Flat wire motor stator, flat wire motor and power assembly
By using a simple winding winding method and the flow discharge connection in the flat wire stator, the problem of serious copper loss of the flat wire motor is solved, and the effect of reducing copper damage and production costs is achieved.
Patent Information
- Application Number
- CN202323366468.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2023-12-08
- Publication Date
- 2025-01-24
- Estimated Expiration
- 2033-12-08
AI Technical Summary
The copper loss of flat wire motors is serious, which affects its performance and increases production costs.
A simple winding winding method is adopted, and the flat -shaped wires that pass through the winding of the stator core are used to achieve electrical connection through the flow row to avoid twisting, bending and welding process.
The copper loss of the flat wire motor stator is reduced, the production process is simplified, and the raw material and production costs are reduced.
Smart Images
Figure CN222395509U_ABST
Abstract
Description
Technical Field
[0001] The present application relates to the technical field of motors, and more specifically, to a flat wire motor stator, a flat wire motor and a power assembly. Background Art
[0002] Flat wire motors have the characteristics of high copper full rate, good heat dissipation, strong pressure resistance, high torque density and power density, etc., and are gradually being used in new energy vehicles and other fields. Electric vehicles or hybrid vehicles driven by flat wire motors are relatively lighter, have longer driving range, and have higher internal space utilization.
[0003] However, due to considerations such as the balance between branches, the winding method of the winding in the motor stator of the flat wire motor is usually more complicated, and the copper loss of the flat wire motor is relatively serious, which affects the performance of the flat wire motor and increases the production cost of the motor flat wire. Utility Model Content
[0004] The present application provides a flat wire motor stator, a flat wire motor and a power assembly. The winding method of the flat wire motor stator winding is simple, which reduces the copper loss of the flat wire motor and avoids affecting the performance of the flat wire motor.
[0005] In a first aspect, a flat wire motor stator is provided, the flat wire motor stator comprising a stator core, a stator winding and at least one group of busbars. The stator core comprises an inner circumferential surface and an outer circumferential surface arranged opposite to each other in the radial direction of the stator core, the inner circumferential surface comprises a plurality of winding slots penetrating in the axial direction of the stator core, the plurality of winding slots are arranged at intervals in the circumferential direction of the stator core, and the slot opening of each winding slot faces the axial hole of the stator core. The stator winding comprises a plurality of groups of flat wires, each group of flat wires comprises a plurality of flat wires, each flat wire of each group of flat wires is used to pass through a winding slot in the axial direction of the stator core, and the plurality of flat wires of each group of flat wires are arranged at intervals in sequence in the radial direction of the stator core. Each group of busbars comprises at least one busbar, and each group of busbars is used to electrically connect one end of the plurality of groups of flat wires arranged in the axial direction of the stator core.
[0006] In the flat wire motor stator provided by the embodiment of the present application, at least one end of the flat wire in the winding slot does not need to be twisted / bent, nor does it need to be welded, and the electrical connection between the flat wires is directly achieved through the busbar. In this way, the winding method of the flat wire motor stator is simple, the height of the winding along the motor axis is reduced, the cost of the raw materials of the flat wire motor stator is reduced, and thus the production cost of the flat wire motor stator is reduced.
[0007] In one implementation, the multiple busbars in each busbar group are arranged radially or circumferentially of the stator core. In this way, the multiple busbars are arranged in layers radially or circumferentially of the stator core, so that the multiple flat wires meet safety requirements.
[0008] In one implementation, each set of busbars is an integrally formed structure, so that conduction and insulation of each set of busbars can be achieved through an integral injection molding process of multiple busbars in each set of busbars, thereby simplifying the processing technology of the busbars.
[0009] In one implementation, two busbars are arranged adjacent to each other in the radial direction of the stator core or in the circumferential direction of the stator core, and the two busbars are spaced apart in the axial direction of the stator core. In this way, the two busbars arranged adjacent to each other in the radial direction of the stator core or in the circumferential direction of the stator core are arranged in an offset manner in the axial direction of the stator core, so that the insulation between the two adjacently arranged busbars meets the safety requirements.
[0010] In one implementation, a busbar in a group of busbars is used to electrically connect one end of a flat wire in one group of flat wires and one end of a flat wire in another group of flat wires, and the winding slots through which one group of flat wires passes are adjacent to the winding slots through which the other group of flat wires passes along the circumference of the stator core.
[0011] One busbar of a group of busbars is connected to a flat wire respectively contained in two adjacent winding slots, thus simplifying the electrical connection method of the flat wire.
[0012] In one implementation, the distance between one flat wire of one group of flat wires and the shaft hole is equal to the distance between one flat wire of another group of flat wires and the shaft hole or the distance between one flat wire of another group of flat wires and the shaft hole. One busbar of a group of busbars connects two flat wires aligned along the circumference of the motor in two adjacent winding slots, so that the connection method of the busbars is simple.
[0013] In one implementation, the distance between one flat wire of one group of flat wires and the shaft hole is smaller than the distance between one flat wire of another group of flat wires and the shaft hole or the distance between one flat wire of another group of flat wires and the shaft hole. One busbar of a group of busbars connects two flat wires in two adjacent winding slots that are staggered along the circumference of the motor, thus making the connection of the busbars simple.
[0014] In one implementation, one group of flat wires is arranged between another group of flat wires and yet another group of flat wires along the circumferential direction of the stator core.
[0015] In one example, one busbar of another group of busbars is used to electrically connect the other end of one flat wire of one group of flat wires and the other end of one flat wire of another group of flat wires.
[0016] The stator winding uses a flat wire with an I-pin structure that is not preformed. In the process of realizing electrical connection of multiple groups of flat wires, the flat wires do not need to undergo a forming process. Moreover, both ends of the flat wires along the axial direction of the stator core do not need to undergo a twisting / bending process, nor do they need to be welded. The electrical connection of both ends of the flat wire along the axial direction of the stator core is directly realized through two groups of bus bars. In this way, the height of the winding along the axial direction of the motor is further reduced, the cost of raw materials for the flat wire motor stator is further reduced, and thus, the production cost of the flat wire motor stator is further reduced.
[0017] In another example, the other end of a flat wire of one group of flat wires is connected to the other end of a flat wire of another group of flat wires.
[0018] The stator winding uses a semi-formed U-pin structure flat wire. In the process of realizing electrical connection of multiple groups of flat wires, the flat wire along the axial direction of the stator core does not need to be twisted / bent, nor does it need to be welded. The electrical connection of the flat wire along the axial direction of the stator core is directly realized through a group of bus bars. In this way, the height of the stator winding along the axial direction of the motor is further reduced, the cost of raw materials of the flat wire motor stator is further reduced, and thus, the production cost of the flat wire motor stator is further reduced.
[0019] In one implementation, one end of each flat wire is arranged on a side of one end face of the stator core away from the other end face along the axial direction of the stator core, and one end of two adjacent flat wires in each group of flat wires are unequally spaced from one end face. In this way, interference between each of the two flat wires and the busbar electrically connected thereto can be avoided.
[0020] In one implementation, each busbar includes two connection holes, each connection hole is used to embed a flat wire, and each connection hole penetrates the busbar along the axial direction of the stator core.
[0021] By machining a connection hole that penetrates each busbar, the busbar and the flat wire can be positioned during assembly through the connection hole. This not only simplifies the processing of the busbar, but also simplifies the installation process of the busbar and the flat wire, thereby improving the installation efficiency between the busbar and the flat wire.
[0022] In one implementation, the busbar includes two side surfaces arranged opposite to each other in the radial direction of the stator core and another two side surfaces arranged opposite to each other in the circumferential direction of the stator core, wherein at least one connection hole is connected to one side surface of the busbar, and one side surface is one of the two side surfaces or one side surface is one of the other two side surfaces.
[0023] A notch is formed on each bus bar to form a connecting hole, so that the bus bar and the flat wire are welded through the notch, thereby simplifying the welding process between the bus bar and the flat wire.
[0024] In one implementation, the projection of at least one of the two axial side surfaces of the stator core is a curve, and the curvature of the curve is toward the inside of the busbar. In this way, the two side surfaces of the busbar are arc surfaces that are concave toward the inside of the busbar, which can prevent the busbar from interfering with other components such as other flat wires.
[0025] In one implementation, the size of each connection hole along the radial direction of the stator core is equal to the size of each flat wire, and the size of each connection hole along the axial direction of the stator core is equal to the size of each flat wire. In this way, the solder between the busbar and the flat wire can be reduced, and the production cost of the flat motor stator is reduced.
[0026] In one implementation, each busbar includes three substrates, two of which are arranged on both sides of another substrate along the axial direction of the stator core, the projection areas of the two substrates along the axial direction of the stator core do not overlap, and each of the two substrates includes a connecting hole.
[0027] In this way, along the axial direction of the stator core, there is a height difference between the welding points of the two flat wires connected to each busbar, so that the two adjacent flat wires meet the insulation safety requirements.
[0028] In one implementation, the size of each flat wire along the axial direction of the stator core is larger than the size of the stator core, so that each flat wire along the axial direction of the stator core can extend out of the winding slot and connect to the busbar.
[0029] In one implementation, the intervals between two adjacent flat wires in each group of flat wires are equal. In this way, on the one hand, the two adjacent flat wires in each group of flat wires can meet the safety requirements. On the other hand, the processing technology of the busbar is simplified, the production efficiency of the busbar is improved, and at the same time, the assembly process of the busbar and the flat wire is simplified.
[0030] In one implementation, along the axial direction of the stator core, the projected area of each winding slot is equal, thus simplifying the processing technology of the winding slot.
[0031] In one implementation, the number of flat wires in each group is a multiple of the number of busbars.
[0032] In one implementation, the number of the plurality of winding slots is a multiple of 3. In this way, the stator winding can constitute a three-phase winding.
[0033] In one implementation, the number of flat wires in each group is an even number, so that one busbar can electrically connect two flat wires.
[0034] In a second aspect, a motor is provided. The motor includes a motor rotor and a motor stator as described in any one of the first aspect and possible implementations of the first aspect, and the motor rotor passes through an axial hole of the motor stator.
[0035] Since the height of the winding of the flat wire motor stator provided by the first aspect along the motor axial direction is reduced, the copper loss of the flat wire motor is reduced, thereby avoiding affecting the performance of the flat wire motor, such as the motor efficiency.
[0036] In a third aspect, a power assembly is provided, which includes a reducer and the motor as described in the second aspect, wherein a motor shaft of the motor is drivingly connected to an input shaft of the reducer.
[0037] In a fourth aspect, an electric vehicle is provided. The electric vehicle includes wheels, a transmission mechanism, and the powertrain as described in the third aspect, wherein the powertrain drives the wheels through the transmission mechanism.
[0038] The technical effects of the third and fourth aspects mentioned above can refer to the corresponding description in the second aspect mentioned above, and will not be repeated here. BRIEF DESCRIPTION OF THE DRAWINGS
[0039] Figure 1 A schematic diagram of the structure of an electric vehicle provided in an embodiment of the present application.
[0040] Figure 2 This is a schematic diagram of the structure of a flat motor rotor provided in an embodiment of the present application.
[0041] Figure 3 and Figure 4 They are respectively schematic diagrams of the structures of the flat wires provided in the embodiments of the present application.
[0042] Figure 5 for Figure 2 An enlarged schematic diagram of part A of the flat motor rotor is shown.
[0043] Figure 6 for Figure 2 The schematic top view of the flat motor rotor is shown.
[0044] Figure 7 for Figure 6 An enlarged schematic diagram of part B of the flat motor rotor is shown.
[0045] Figure 8 for Figure 2 A bottom view schematic diagram of a flat motor rotor is shown.
[0046] Fig. 9 for Figure 7 An enlarged schematic diagram of part C of the flat motor rotor is shown.
[0047] Figures 10 to 15 They are respectively schematic diagrams of the structures of the busbars provided in the embodiments of the present application. DETAILED DESCRIPTION
[0048] The technical solution in this application will be described below in conjunction with the accompanying drawings.
[0049] In the description of the embodiments of the present application, unless otherwise specified, “ / ” means or. For example, A / B can mean A or B. The “and / or” in this article is merely a way to describe the association relationship of associated objects, indicating that three relationships may exist. For example, A and / or B can mean: A exists alone, A and B exist at the same time, and B exists alone.
[0050] The terms "upper", "lower", "inside", "outside", etc. in the embodiments of the present application indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as a limitation on the present application.
[0051] References to "some embodiments" and the like described in this specification mean that a particular feature, structure or characteristic described in conjunction with the embodiment is included in one or more embodiments of the present application. Thus, the phrases "in some embodiments" and the like appearing in different places in this specification do not necessarily all refer to the same embodiment, but rather mean "one or more but not all embodiments", unless otherwise specifically emphasized. The terms "include", "comprising", "having" and their variations all mean "including but not limited to", unless otherwise specifically emphasized.
[0052] The "equal" in this application is not strictly equal, but within the tolerance range. The "perpendicular" is not strictly perpendicular, but within the tolerance range.
[0053] In the embodiments of the present application, the same reference numerals represent the same component or the same part. In the embodiments of the present application, for multiple identical parts, only one of the parts may be marked with a reference numeral in the drawings as an example. For other identical parts or components, the reference numerals are also applicable. In addition, the sizes and dimensions of the parts shown in the drawings are only exemplary.
[0054] The embodiment of the present application provides a flat wire motor stator, which includes a stator core, a stator winding and at least one group of busbars. The stator core includes an inner circumferential surface and an outer circumferential surface arranged opposite to each other along the radial direction of the stator core, and the inner circumferential surface includes a plurality of winding slots penetrating along the axial direction of the stator core. The plurality of winding slots are arranged at intervals along the circumferential direction of the stator core, and the slot opening of each winding slot faces the axial hole of the stator core. The stator winding includes a plurality of groups of flat wires, each group of flat wires includes a plurality of flat wires, each flat wire of each group of flat wires is used to pass through a winding slot along the axial direction of the stator core, and the plurality of flat wires of each group of flat wires are arranged at intervals in sequence along the radial direction of the stator core. Each group of busbars includes at least one busbar, and each group of busbars is used to electrically connect one end of the plurality of groups of flat wires arranged along the axial direction of the stator core.
[0055] In the flat wire motor stator provided by the embodiment of the present application, at least one end of the flat wire in the winding slot does not need to be twisted / bent, nor does it need to be welded, and the electrical connection between the flat wires is directly achieved through the busbar. In this way, on the one hand, the winding method of the flat wire motor stator is simple, the height of the winding along the motor axis is reduced, the cost of the raw materials of the flat wire motor stator is reduced, and then the production cost of the flat wire motor stator is reduced.
[0056] The present application also provides an electric vehicle. Figure 1 The electric vehicle provided in the embodiment of the present application is first described in detail.
[0057] Figure 1 This is a schematic structural diagram of an electric vehicle provided in an embodiment of the present application. Figure 1 As shown, the electric vehicle includes a battery 1, wheels 2 and one or more powertrains 3. The powertrain 3 is used to receive power from the battery 1 and drive the wheels 2, and the powertrain 3 is used to convert electrical energy into mechanical energy. The powertrain 3 includes a flat wire motor 30 and a reducer 31. The reducer 31 is connected to the motor 30. The reducer 31 is used to connect the flat wire motor 30 and the wheels 2.
[0058] The electric vehicles provided in the embodiments of the present application include pure electric vehicles, hybrid electric vehicles, extended-range electric vehicles, plug-in hybrid electric vehicles or new energy vehicles, etc. Among them, pure electric vehicles are also called pure electric vehicle / battery electric vehicle, or simply pure EV / battery EV. Hybrid electric vehicles are also called hybrid electric vehicles, or simply HEV. Extended-range electric vehicles are also called range extended electric vehicles, or simply REEV. Plug-in hybrid electric vehicles are also called plug-in hybrid electric vehicles, or simply PHEV. New energy vehicles are also called new energy vehicles, or simply NEV.
[0059] In some embodiments, the power assembly 3 further includes a controller for controlling the start or stop, forward or reverse rotation, speed increase or decrease, drive torque increase or decrease, brake torque increase or decrease, etc. of the flat wire motor 30 .
[0060] The flat wire motor 30 includes a motor rotor and a flat wire motor stator, and the motor rotor passes through the shaft hole of the flat wire motor stator. Figures 2 to 15 The structure of the flat wire motor stator 300 provided in the embodiment of the present application is described in detail.
[0061] like Figure 2 As shown, the flat wire motor stator 300 includes a stator core 310, and the stator core 310 includes an inner circumferential surface 311 and an outer circumferential surface 312 arranged in opposite directions along the radial direction of the stator core 310. The inner circumferential surface 311 includes a plurality of winding slots G penetrating along the axial direction of the stator core 310. The plurality of winding slots G are arranged at intervals along the circumferential direction of the stator core 310, and the slot opening of each winding slot G faces the axial hole O of the stator core 310.
[0062] Exemplarily, the stator core 310 includes a plurality of stator punchings, which are arranged axially of the stator punchings. The inner wall of the center hole of each stator punching includes a plurality of grooves, which are arranged circumferentially at intervals of the stator punchings. Each groove penetrates the stator punchings axially, and the notch of each groove faces the center hole of the stator punchings. The plurality of grooves of two adjacent stator punchings are respectively connected to form a plurality of winding slots G.
[0063] In some embodiments, the projected area of each winding slot G along the axial direction of the stator core 310 is equal, so that the processing technology of the winding slot G is simplified.
[0064] In some embodiments, the number of the plurality of winding slots G is a multiple of 3. For example, the number of the plurality of winding slots G may be 48, 54, 60, etc. In this way, the stator winding can form a three-phase winding.
[0065] The flat wire motor stator 300 also includes a stator winding, which includes multiple groups of flat wires. Each group of flat wires includes multiple flat wires. Each flat wire of each group of flat wires is used to pass through a winding slot G along the axial direction of the stator core 310. The multiple flat wires of each group of flat wires are arranged in sequence along the radial direction of the stator core 310.
[0066] In one example, the flat wire of the stator winding is made of Figure 3 The flat wire 320a of the I-pin structure is shown. In this example, there is no need to perform a twisting / bending process on the flat wire, and a plurality of straight flat wires are directly inserted into the winding slots G to form the stator winding.
[0067] In another example, the flat wire of the stator winding is made of Figure 4 The semi-formed U-pin structure flat wire 320b is shown. In this example, the flat wire needs to be twisted / bent, and a flat wire is pre-formed into a U-shape / V-shape and inserted into two adjacent winding slots G along the circumferential direction of the stator core to form the stator winding.
[0068] like Figures 5 to 9 As shown, the stator winding includes three groups of flat wires 321-323, and the first group of flat wires 321 is arranged between the second group of flat wires 322 and the third group of flat wires 323 along the circumferential direction of the stator core 310. The first group of flat wires 321 includes 6 flat wires 321a-321f, the second group of flat wires 322 includes 6 flat wires 322a-322f, and the third group of flat wires 323 includes 6 flat wires 323a-323f.
[0069] In some embodiments, such as Figure 2 As shown, the stator core 310 includes two end faces arranged opposite to each other in the axial direction of the stator core 310, one end of each flat wire is arranged on the side of one end face A1 of the stator core 310 away from the other end face A2 in the axial direction of the stator core 310, and the distances between one end of two flat wires arranged adjacent to each other in the radial direction of the stator core 310 in the plurality of flat wires in each group of flat wires and one end face A1 of the stator core 310 are unequal. In this way, interference between each of the two flat wires and the busbar electrically connected thereto can be avoided.
[0070] Furthermore, in some embodiments, the plurality of flat wires in each group of flat wires can be divided into a middle part and two end parts, and the flat wires in the middle part include at least one flat wire. The flat wires in the radial middle part of the stator core 310 are arranged between the flat wires in the two end parts.
[0071] In one example, the distance between one end of the flat wire in the middle portion and one end surface A1 of the stator core 310 is greater than the distance between one end of the flat wire at both ends and one end surface A1 of the stator core 310. Figure 5 As shown, the flat wires in the middle part of another group of flat wires 322 include flat wires 322c and flat wires 322d, and the flat wires at the two end parts of another group of flat wires 322 include flat wires 322a, flat wires 322b, flat wires 322e, and flat wires 322f. Among them, the distance between one end of the flat wire 322c and one end face A1 of the stator core 310 and the distance between one end of the flat wire 322d and one end face A1 of the stator core 310 are respectively greater than the distance between one end of the flat wire 322a and one end face A1 of the stator core 310, the distance between one end of the flat wire 322b and one end face A1 of the stator core 310, the distance between one end of the flat wire 322e and one end face A1 of the stator core 310, and the distance between one end of the flat wire 322f and one end face A1 of the stator core 310.
[0072] In another example, the distance between one end of the flat wire in the middle portion and one end face A1 of the stator core 310 is smaller than the distance between one end of the flat wire in the two end portions and one end face A1 of the stator core 310. In this way, the assembly process of the plurality of flat wires in each group of flat wires and the winding slots G is simplified.
[0073] In some embodiments, the size of each flat wire along the axial direction of the stator core is larger than the size of the stator core 310. In this way, each flat wire along the axial direction of the stator core can extend out of the winding slot G and connect to the busbar.
[0074] In some embodiments, the intervals between two adjacent flat wires in each group of flat wires are equal. In this way, on the one hand, the two adjacent flat wires in each group of flat wires can meet the safety requirements. On the other hand, the processing technology of the busbar is simplified, the production efficiency of the busbar is improved, and at the same time, the assembly process of the busbar and the flat wires is simplified.
[0075] In some embodiments, the number of flat wires in each group is a multiple of the number of bus bars.
[0076] In some embodiments, the number of flat wires in each group is an even number, so that one busbar can electrically connect two flat wires.
[0077] In some embodiments, the three groups of flat wires arranged in sequence along the circumference of the stator core are respectively U phase, V phase, and W phase. In some embodiments, a group of flat wires contained in the same winding slot G are in the same phase, so that there is no need to set insulating paper between the multiple flat wires in the same winding slot G, thereby reducing the production cost of the flat wire motor stator 300.
[0078] The flat wire motor stator 300 further includes at least one set of busbars, each set of busbars includes at least one busbar, and each set of busbars is used to electrically connect one end of a plurality of sets of flat wires arranged along the axial direction of the stator punching sheets.
[0079] In some embodiments, the flat wires are I-pin flat wires, and the busbars are two groups, one of which is used to electrically connect one end of the plurality of groups of flat wires arranged along the axial direction of the stator laminations, and the other is used to electrically connect the other end of the plurality of groups of flat wires arranged along the axial direction of the stator laminations. Figure 6 and Figure 7 The busbars 331a-331f shown belong to a group of busbars, such as Figure 8 and Fig. 9 The busbars 332a-332f shown belong to another group of busbars.
[0080] In this embodiment, among the three groups of flat wires arranged in sequence along the circumference of the stator core, one end of a flat wire of one group of flat wires and one end of a flat wire of another group of flat wires are connected through a bus, and the other end of a flat wire of one group of flat wires and the other end of a flat wire of another group of flat wires are connected through a bus of another group of buses. Among them, one group of flat wires is arranged between another group of flat wires and another group of flat wires along the circumference of the stator core 310. In this way, both ends of the flat wires along the axial direction of the stator core 310 do not need to be twisted / bent, and the flat wires do not need to be welded. The electrical connection of the two ends of the flat wires along the axial direction of the stator core 310 is directly realized through two groups of buses, which reduces the height of the stator winding along the axial direction of the motor, reduces the cost of raw materials of the flat wire motor stator 300, and further reduces the production cost of the flat wire motor stator 300.
[0081] In one example, the distance between one flat wire of one group of flat wires and the shaft hole is equal to the distance between one flat wire of another group of flat wires and the shaft hole or the distance between one flat wire of another group of flat wires and the shaft hole. One busbar of a group of busbars connects two flat wires aligned along the circumferential direction of the motor in two adjacent winding slots G, so that the connection method of the busbar is simple.
[0082] In another example, the distance between one flat wire of one group of flat wires and the shaft hole is smaller than the distance between one flat wire of another group of flat wires and the shaft hole or the distance between one flat wire of another group of flat wires and the shaft hole. One busbar of a group of busbars connects two flat wires in two adjacent winding slots G that are staggered along the circumferential direction of the motor, so that the connection method of the busbar is simple.
[0083] For example, a group of flat wires is Figures 6 to 9 The first group of flat wires 321 shown in FIG. 1 and the other group of flat wires are Figures 6 to 9 The second group of flat wires 322 shown in FIG. 1 and another group of flat wires are Figures 6 to 9 The third group of flat wires 323 is shown in FIG.
[0084] For example, Figure 7 As shown, one end of the flat wire 321a in the first group of flat wires 321 is connected to one end of the flat wire 322b in the second group of flat wires 322 through a bus bar 331a in a group of bus bars. Fig. 9 As shown, the other end of the flat wire 321a in the first group of flat wires 321 and the other end of the flat wire 323b in the third group of flat wires 323 are connected via a busbar 332a in another group of busbars.
[0085] For example, Figure 7 As shown, one end of the flat wire 321c in the first group of flat wires 321 is connected to one end of the flat wire 322d in the second group of flat wires 322 through a bus bar 331b in a group of bus bars. Fig. 9 As shown, the other end of the flat wire 321c in the first group of flat wires 321 is connected to the other end of the wire 323d in the third group of flat wires 323 through a bus bar 332b in another group of bus bars.
[0086] For example, Figure 7 As shown, one end of the flat wire 321e in the first group of flat wires 321 is connected to one end of the flat wire 322f in the second group of flat wires 322 through a bus bar 331c in a group of bus bars. Fig. 9 As shown, the other end of the flat wire 321e in the first group of flat wires 321 and the other end of the flat wire 323f in the third group of flat wires 323 are connected through a bus bar 332c in another group of bus bars.
[0087] For example, a group of flat wires is Figures 6 to 9 The first group of flat wires 321 shown in FIG. 1 and the other group of flat wires are Figures 6 to 9 The third group of flat wires 323 shown in FIG. 1 and another group of flat wires are Figures 6 to 9 The second group of flat wires 322 is shown in FIG.
[0088] For example, Figure 7 As shown, one end of the flat wire 321b in the first group of flat wires 321 is connected to one end of the flat wire 323a in the third group of flat wires 323 through a bus bar 331d in a group of bus bars. Fig. 9 As shown, the other end of the flat wire 321 b in the first group of flat wires 321 is connected to the other end of the flat wire 322 a in the second group of flat wires 322 via a bus bar 332 d in another group of bus bars.
[0089] For example, Figure 7 As shown, one end of the flat wire 321d in the first group of flat wires 321 is connected to one end of the flat wire 323c in the third group of flat wires 323 through a bus bar 331e in a group of bus bars. Fig. 9 As shown, the other end of the flat wire 321d in the first group of flat wires 321 is connected to the other end of the flat wire 322c in the second group of flat wires 322 via a bus bar 332e in another group of bus bars.
[0090] For example, Figure 7 As shown, one end of the flat wire 321f in the first group of flat wires 321 is connected to one end of the flat wire 323e in the third group of flat wires 323 through a bus bar 331f in a group of bus bars. Fig. 9 As shown, the other end of the flat wire 321f in the first group of flat wires 321 and the other end of the flat wire 322e in the second group of flat wires 322 are connected via a busbar 332f in another group of busbars.
[0091] In some other embodiments, the flat conductor is a semi-formed U-pin structure flat conductor, and the busbars are grouped together.
[0092] In this embodiment, among the three groups of flat wires arranged in sequence along the circumference of the stator core, one end of a flat wire of one group of flat wires and one end of a flat wire of another group of flat wires are connected through a bus bar, and the other end of a flat wire of one group of flat wires and the other end of a flat wire of another group of flat wires are directly connected. Among them, one group of flat wires is arranged between another group of flat wires and another group of flat wires along the circumference of the stator core 310. In this way, one end of the flat wire along the axial direction of the stator core 310 does not need to be twisted / bent, and the flat wire does not need to be welded. The electrical connection of one end of the flat wire along the axial direction of the stator core 310 is directly realized through a group of bus bars, which reduces the height of the stator winding along the axial direction of the motor, reduces the cost of raw materials of the flat wire motor stator 300, and further reduces the production cost of the flat wire motor stator 300.
[0093] In one example, the distance between one flat wire of one group of flat wires and the shaft hole is equal to the distance between one flat wire of another group of flat wires and the shaft hole or the distance between one flat wire of another group of flat wires and the shaft hole. One busbar of a group of busbars connects two flat wires aligned along the circumferential direction of the motor in two adjacent winding slots G, so that the connection method of the busbar is simple.
[0094] In another example, the distance between one flat wire of one group of flat wires and the shaft hole is smaller than the distance between one flat wire of another group of flat wires and the shaft hole or the distance between one flat wire of another group of flat wires and the shaft hole. One busbar of a group of busbars connects two flat wires in two adjacent winding slots G that are staggered along the circumferential direction of the motor, so that the connection method of the busbar is simple.
[0095] For example, a group of flat wires is Figures 6 to 9 The first group of flat wires 321 shown in FIG. 1 and the other group of flat wires are Figures 6 to 9 The second group of flat wires 322 shown in FIG. 1 and another group of flat wires are Figures 6 to 9 The third group of flat wires 323 is shown in FIG.
[0096] For example, the flat wire 321a in the first group of flat wires 321 and the flat wire 323a in the third group of flat wires 323 are pre-formed into a U-shape or a V-shape by the same flat wire, and inserted into two adjacent groups of winding slots G along the circumferential direction of the stator core. In this way, the other end of the flat wire 321a in the first group of flat wires 321 and the other end of the flat wire 323a in the third group of flat wires 323 are directly connected without welding. In addition, as Figure 7 As shown, one end of the flat wire 321a in the first group of flat wires 321 and one end of the flat wire 322b in the second group of flat wires 322 are connected via a busbar 331a in a group of busbars.
[0097] For another example, the flat wire 321c in the first group of flat wires 321 and the flat wire 323c in the third group of flat wires 323 are pre-formed into a U-shape or a V-shape by the same flat wire, and inserted into two adjacent groups of winding slots G along the circumferential direction of the stator core. In this way, the other end of the flat wire 321c in the first group of flat wires 321 and the other end of the flat wire 323c in the third group of flat wires 323 are directly connected without welding. In addition, as Figure 7 As shown, one end of the flat wire 321c in the first group of flat wires 321 and one end of the flat wire 322d in the second group of flat wires 322 are connected through a bus bar 331b in a group of bus bars.
[0098] For another example, the flat wire 321e in the first group of flat wires 321 and the wire 323e in the third group of flat wires 323 are pre-formed into a U-shape or a V-shape from the same flat wire and inserted into two adjacent groups of winding slots G along the circumferential direction of the stator core. In this way, the other end of the flat wire 321e in the first group of flat wires 321 is directly connected to the other end of the wire 323e in the third group of flat wires 323 without welding. Figure 7 As shown, one end of the flat wire 321e in the first group of flat wires 321 and one end of the flat wire 322f in the second group of flat wires 322 are connected through a bus bar 331c in a group of bus bars.
[0099] For example, a group of flat wires is Figures 6 to 9 The first group of flat wires 321 shown in FIG. 1 and the other group of flat wires are Figures 6 to 9 The third group of flat wires 323 shown in FIG. 1 and another group of flat wires are Figures 6 to 9 The second group of flat wires 322 is shown in FIG.
[0100] For example, the flat wire 321b in the first group of flat wires 321 and the flat wire 323b in the third group of flat wires 323 are pre-formed into a U-shape or a V-shape by the same flat wire, and inserted into two adjacent groups of winding slots G along the circumferential direction of the stator core. In this way, the other end of the flat wire 321b in the first group of flat wires 321 and the other end of the flat wire 323b in the third group of flat wires 323 are directly connected without welding. In addition, as Figure 7 As shown, one end of the flat wire 321b in the first group of flat wires 321 and one end of the flat wire 323a in the third group of flat wires 323 are connected through a bus bar 331d in a group of bus bars.
[0101] For another example, the flat wire 321d in the first group of flat wires 321 and the flat wire 323d in the third group of flat wires 323 are pre-formed into a U-shape or a V-shape by the same flat wire, and inserted into two adjacent groups of winding slots G along the circumferential direction of the stator core. In this way, the other end of the flat wire 321d in the first group of flat wires 321 and the other end of the flat wire 323d in the third group of flat wires 323 are directly connected without welding. In addition, as Figure 7 As shown, one end of the flat wire 321d in the first group of flat wires 321 and one end of the flat wire 322c in the third group of flat wires 323 are connected through a bus bar 331e in a group of bus bars.
[0102] For another example, the flat wire 321f in the first group of flat wires 321 and the wire 323f in the third group of flat wires 323 are pre-formed into a U-shape or a V-shape from the same flat wire and inserted into two adjacent groups of winding slots G along the circumferential direction of the stator core. In this way, the other end of the flat wire 321f in the first group of flat wires 321 is directly connected to the other end of the wire 323f in the third group of flat wires 323 without welding. In addition, if Figure 7 As shown, one end of the flat wire 321f in the first group of flat wires 321 and one end of the flat wire 322e in the third group of flat wires 323 are connected via a bus bar 331f in a group of bus bars.
[0103] In some embodiments, each group of busbars is a split structure. Multiple busbars in each group of busbars are arranged along the radial direction of the stator core 310 or along the circumferential direction of the stator core 310. In this way, multiple busbars are arranged in layers along the radial direction of the stator core or the circumferential direction of the stator core, so that multiple flat wires meet safety regulations. Furthermore, in order to avoid interference between adjacently arranged busbars, each flat wire can also be expanded in a direction away from the axial hole O of the stator core.
[0104] In some embodiments, each busbar group is an integrally formed structure, that is, multiple busbars in each busbar group are an integrally formed structure. In this way, conduction and insulation of each busbar group can be achieved through an integral injection molding process of multiple busbars in each busbar group, simplifying the processing technology of the busbar.
[0105] In some embodiments, the multiple busbars in each group of busbars include two types of busbars, and each type of busbar includes at least one busbar. Among them, one type of busbar is a busbar of an integrally formed structure, and the other type of busbar is a busbar of a split structure. In this way, the busbars can be flexibly arranged according to needs.
[0106] In some embodiments, Figure 5 As shown, the two busbars are arranged adjacent to each other in the radial direction of the stator core 310 or in the circumferential direction of the stator core 310, and the two busbars are spaced apart in the axial direction of the stator core 310. In this way, the two busbars arranged adjacent to each other in the radial direction of the stator core 310 or in the circumferential direction of the stator core 310 are arranged in a staggered manner in the axial direction of the stator core 310, so that the insulation between the two adjacently arranged busbars meets the safety requirements.
[0107] In some embodiments, Figure 5 As shown, the side of each busbar facing away from the stator core 310 is substantially flush with the side of the flat wire facing away from the stator core 310. In this way, not only is welding between the busbar and the flat wire convenient, but also the raw materials of the flat wire can be saved.
[0108] In some embodiments, the side of each flat wire of the three flat wires away from the stator core 310 is distributed on the side of the busbar connecting each flat wire away from the stator core 310. In this way, the three flat wires can be used as three-phase lead-out terminals of the motor rotor.
[0109] like Figures 10 to 15 As shown, each busbar includes two connection holes H. Each connection hole H is used to embed a flat wire. Each connection hole H penetrates the busbar along the axial direction of the stator core 310.
[0110] like Figures 10 to 15 As shown, the busbar includes four side surfaces F1 - F4 , two side surfaces F1 - F2 along the radial direction of the stator core 310 are arranged opposite to each other, and the other two side surfaces F3 - F4 along the circumferential direction of the stator core 310 are arranged opposite to each other.
[0111] In some embodiments, Fig.10 As shown, the two connection holes H are not connected to the four side surfaces F1 - F4 of the busbar.
[0112] In some embodiments, Figures 11 to 15 As shown, at least one of the two connection holes H is connected to one of the four side surfaces of the busbar.
[0113] For example, Fig.11 As shown, each of the two connection holes H is connected to the side surface F2 of the four side surfaces F1-F4 of the busbar. Fig.12 As shown, one of the two connection holes H is connected to the side F3 among the four side faces F1-F4 of the busbar, and the other connection hole H is connected to the side F4 among the four side faces F1-F4 of the busbar. Fig.13 As shown, one of the two connection holes H is connected to the side F2 among the four side faces F1-F4 of the busbar, and the other connection hole H is connected to the side F4 among the four side faces F1-F4 of the busbar. Fig.14 As shown, only one of the two connection holes H is connected to the side surface F2 of the four side surfaces F1-F4 of the busbar, and the other connection hole H is not connected to any of the four side surfaces F1-F4 of the busbar. Fig.15 As shown, only one of the two connection holes H is connected to the side surface F4 of the four side surfaces F1 - F4 of the busbar, and the other connection hole H is not connected to any of the four side surfaces F1 - F4 of the busbar.
[0114] In some embodiments, the projection of at least one of the two side surfaces F1-F2 of the busbar along the axial direction of the stator core 310 is a curve, and the bending direction of the curve is toward the inside of the busbar. In this way, the two side surfaces of the busbar are respectively arc surfaces that are concave toward the inside of the busbar, which can prevent the busbar from interfering with other components such as other flat wires.
[0115] In some embodiments, the size of each connection hole H along the radial direction of the stator core 310 is equal to the size of each flat wire, and the size of each connection hole H along the axial direction of the stator core 310 is equal to the size of each flat wire. In this way, the solder between the busbar and the flat wire can be reduced, and the production cost of the flat motor stator is reduced.
[0116] In some embodiments, each bus bar includes a substrate, and two connection holes H are distributed on the substrate, so that the production cost of the bus bar can be saved.
[0117] In some embodiments, each bus bar includes three substrates, another substrate among the three substrates is used to connect the two substrates, and each of the two substrates includes a connecting hole.
[0118] In one example, two substrates are arranged on both sides of another substrate along the axial direction of the stator core 310, and the projection areas of the two substrates do not overlap along the axial direction of the stator core 310. In this way, there is a height difference between the welding points of the two flat wires connected to each busbar along the axial direction of the stator core, so that the two adjacent flat wires meet the insulation safety requirements.
[0119] In another example, two substrates are arranged on both sides of another substrate in the radial direction of the stator core 310, and the projection areas of the two substrates in the radial direction of the stator core 310 do not overlap. In this way, the welding points of the two flat wires connected to each busbar in the radial direction of the stator core have a height difference, so that the two adjacent flat wires meet the insulation safety requirements.
[0120] The steps for assembling the flat motor stator provided in the embodiment of the present application are as follows:
[0121] S1, a plurality of stator punching sheets are welded, riveted or glued to form a stator core 310, and the stator core 310 is loaded.
[0122] S2, fold the insulating paper according to the shape of the winding slot G of the stator core 310 and insert it into the winding slot G.
[0123] S3, shaping the flat wire and inserting it into the winding slot G. Exemplarily, shaping the flat wire includes straightening the flat wire, removing the paint coating, and the like.
[0124] S4, expand one end of the flat wire and weld a set of bus bars to one end of the flat wire. Here, the other end of the flat wire needs to be limited and protected.
[0125] The embodiment of the present application does not limit the welding method between the busbar and the flat wire. For example, the welding method includes tungsten inert gas welding (TIG), laser welding, etc.
[0126] S5, protect one end of the welded flat wire to prevent the soldering point from colliding with other components and damaging the soldering point.
[0127] S6, flip the flat wire stator 180 degrees, expand the other end of the flat wire, weld another set of busbars to the other end of the flat wire, and protect the other end of the welded flat wire.
[0128] It should be noted that the axial direction of the stator punching sheet involved in this application can be understood as the axial direction of the stator core, the axial direction of the motor, and the thickness direction of the busbar. The radial direction of the stator punching sheet can be understood as the radial direction of the stator core or the radial direction of the motor. The circumferential direction of the stator punching sheet can be understood as the circumferential direction of the stator core or the circumferential direction of the motor. In addition, Figures 2 to 9 In the examples, the stator winding is accommodated in three winding slots G arranged in sequence along the circumferential direction of the stator core 310.
[0129] The above is only a specific implementation of the present application, but the protection scope of the present application is not limited thereto. Any person skilled in the art who is familiar with the present technical field can easily think of changes or substitutions within the technical scope disclosed in the present application, which should be included in the protection scope of the present application. Therefore, the protection scope of the present application should be based on the protection scope of the claims.
Claims
1. A flat wire motor stator, characterized in that: The flat wire motor stator comprises: A stator core, the stator core comprising an inner circumferential surface and an outer circumferential surface arranged opposite to each other in a radial direction of the stator core, the inner circumferential surface comprising a plurality of winding slots penetrating in an axial direction of the stator core, the plurality of winding slots being arranged at intervals in a circumferential direction of the stator core, and a slot opening of each winding slot facing an axial hole of the stator core; A stator winding, wherein the stator winding comprises a plurality of groups of flat wires, each group of flat wires comprises a plurality of flat wires, each flat wire of each group of flat wires is used to pass through one of the winding slots along the axial direction of the stator core, and the plurality of flat wires of each group of flat wires are sequentially arranged at intervals along the radial direction of the stator core; At least one group of busbars, each group of busbars includes at least one busbar, and each group of busbars is used to electrically connect one end of the plurality of groups of flat wires arranged along the axial direction of the stator core.
2. The flat wire motor stator according to claim 1, characterized in that: Each set of busbars is an integrally formed structure; or, The multiple busbars in each group of busbars are arranged along the radial direction of the stator core or along the circumferential direction of the stator core.
3. The flat wire motor stator according to claim 2, characterized in that: The two busbars are arranged adjacent to each other in a radial direction of the stator core or in a circumferential direction of the stator core, and there is a gap between the two busbars in an axial direction of the stator core.
4. The flat wire motor stator according to claim 1, characterized in that: One busbar in a group of the busbars is used to electrically connect one end of a flat wire in one group of the flat wires and one end of a flat wire in another group of the flat wires. The group of flat wires and the other group of flat wires are arranged adjacent to each other along the circumferential direction of the stator core.
5. The flat wire motor stator according to claim 4, characterized in that: The group of flat wires is arranged between the other group of flat wires and the other group of flat wires along the circumferential direction of the stator core, wherein: The other end of one flat wire of the group of flat wires is connected to the other end of one flat wire of the further group of flat wires, or, One of the busbars of the other group of busbars is used to electrically connect the other end of one of the flat wires of the group of flat wires and the other end of one of the flat wires of the further group of flat wires.
6. The flat wire motor stator according to claim 4 or 5, characterized in that: The distance between one flat wire of the group of flat wires and the axial hole is equal to the distance between one flat wire of the other group of flat wires and the axial hole or the distance between one flat wire of another group of flat wires and the axial hole; or, The distance between a flat wire of the group of flat wires and the axial hole is smaller than the distance between a flat wire of the other group of flat wires and the axial hole or the distance between a flat wire of yet another group of flat wires and the axial hole.
7. The flat wire motor stator according to claim 1, characterized in that: One end of each flat wire is arranged on a side of one end face of the stator core away from another end face along the axial direction of the stator core, and one end of two adjacent flat wires in each group of flat wires are unequally spaced from the one end face.
8. The flat wire motor stator according to claim 1, characterized in that: Each of the busbars comprises two connection holes, each of which is used to embed one of the flat wires, and each of the connection holes penetrates the busbar along the axial direction of the stator core.
9. The flat wire motor stator according to claim 8, characterized in that: The busbar comprises two side surfaces arranged opposite to each other in the radial direction of the stator core and another two side surfaces arranged opposite to each other in the circumferential direction of the stator core, wherein: At least one of the connection holes is communicated with one side surface of the busbar, and the one side surface is one of the two side surfaces or the one side surface is one of the other two side surfaces.
10. The flat wire motor stator according to claim 8, characterized in that: A projection of at least one of the two side surfaces along the axial direction of the stator core is a curve, and a bending direction of the curve is toward the inside of the busbar.
11. The flat wire motor stator according to claim 8, characterized in that: The size of each of the connection holes along the radial direction of the stator core is equal to the size of each of the flat wires, and the size of each of the connection holes along the axial direction of the stator core is equal to the size of each of the flat wires.
12. The flat wire motor stator according to claim 8, characterized in that: Each busbar includes three substrates, two of which are arranged on both sides of another substrate along the axial direction of the stator core, and the projection areas of the two substrates along the axial direction of the stator core do not overlap, and each of the two substrates includes one connecting hole.
13. The flat wire motor stator according to any one of claims 1 to 5 and 7 to 12, characterized in that: The size of each of the flat wires along the axial direction of the stator core is larger than the size of the stator core; The intervals between two adjacent flat wires in each group of flat wires are equal; Along the axial direction of the stator core, the projected area of each winding slot is equal; The number of each group of flat wires is a multiple of the number of the busbars; The number of the plurality of winding slots is a multiple of 3, and the number of the flat wires in each group is an even number.
14. A flat wire motor, characterized in that: The flat wire motor comprises a motor rotor and the flat wire motor stator according to any one of claims 1 to 13, wherein the motor rotor passes through an axial hole of the flat wire motor stator.
15. A powertrain, characterized in that: The power assembly includes a reducer and the flat wire motor as claimed in claim 14, wherein a motor shaft of the flat wire motor is drivingly connected to an input shaft of the reducer.