prior art where the lead wires are scattered, resulting in a complex and large busbar topology.

[0005] To achieve the above objectives, the present invention provides a stator assembly, the stator assembly comprising: The stator core 101 is annular and has a plurality of stator slots 102 evenly spaced along the circumferential direction on its inner side. The three-phase winding is formed by winding multiple sets of flat wire conductor coils 103 in multiple layers in the stator slot 102. The three-phase winding is provided with terminals 105. The terminals 105 include a first terminal part located radially close to the axis in the stator slot 102 and a second terminal part located radially away from the axis in the stator slot 102. The first terminal part and the second terminal part are continuous in slot number around the stator core 101. Busbar assembly, wherein the busbar assembly is electrically connected to the first terminal and the second terminal respectively. Optionally, the bus assembly includes a bus, which includes a first phase bus 104a, a second phase bus 104b, and a third bus. Each phase bus includes at least a main body and a three-phase connection portion, and the main body and the three-phase connection portion are fixedly connected. The main body of the first phase busbar 104a, the main body of the second phase busbar 104b, and the main body of the third busbar are stacked sequentially along the axial direction.

[0006] Optionally, the main body of the second phase busbar 104b is rotated 4 slots circumferentially relative to the main body of the first phase busbar 104a along the stator core 101, and then stacked sequentially along the axial direction. The main body of the first busbar is rotated circumferentially by four slots relative to the main body of the second phase busbar 104b, and then stacked sequentially along the axial direction.

[0007] Optionally, the flat wire conductor coil 103 includes a bent portion 103a and a welding end, the welding end including a first end portion 103b and a second end portion 103b connected to the bent portion 103a.

[0008] Optionally, the bent portion 103a forms a hairpin end of a three-phase winding at one end of the stator core 101 in the axial direction, and the first end portion 103b and the second end portion 103b form twisted ends at the other end of the stator core 101 in the axial direction.

[0009] Optionally, the twisted end includes: a first end 103b and a second end 103b that are inserted into the odd-numbered layers in the stator slot 102 and twisted by a preset angle along the first twisting direction of the circumference of the stator core 101. And, the first end 103b and the second end 103b, which are inserted into the even-numbered layers in the stator slot 102 and twisted by a predetermined angle in the second torsional direction along the circumference of the stator core 101.

[0010] Optionally, the first torsion direction and the second torsion direction are opposite directions in the circumferential direction of the stator core 101.

[0011] Optionally, the torsional distance between the first end 103b and the second end 103b inserted into the m-th layer in the stator slot 102 is greater than the torsional distance between the first end 103b and the second end 103b inserted into the 1st to m-1th layers in the stator slot 102, where m is the maximum number of slot layers in the stator slot 102, and m≥5.

[0012] Optionally, the wiring terminal 105 and the twisted wire end are located at the same end of the stator core 101 along its axial direction.

[0013] In addition, to achieve the above objectives, the present invention also proposes an electric motor, which includes a stator assembly as described above.

[0014] This invention provides a stator assembly, comprising: a stator core 101, wherein the stator core 101 is annular and its inner surface is provided with a plurality of stator slots 102 evenly spaced circumferentially; a three-phase winding, wherein the three-phase winding is formed by winding multiple sets of flat wire conductor coils 103 in multiple layers within the stator slots 102, the three-phase winding being provided with terminals 105, each terminal 105 including a first terminal portion located radially close to the axis within the stator slot 102 and a second terminal portion located radially away from the axis within the stator slot 102, the first terminal portion and the second terminal portion being continuously numbered in the slot number circumferentially of the stator core 101; and a busbar assembly, wherein the busbar assembly is electrically connected to the first terminal portion and the second terminal portion respectively. By continuously arranging the terminals 105 of the three-phase winding within the stator slots 102, the distribution of the stator winding leads is concentrated, thereby reducing the structural complexity and size of the busbar. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the busbar side of the stator assembly of the present invention; Figure 2 This is a schematic diagram of the stator assembly terminal 105 of the present invention; Figure 3 This is a schematic diagram of the structure of the flat wire conductor coil 103 of the stator assembly of the present invention; Figure 4 This is a schematic diagram of the twist at the twisted end of the stator assembly of the present invention; Figure 5 This is a schematic diagram showing the torsion angles of the twisted ends of the 5th and 6th layers of the stator assembly of the present invention.

[0016] Explanation of icon numbers: The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0017] It should be understood that the specific embodiments described herein are for illustrative purposes only and are not intended to limit the scope of the invention.

[0018] This invention provides a stator assembly, with reference to... Figure 1 , Figure 1 This is a schematic diagram of the busbar side of a stator assembly according to the present invention.

[0019] In this embodiment, the stator assembly includes: The stator core 101 is annular and has multiple stator slots 102 evenly spaced along the circumference on its inner side. The three-phase winding is formed by multiple sets of flat wire conductor coils 103 wound in multiple layers in the stator slot 102. The three-phase winding is provided with terminals 105. The terminals 105 include a first terminal part located radially close to the axis in the stator slot 102 and a second terminal part located radially away from the axis in the stator slot 102. The first terminal part and the second terminal part are continuous in the slot number on the circumference of the stator core 101. The bus assembly is electrically connected to the first terminal and the second terminal respectively.

[0020] This embodiment includes: a stator core 101, which is annular and has multiple stator slots 102 evenly spaced circumferentially on its inner side; a three-phase winding, which is formed by winding multiple sets of flat wire conductor coils 103 in multiple layers within the stator slots 102; the three-phase winding is provided with terminals 105, each terminal 105 including a first terminal portion located radially close to the axis within the stator slot 102 and a second terminal portion located radially away from the axis within the stator slot 102; the first terminal portion and the second terminal portion are continuously numbered in the slot number circumferentially around the stator core 101; and a bus assembly, which is electrically connected to the first terminal portion and the second terminal portion respectively. By continuously arranging the terminals 105 of the three-phase winding within the stator slots 102, the distribution of the stator winding leads is concentrated, thereby reducing the structural complexity and size of the bus.

[0021] In this field, conventional winding leads are located in dispersed positions and cover a sector angle of more than 2 / 3 of a circle. Therefore, a large-area busbar is generally used at one end of the stator winding to connect the leads. This reduces the torsional coverage angle and cost of the leads and ensures the potential balance of each branch. However, this results in a complex busbar topology and large size, making the size and cost of the busbar a bottleneck for the motor.

[0022] Based on this, this embodiment sets the winding method of the stator winding to concentrate the position of the lead wires of each branch, thereby greatly reducing the coverage size and number of busbars.

[0023] The three phase windings are U-phase, V-phase, and W-phase. By rotating the three phase windings along the direction of increasing slot size, a 120° spatial phase difference can be naturally formed. After three-phase AC power is applied, a positive circular rotating magnetic field is generated, which will not cause magnetomotive force distortion, reverse rotation, pulsating stall. At the same time, it makes the stator winding axial end wiring layered and orderly, without random crossing, which facilitates the arrangement of busbars, leads, and insulation frames. The structure and process are good for mass production.

[0024] Each phase winding in the three-phase winding is formed by four branches connected in parallel. Each branch is formed by four types of flat wire conductor coils 103 being wound in multiple layers within the stator core 101102. The four types of flat wire conductor coils 103 are one of the following: full-pitch flat wire conductor coil 103, two types of long-pitch flat wire conductor coils 103, and short-pitch flat wire conductor coil 103.

[0025] Specifically, the stator assembly in this embodiment is a 72-slot, 12-pole, 4-branch, 5-layer flat wire motor winding. Correspondingly, the four branches include: the first branch, the second branch, the third branch, and the fourth branch. The first branch of the U-phase winding is formed by the flat wire conductor coil 103 starting from the first starting point located in the 5th layer and winding through 5 layers of 72 stator cores 101102 according to the first winding method. The second branch is formed by winding the flat wire conductor coil 103 through 5 layers of 72 stator cores 101102 starting from the second starting point located in the 5th layer based on the second winding method; The third branch is formed by the flat wire conductor coil 103 starting from the third starting point located in the 5th layer and winding through 5 layers of 72 stator cores 101102 using the third winding method. The fourth branch is formed by winding the flat wire conductor coil 103 through 5 layers of 72 stator cores 101102 based on the fourth winding method, starting from the fourth starting point located in the 5th layer.

[0026] Based on the configuration of the three-phase winding in this embodiment, the first terminal and the second terminal in the terminal 105 are respectively the lead-out wire and the lead-in wire, which are used to provide three-phase electrical signals or to lead out three-phase electrical signals.

[0027] Meanwhile, the first connection part is located in the innermost layer of the stator slot 102 of the stator core 101, radially close to the axis, while the second connection part is located in the outermost layer of the stator slot 102 of the stator core 101, radially close to the axis.

[0028] In an optional embodiment, the bus assembly includes a bus, which includes a first phase bus 104a, a second phase bus 104b, and a third bus 104c. Each phase bus includes at least a main body and a three-phase connection portion, and the main body and the three-phase connection portion are fixedly connected. The main body of the first phase busbar 104a, the main body of the second phase busbar 104b, and the main body of the third busbar are stacked sequentially along the axial direction.

[0029] To reduce the size and space ratio of the busbar, this embodiment divides the busbar into three phase busbars with the same structure, which are connected to each phase winding respectively. By stacking the phase busbars along the axial direction, the space ratio of the busbar is reduced, thereby reducing the overall size.

[0030] In an optional embodiment, the main body of the second phase bus 104b is rotated four slots circumferentially relative to the main body of the first phase bus 104a along the stator core 101, and then stacked sequentially along the axial direction. The main body of the third busbar is rotated circumferentially by four slots relative to the main body of the second phase busbar 104b, and then stacked sequentially along the axial direction.

[0031] Since the three-phase windings are U-phase winding, V-phase winding, and W-phase winding, each of the U-phase, V-phase, and W-phase windings is formed by four branch flat conductors connected in parallel; the V-phase winding is obtained by rotating 4 slots relative to the U-phase winding in the direction of increasing slot size; the W-phase winding is obtained by rotating 8 slots relative to the U-phase winding in the direction of increasing slot size. Since the lead wires of each phase winding are generally at the start and end points of each phase winding, the position of the lead wires corresponding to each phase winding is also obtained by rotating multiple slots in the direction of increasing slot size. Based on this, in order to minimize the size of the busbar, this embodiment can connect the lead wires of one phase winding to each phase busbar, rotate the main body of each phase busbar circumferentially by multiple slots, and stack them to obtain the busbar, thereby reducing the overall size of the busbar.

[0032] In an optional embodiment, the flat wire conductor coil 103 includes a bent portion 103a and a welding end, the welding end including a first end portion 103b and a second end portion 103b connected to the bent portion 103a.

[0033] refer to Figure 3 , Figure 3 This is a schematic diagram of the structure of the flat wire conductor coil 103 in this embodiment. The number of stator cores 101 between the first end 103b and the second end 103b on the stator winding is the span of the flat wire conductor coil 103. In this embodiment, there are four types of spans for the flat wire conductor coil 103: a short-pitch flat wire conductor coil 103 with a span of 5, a full-pitch flat wire conductor coil 103 with a span of 6, and long-pitch flat wire conductor coils 103 with spans of 7 and 8. In each branch, the 5th to 2nd layers are alternately wound with full-pitch flat wire conductor coils 103 with a span of 6 and long-pitch flat wire conductor coils 103 with a span of 8. In the coils wound in the same layer of the 1st layer, the short-pitch flat wire conductor coil 103 with a span of 5 and the long-pitch flat wire conductor coil 103 with a span of 7 are alternately wound in the same layer.

[0034] In an optional embodiment, the bent portion 103a forms a hairpin end of a three-phase winding at one end of the stator core 101 in the axial direction, and the first end portion 103b and the second end portion 103b form a twisted end at the other end of the stator core 101 in the axial direction.

[0035] In order to achieve closed loop of each branch, in this embodiment, the flat wire conductor coil 103 is wound in the stator core 101 in the form of insertion, that is, the bent part 103a is stacked at one end of the stator core 101 in the axial direction to form a hairpin end, and the first end 103b and the second end 103b pass through the stator core 101 and are twisted and welded at the other end of the stator core 101 in the axial direction to form a twisted end.

[0036] In an optional embodiment, the twisted end includes: The first end 103b and the second end 103b of the odd-numbered layers inserted in the stator slot 102 are twisted by a preset angle along the first torsional direction of the stator core 101 in the circumferential direction. And, the first end 103b and the second end 103b, which are inserted into the even-numbered layers in the stator slot 102 and twisted by a predetermined angle in the second torsional direction along the circumference of the stator core 101.

[0037] In an optional embodiment, the first torsion direction and the second torsion direction are opposite directions in the circumferential direction of the stator core 101, and the first torsion direction is along the direction of increasing slot size, and the second torsion direction is along the direction of decreasing slot size, or the first torsion direction is consistent with the cross-layer winding direction of each flat wire conductor coil, and the second torsion direction is opposite to the cross-layer winding direction of each flat wire conductor coil.

[0038] refer to Figure 4 , Figure 4 This is a schematic diagram of the twisting at the twisted end in this embodiment. Since the flat wire conductor coil 103 is directly inserted into the stator slot 102 across layers or within the same layer, and forms a twisted end at the other end after passing through the stator slot 102 and being welded, in order to reduce the size of the welded end and the difficulty of the welding process, this embodiment can twist the first end 103b or the second end 103b, so that the distance between multiple ends is as close as possible and the spatial height is similar. When twisting, the twisting directions of odd-numbered layers and even-numbered layers are set to be opposite, which simplifies the subsequent welding process. For example, define xy as the y-th layer of the x-th slot, where x∈[1, 72], y∈[a, e], and the first end of the first flat wire conductor coil is a. 6. The second end is b14, the first end of the second flat wire conductor coil is a19, and the second end is b25. Theoretically, the second end b14 of the first flat wire conductor needs to be welded to the first end a19 of the second flat wire conductor coil. However, as can be seen from the slot number, the two slots are relatively far apart. If they are welded directly, a large number of welding rods will be used, occupying a lot of space at the twisted end, which is not conducive to wiring. Therefore, the second end b14 of the first flat wire conductor located in the second layer and the first end a19 of the second flat wire conductor coil located in the first layer can be twisted in opposite directions, so that the height and distance of the two ends to be welded are close, reducing the space occupied by welding and optimizing the wiring space at the twisted end.

[0039] In an optional embodiment, the torsional distance between the first end 103b and the second end 103b inserted into the m-th layer in the stator slot 102 is greater than the torsional distance between the first end 103b and the second end 103b inserted into the 1st to m-1th layers in the stator slot 102, where m is the maximum number of slot layers in the stator slot 102, and m≥5.

[0040] In an alternative embodiment, the terminal 105 and the twisted end are located at the same end of the stator core 101 along the axial direction.

[0041] In the specific implementation, refer to Figure 5 , Figure 5 This is a schematic diagram of the twisting of the 5th and 6th layers in this embodiment. Since the outermost flat wire conductor coil 103, which is far from the axis, is wound in the same layer, an additional 6th layer is provided at the twisting end in this embodiment in order to weld the flat wire conductor coil 103 in the same layer. The 6th layer is formed by twisting the first end 103b or the second end 103b of the same layer coil in the 5th layer. However, since only 5 slot layers are provided in the stator slot 102, during twisting, the twisting distance of the first end 103b and the second end 103b of the 5th layer can be controlled to be greater than that of the first 4 layers, forming a spatial distance to avoid positional conflict at the ends of the flat wire conductor coil 103. Moreover, the twisting distance of the 5th layer is one slot larger than that of the first 4 layers.

[0042] The above are merely preferred embodiments of the present invention and do not limit the scope of the patent. Any equivalent structural or procedural transformations made based on the description and drawings of the present invention, or direct or indirect applications in other related technical fields, are similarly included within the scope of patent protection of the present invention.

Claims

1. A stator assembly characterized by, The stator assembly includes: The stator core is annular and has multiple stator slots evenly spaced along the circumference on its inner side. The three-phase winding is formed by winding multiple sets of flat wire conductor coils in multiple layers in the stator slot. The three-phase winding is provided with terminals, including a first terminal located radially close to the axis in the stator slot and a second terminal located radially away from the axis in the stator slot. The first terminal and the second terminal are continuous in slot number around the stator core. A bus assembly, wherein the bus assembly is electrically connected to the first wiring portion and the second wiring portion respectively.

2. The stator assembly of claim 1, wherein, The bus assembly includes a bus, which includes a first phase bus, a second phase bus, and a third phase bus. Each phase bus includes at least a main body and a three-phase connection part, and the main body and the three-phase connection part are fixedly connected. The main body of the first phase busbar, the main body of the second phase busbar, and the main body of the third busbar are stacked sequentially along the axial direction.

3. The stator assembly of claim 2, wherein, The main body of the second phase busbar is rotated 4 slots relative to the main body of the first phase busbar along the circumference of the stator core and stacked sequentially along the axial direction. The main body of the first busbar is rotated circumferentially by 4 slots relative to the main body of the second phase busbar, and then stacked sequentially along the axial direction.

4. The stator assembly of claim 1, wherein, The flat wire conductor coil includes a bent portion and a welded end, the welded end including a first end and a second end connected to the bent portion.

5. The stator assembly of claim 4, wherein, The bent portion forms a three-phase winding hairpin end at one end of the stator core along the axial direction, and the first end and the second end form a twisted end at the other end of the stator core along the axial direction.

6. The stator assembly of claim 5, wherein, The twisted end includes: The first and second ends of the odd-numbered layers inserted into the stator slots are twisted by a preset angle along the first torsional direction of the stator core in the circumferential direction; And, the first end and the second end, which are inserted into the even-numbered layers in the stator slot and twisted by a predetermined angle in the second torsional direction along the circumference of the stator core.

7. The stator assembly of claim 6, wherein, The first torsion direction and the second torsion direction are opposite directions in the circumferential direction of the stator core.

8. The stator assembly of claim 6, wherein, The torsional distance between the first end and the second end of the m-th layer inserted into the stator slot is greater than the torsional distance between the first end and the second end of the 1st to m-1th layers inserted into the stator slot, where m is the maximum number of slot layers in the stator slot, and m≥5.

9. The stator assembly of claim 1, wherein, The wiring terminal and the twisted wire terminal are located at the same end of the stator core along its axial direction.

10. An electric machine characterized by The motor includes a stator assembly as described in any one of claims 1 to 9.

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