Stator assembly and flat wire motor

Abstract

The embodiment of the utility model relates to the technical field of motors, and particularly discloses a stator assembly and a flat wire motor, the stator assembly comprises a stator iron core, the inner wall of the stator iron core is provided with a plurality of winding grooves, the plurality of winding grooves are uniformly arranged along the circumferential direction of the inner wall of the stator iron core, and any winding groove extends along the axis direction of the stator iron core; the stator winding comprises flat wire conductors inserted in the winding grooves, each flat wire conductor comprises an in-groove part arranged in the winding groove and a first end and a second end located outside the stator core, the in-groove part is located between the first end and the second end, the first ends of the flat wire conductors form a crown end, and the second ends of the flat wire conductors form a crown end. The star point connecting end of each phase of the stator winding extends out from the radial direction of the crown end; the busbar is arranged on the crown end, the busbar is connected with the star point connecting end of each phase of the stator winding, and the projection of the busbar does not coincide with the projection of the crown end when observed in the axial direction of the stator iron core. Through the above mode, the size of the stator assembly in the axial direction can be reduced.

Description

Technical Field

[0001] The utility model relates to the technical field of motors, in particular to a stator assembly and a flat wire motor. Background Art

[0002] New energy vehicles do not burn gasoline or diesel to generate power, so they have many characteristics such as environmental protection and low pollution. With the vigorous promotion and application of new energy power generation such as hydropower, wind power, and solar energy, many new energy vehicles are gradually being promoted and applied, such as new energy electric cars, new energy electric buses, new energy electric trucks, new energy electric cleaning vehicles, new energy electric rail transportation tools, new energy electric flying vehicles, new energy electric shipping vehicles, etc. As a key component of new energy vehicles, the output performance of the drive motor directly affects the efficient operation of the whole machine. Existing drive motors can be divided into round wire motors and flat wire motors according to the winding structure of the stator winding. Compared with traditional round wire motors, flat wire motors have the advantages of high slot fill rate, high power density, and good temperature performance. In the prior art, the stator assembly in the flat wire motor usually includes a welding end and a crown end arranged opposite to the welding end, and the star point connection lines on each phase located on the welding end are connected through a bus.

[0003] The inventor of the utility model found that the busbar in the prior art is usually located in the axial direction of the stator assembly, which affects the axial size of the stator assembly. The stator assembly occupies the axial space inside the flat wire motor, which affects the overall volume of the flat wire motor. Utility Model Content

[0004] In view of the above problems, the embodiments of the utility model provide a flat wire winding structure and a flat wire motor, which overcome the problems in the above-mentioned prior art that the bus is usually located in the axial direction of the stator assembly, affecting the axial size of the stator assembly, and the stator assembly occupies the axial space inside the flat wire motor, affecting the overall volume size of the flat wire motor.

[0005] According to one aspect of the utility model, a stator assembly is provided, comprising: a stator core, the inner wall of the stator core is provided with a plurality of winding slots, the plurality of winding slots are uniformly arranged along the circumference of the inner wall of the stator core, and any of the winding slots extends along the axial direction of the stator core; a stator winding, the stator winding comprises a flat wire conductor inserted in the winding slot, each of the flat wire conductors comprises an in-slot portion arranged in the winding slot and a first end and a second end located outside the stator core, the in-slot portion is connected between the first end and the second end, the first ends of the plurality of flat wire conductors form a crown end, the first ends of the plurality of flat wire conductors are coated with an insulating layer, and the star point connection end of each phase of the stator winding extends radially outward from the crown end; a bus bar is provided on the crown end, the bus bar is connected to the star point connection end of each phase of the stator winding, and when observed along the axial direction of the stator core, the projection of the bus bar does not overlap with the projection of the crown end.

[0006] In an optional manner, an outward-turned structure protruding away from the crown end is provided on the star-point connecting end, and the outward-turned structure is spaced a preset distance from the crown end.

[0007] In an optional manner, the star point connecting end includes a first vertical segment, a bending segment and a second vertical segment, the second vertical segment is spaced apart on the outside of the first vertical segment, one end of the first vertical segment is connected to the crown end, the other end of the first vertical segment is connected to one end of the bending segment, the other end of the bending segment is connected to one end of the second vertical segment, the bending segment is located between the first vertical segment and the second vertical segment, and the bus is connected to the outside of the second vertical segment.

[0008] In an optional manner, the bending direction of the bending section is towards a direction away from the crown end.

[0009] In an optional manner, N layers of the flat wire conductors are provided in any of the winding slots, and the N layers of the flat wire conductors are arranged along the radial direction of the stator core, and N is an odd number.

[0010] In an optional manner, the star point connection end of any phase in the stator winding is led out from the outermost layer of the N layers of flat wire conductors.

[0011] In an optional manner, the stator winding includes a plurality of phase windings, and each phase winding includes two parallel branches.

[0012] In an optional manner, the number of winding slots is M, where M is a natural number that is a multiple of 3; each phase winding includes a first parallel branch and a second parallel branch; the first parallel branch includes a first lead-out flat wire conductor and a plurality of first U-shaped flat wire conductors, the first lead-out flat wire conductor is connected to the plurality of first U-shaped flat wire conductors, one end of the first U-shaped flat wire conductor is plugged into the n1th layer of the m1th winding slot, and the other end of the first U-shaped flat wire conductor is plugged into the n2th layer of the m2th winding slot, and the m1 differs from the m2 by a span, so The absolute value of the difference between n1 and n2 is less than or equal to 1; the second parallel branch includes a second lead-out flat wire conductor and a plurality of second U-shaped flat wire conductors, the second lead-out flat wire conductor is connected to the plurality of second U-shaped flat wire conductors, one end of the second U-shaped flat wire conductor is plugged into the n1+1th layer of the m1 winding slot, and the other end of the second U-shaped flat wire conductor is plugged into the n2+1th layer of the m2 winding slot, m1 and m2 are natural numbers from 1 to M in the same phase winding, and n1 and n2 are natural numbers from 1 to N-1 in the same parallel branch.

[0013] In an optional manner, the number of the winding grooves is 48.

[0014] In an optional manner, the lead wire of any phase in the stator winding extends from the crown end along the axial direction of the stator core.

[0015] According to another aspect of the utility model, a flat wire motor is provided, comprising the stator assembly as described above.

[0016] The beneficial effects of the embodiments of the utility model are as follows: (1) the first ends of the plurality of flat wire conductors are coated with an insulating layer, the star point connection ends of each phase of the stator winding extend radially from the crown end, the busbar is arranged on the crown end, the busbar is connected to the star point connection ends of each phase of the stator winding, and when observed along the axial direction of the stator core, the projection of the busbar does not overlap with the projection of the crown end. In this way, the busbar and the star point connection ends of each phase on the stator winding are located in the radial direction of the crown end, reducing the space occupied by the busbar and the star point connection ends in the axial direction of the stator assembly, thereby reducing the axial size of the stator assembly, thereby reducing the internal space of the motor occupied by the stator assembly in the axial direction;

[0017] (2) In addition, the star point connection terminal and the bus are both arranged at the crown end, and the flat wire conductor at the crown end is usually covered with an insulating layer. The insulating layer can prevent the star point connection terminal and the bus from contacting the flat wire conductor at the crown end, thereby reducing the short circuit of the star point connection terminal and the bus. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] In order to more clearly illustrate the specific embodiments of the utility model or the technical solutions in the prior art, the following is a brief introduction to the drawings required for the specific embodiments or the prior art description. In all the drawings, similar elements or parts are generally identified by similar reference numerals. In the drawings, each element or part is not necessarily drawn according to the actual scale.

[0019] Figure 1 This is an angled schematic diagram of the overall structure of the stator assembly of the embodiment of the utility model;

[0020] Figure 2 It is a partial structural exploded schematic diagram of a stator assembly of an embodiment of the utility model;

[0021] Figure 3 It is a side sectional view of the overall structure of the stator assembly of the embodiment of the utility model;

[0022] Figure 4 It is a schematic diagram of the overall structure of the stator assembly of the embodiment of the utility model from another angle;

[0023] Figure 5 yes Figure 3 A schematic diagram of the structure enlargement in the middle;

[0024] Figure 6 This is another angle schematic diagram of the overall structure of the stator assembly of the embodiment of the utility model;

[0025] Figure 7 yes Figure 6 Enlarged schematic diagram of the structure at point B in the middle. DETAILED DESCRIPTION

[0026] In order to facilitate the understanding of the utility model, the utility model is described in more detail below in conjunction with the accompanying drawings and specific embodiments. It should be noted that when an element is described as "fixed to" another element, it can be directly on the other element, or there can be one or more centered elements therebetween. When an element is described as "connected to" another element, it can be directly connected to the other element, or there can be one or more centered elements therebetween. The terms "vertical", "horizontal", "left", "right" and similar expressions used in this specification are for illustrative purposes only.

[0027] Unless otherwise defined, all technical and scientific terms used in this specification have the same meaning as those commonly understood by technicians in the technical field of the present invention. The terms used in this specification are only for the purpose of describing specific embodiments and are not used to limit the present invention. The term "and / or" used in this specification includes any and all combinations of one or more related listed items.

[0028] In addition, the technical features involved in the different embodiments of the present application described below can be combined with each other as long as they do not conflict with each other.

[0029] For ease of understanding, the professional terms appearing in this application are explained below.

[0030] Stator assembly: refers to the stationary part of the motor, whose function is to generate a rotating magnetic field.

[0031] Rotor: refers to the rotating part in the motor, which is used to realize the conversion of electrical energy into mechanical energy.

[0032] Span: Also known as the first pitch, it refers to the distance between the two sides of the same element in the motor winding on the armature surface, usually expressed by the number of winding slots opened on the stator core.

[0033] Welding end: usually refers to the end where each phase circuit in the stator assembly is welded to form a three-phase circuit.

[0034] See also Figure 1 and Figure 2 The stator assembly 1000 includes a stator core 10, a stator winding 20 and a busbar 30. The stator winding 20 is inserted into the stator core 10, and the busbar 30 is connected to the star point connection end 201 of each phase in the stator winding 20. The stator core 10, the stator winding 20 and the busbar 30 are described in detail below.

[0035] For the above-mentioned stator core 10, as Figure 2 and Figure 3 As shown, the inner wall of the stator core 10 is provided with a plurality of winding slots 10a, the plurality of winding slots 10a are uniformly arranged along the circumferential direction of the inner wall of the stator core 10, and any of the winding slots 10a extends along the axial direction of the stator core 10, the plurality of winding slots 10a are provided for inserting the flat wire conductors in the stator winding 20, the number of the winding slots 10a can be represented by M, and M is a natural number that is a multiple of 3. Optionally, the number of the winding slots 10a is 48, that is, M=48.

[0036] For the above-mentioned stator winding 20 and busbar 30, as Figure 1-Figure 3As shown, the stator winding 20 includes a flat wire conductor inserted in the winding slot 10a, each of the flat wire conductors includes an in-slot portion arranged in the winding slot 10a and a first end and a second end located outside the stator core 10, the in-slot portion is connected between the first end and the second end, the first ends of multiple flat wire conductors form a crown end 20a, the first ends of multiple flat wire conductors are coated with an insulating layer, and the second ends of multiple flat wire conductors form a welding end 20b, the star point connection end 201 of each phase of the stator winding 20 extends radially outward from the crown end 20a, the bus 30 is arranged on the crown end 20a, the bus 30 is connected to the star point connection end 201 of each phase of the stator winding 20, and the star point connection ends 201 are connected together through the bus 30 to lead out the neutral line. The insulating layer can prevent the star point connection end 201 and the bus bar 30 from contacting the flat wire conductor at the crown end 20 a, thereby reducing the short circuit between the star point connection end 201 and the bus bar 30 .

[0037] In some embodiments, please refer to Figure 4 , when observed along the axial direction of the stator core 10, the projection of the busbar 30 does not overlap with the projection of the crown end 20a, and the busbar 30 and the star-point connection ends 201 of each phase on the stator winding 20 are all located in the radial direction of the crown end 20a, thereby reducing the axial space occupied by the busbar 30 and the star-point connection ends 201 of the stator assembly, thereby reducing the axial size of the stator assembly, and thus reducing the internal space of the motor occupied by the stator assembly in the axial direction.

[0038] In some embodiments, the stator winding 20 includes multiple phase windings, and each phase winding includes two parallel branches. In the present application, the stator winding 20 is applied to a three-phase motor. The stator winding 20 of the three-phase motor includes: a U-phase winding, a V-phase winding, and a W-phase winding. The number of parallel branches in each phase winding is 2. It can be understood that the number of parallel branches in each phase winding can be set according to actual conditions, and the number of parallel branches can be 1, 3, 4, etc.

[0039] In some embodiments, each phase winding includes a first parallel branch and a second parallel branch, the first parallel branch includes a first lead-out flat wire conductor and a plurality of first U-shaped flat wire conductors, the first lead-out flat wire conductor is connected to the plurality of first U-shaped flat wire conductors, one end of the first U-shaped flat wire conductor is plugged into the n1th layer of the m1th winding slot, the other end of the first U-shaped flat wire conductor is plugged into the n2th layer of the m2th winding slot, the m1 differs from the m2 by a span, the absolute value of the difference between the n1 and the n2 is less than or equal to 1, the second parallel branch includes a second lead-out flat wire conductor and a plurality of second U The first lead-out flat wire conductor is a flat wire conductor, the second lead-out flat wire conductor is connected to the plurality of second U-shaped flat wire conductors, one end of the second U-shaped flat wire conductor is plugged into the n1+1th layer of the m1 winding slot, and the other end of the second U-shaped flat wire conductor is plugged into the n2+1th layer of the m2 winding slot, m1 and m2 are natural numbers from 1 to M in the same phase winding, and n1 and n2 are natural numbers from 1 to N-1 in the same parallel branch. In this structure, the positions of the incoming and outgoing terminals of different parallel branches of the same phase winding are close to each other, so that they can be led out from different layers of flat wire conductors in the same winding slot 10a for easy connection. Optionally, the m1 differs from the m2 by a span, which is 6 winding slots 10a. The first lead-out flat wire conductor and the second lead-out flat wire conductor are connected to the bus 30 as the star point connection terminals in this application.

[0040] In some embodiments, the lead wire 202 of any phase in the stator winding 20 extends from the crown end 20a along the axial direction of the stator core 10. The lead wire 202 is used to connect to an external circuit, and since the crown end 20a is provided with an insulating layer, the insulating layer can reduce the short circuit phenomenon of the lead wire 202.

[0041] In some embodiments, please refer to Figure 5 , N layers of the flat wire conductor are provided in any of the winding slots 10a, and the N layers of flat wire conductor are arranged along the radial direction of the stator core 10, and N is an odd number. Optionally, N=7. It should be noted that: the outermost layer of the N layers of flat wire conductor refers to a layer located at the bottom of the winding slot 10a. Taking N=7 as an example, the first layer is defined as L1, the second layer as L2, and so on. The seventh layer is L7, wherein L1 is located at the bottom of the winding slot 10a, and L7 is located at the slot mouth of the winding slot 10a, then L1 is the outermost layer, and L7 is the innermost layer.

[0042] Optionally, the star point connection terminal 201 of any phase in the stator winding 20 is led out from the outermost layer of the N-layer flat wire conductor. The star point connection terminal 201 located at the outermost layer can be easily connected to the busbar 30, and the lead wire 202 is arranged in the flat wire conductor adjacent to the star point connection terminal 201. Since an insulating layer is arranged on the flat wire conductor where the star point connection terminal 201 is located, the insulating layer can reduce the contact between the lead wire 202 and the flat wire conductor at the crown end, thereby reducing the short circuit of the lead wire 202.

[0043] In some embodiments, please refer to Figure 6 and Figure 7 The star point connection end 201 includes a first vertical section 2011, a bending section 2012 and a second vertical section 2013, one end of the first vertical section 2011 is connected to the crown end 20a, the other end of the first vertical section 2011 is connected to one end of the bending section 2012, the other end of the bending section 2012 is connected to one end of the second vertical section 2013, the bending section 2012 is located between the first vertical section 2011 and the second vertical section 2013, and one side of the second vertical section 2013 is connected to the busbar 30. Optionally, the bending direction of the bending section 2012 is bent in a direction away from the crown end 20a, so that the star point connection end 201 is spaced apart from the crown end 20a by a preset safety distance in the radial direction.

[0044] In some embodiments, the star point connection end 201 is provided with an outward-turned structure protruding away from the crown end 20a, the outward-turned structure is spaced from the crown end by a preset distance, and the outward-turned structure can be used to connect with the bus 30. At the same time, the outward-turned structure can also reduce the contact between the bus 30 and the crown end 20a, thereby reducing the short circuit of the bus 30. Optionally, the bending section 2012 and the second vertical section 2013 form the outward-turned structure.

[0045] In the embodiment of the utility model, a stator core 10, a stator winding 20 and a busbar 30 are provided. The inner wall of the stator core 10 is provided with a plurality of winding slots 10a, the plurality of winding slots 10a are evenly arranged along the circumference of the inner wall of the stator core 10, and any of the winding slots 10a extends along the axial direction of the stator core 10, the stator winding 20 includes a flat wire conductor inserted in the winding slot 10a, each of the flat wire conductors includes a slot portion arranged in the winding slot 10a and a first end and a second end located outside the stator core 10, the slot portion is located between the first end and the second end, the first ends of the plurality of flat wire conductors form a crown end 20a, and the star point connection end 201 of each phase of the stator winding 20 is connected from the first end to the second end. The crown end 20a extends radially, and the bus-bar 30 is arranged on the crown end 20a. The bus-bar 30 is connected to the star-point connection ends 201 of each phase of the stator winding 20, and when observed along the axial direction of the stator core 10, the projection of the bus-bar 30 does not overlap with the projection of the crown end 20a. In this way, the bus-bar 30 and the star-point connection ends 201 of each phase on the stator winding 20 are all located in the radial direction of the crown end 20a, thereby reducing the axial space occupied by the bus-bar 30 and the star-point connection end 201 of the stator assembly, thereby reducing the axial size of the stator assembly, thereby reducing the internal space of the motor occupied by the stator assembly in the axial direction.

[0046] The utility model also provides an embodiment of a flat wire motor, which includes a rotor and the stator assembly as described above, wherein the rotor is arranged in a space surrounded by the inner wall of the stator core, and the function and structure of the stator assembly can be referred to the above embodiment, which will not be described one by one here.

[0047] The above description is only an embodiment of the present invention, and does not limit the patent scope of the present invention. Any equivalent structure or equivalent process transformation made by using the contents of the specification and drawings of the present invention, or directly or indirectly applied in other related technical fields, are also included in the patent protection scope of the present invention.

Claims

1. A stator assembly, It is characterized in that include: A stator core, wherein the inner wall of the stator core is provided with a plurality of winding grooves, the plurality of winding grooves are evenly arranged along the circumference of the inner wall of the stator core, and any of the winding grooves extends along the axial direction of the stator core; A stator winding, the stator winding comprising a flat wire conductor inserted in the winding slot, each of the flat wire conductors comprising a slot portion arranged in the winding slot and a first end and a second end located outside the stator core, the slot portion being connected between the first end and the second end, the first ends of a plurality of the flat wire conductors forming a crown end, the first ends of a plurality of the flat wire conductors being coated with an insulating layer, and the star point connection end of each phase of the stator winding extending radially outward from the crown end; A bus is arranged on the crown end, the bus is connected to the star point connection end of each phase of the stator winding, and when observed along the axial direction of the stator core, the projection of the bus does not overlap with the projection of the crown end.

2. The stator assembly according to claim 1, It is characterized in that The star point connecting end is provided with an outward-turned structure protruding away from the crown end, and the outward-turned structure is spaced a preset distance from the crown end.

3. The stator assembly according to claim 1, It is characterized in that The star point connecting end includes a first vertical segment, a bending segment and a second vertical segment, the second vertical segment is spaced apart on the outside of the first vertical segment, one end of the first vertical segment is connected to the crown end, the other end of the first vertical segment is connected to one end of the bending segment, the other end of the bending segment is connected to one end of the second vertical segment, the bending segment is located between the first vertical segment and the second vertical segment, and the bus is connected to the outside of the second vertical segment.

4. The stator assembly according to claim 1, It is characterized in that Any of the winding slots is provided with N layers of the flat wire conductors, the N layers of the flat wire conductors are arranged along the radial direction of the stator core, and N is an odd number.

5. The stator assembly according to claim 4, It is characterized in that The star point connection end of any phase in the stator winding is led out from the outermost layer of the N layers of flat wire conductors.

6. The stator assembly according to claim 4, It is characterized in that The stator winding includes a plurality of phase windings, and each phase winding includes two parallel branches.

7. The stator assembly according to claim 6, It is characterized in that The number of the winding grooves is M, where M is a natural number that is a multiple of 3; Each phase winding includes a first parallel branch and a second parallel branch; The first parallel branch includes a first lead-out flat wire conductor and a plurality of first U-shaped flat wire conductors, the first lead-out flat wire conductor is connected to the plurality of first U-shaped flat wire conductors, one end of the first U-shaped flat wire conductor is plugged into the n1th layer of the m1th winding slot, and the other end of the first U-shaped flat wire conductor is plugged into the n2th layer of the m2th winding slot, the m1 and m2 differ by a span, and the absolute value of the difference between n1 and n2 is less than or equal to 1; The second parallel branch includes a second lead-out flat wire conductor and a plurality of second U-shaped flat wire conductors, the second lead-out flat wire conductor is connected to the plurality of second U-shaped flat wire conductors, one end of the second U-shaped flat wire conductor is plugged into the n1+1th layer of the m1 winding slot, and the other end of the second U-shaped flat wire conductor is plugged into the n2+1th layer of the m2 winding slot, m1 and m2 are natural numbers from 1 to M in the same phase winding, and n1 and n2 are natural numbers from 1 to N-1 in the same parallel branch.

8. The stator assembly according to claim 1, It is characterized in that The number of the winding grooves is 48.

9. The stator assembly according to claim 1, It is characterized in that The lead wire of any phase in the stator winding extends from the crown end along the axial direction of the stator core.

10. A flat wire motor, It is characterized in that It comprises a rotor and a stator assembly as claimed in any one of claims 1 to 9, wherein the rotor is arranged in a space surrounded by an inner wall of the stator core.

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