Flat wire vertically-wound armature with magnetic slot wedge

Abstract

The utility model particularly relates to a flat wire vertically-wound armature with a magnetic slot wedge. The flat wire vertically-wound armature comprises an iron core, a three-phase vertically-wound coil assembly and the magnetic slot wedge. The iron core is of an annular structure, and a plurality of tooth parts are evenly distributed on the outer side of the annular structure in the circumferential direction. An open slot is formed between every two adjacent tooth parts; each phase of vertically-wound coil group is composed of an A group of vertically-wound coil units and A-1 bridging lines; each vertically-wound coil unit comprises a plurality of vertically-wound coils; the vertical winding ring is arranged on the tooth part in a sleeving manner; the magnetic slot wedge is arranged on the tooth part; bridging lines are arranged between every two adjacent sets of vertically-wound coil units. According to the armature, hairpin line types are greatly reduced, winding ends are reduced, the winding difficulty is effectively reduced, the number of welding spots and the cost input of automatic production equipment are reduced, and the motor efficiency and the torque density are effectively improved; and the magnetic slot wedge is connected with the tooth part in a mortise and tenon joint structure mode, so that the harmonic loss of the motor can be effectively reduced, and the reliability of the slot wedge is improved.

Description

Technical Field

[0001] The utility model belongs to the field of motor armatures, and in particular relates to a flat wire vertically wound armature with magnetic slot wedges. Background Art

[0002] As the core part of electromagnetic conversion, the slot fill rate and structure of the motor stator armature have a huge impact on the motor efficiency and cost. The winding formed by flat wire is widely used because of its higher slot fill rate and motor efficiency. At present, most flat wire motors adopt hairpin and I-pin structures. This structure not only has high copper wire height at the end, large waste, and many welding points, but also as the number of winding layers increases, the number of hairpin types and corresponding molding dies required also increases accordingly, resulting in high production process and material costs.

[0003] The Chinese patent with publication number CN116599251A discloses a motor stator and a motor, wherein the motor stator comprises an iron core and a three-phase winding; the iron core has a plurality of teeth arranged in a circumferential array, and slots communicating with the hollow part of the iron core are formed between the teeth; the winding of each phase is composed of two parallel branches, and each parallel branch is composed of a plurality of groups of double-coil components; the two flat wire vertically wound coils contained in each group of double-coil components are wound in opposite directions, and both occupy two consecutive teeth on the iron core; the double-coil components contained in the three-phase winding are arranged alternately in the circumferential direction of the iron core; The coil layouts of two adjacent groups of double-coil assemblies are opposite; in the two parallel branches belonging to the adjacent two-phase windings, the winding directions of the flat wire vertically wound coils near their respective head ends are opposite; the invention reduces the winding end by using a flat wire to continuously wind the coils directly on the iron core, but due to the existence of the iron core pole shoes, it is very difficult for the automatic winding equipment to directly unwind the iron core, and the bridging copper wire between the two coils needs to be continuously wound and then bent into shape. The automated continuous winding is extremely difficult and the paint is easily damaged, the qualified rate is low, it is not easy to form automated production, and the process cost is correspondingly increased. Utility Model Content

[0004] In order to solve the above technical problems, the utility model provides a flat wire vertically wound armature with magnetic slot wedges.

[0005] The utility model is realized through the following technical solutions.

[0006] A flat wire vertically wound armature with magnetic slot wedges, comprising an iron core, a three-phase vertically wound coil group and a magnetic slot wedge; the iron core is an annular structure, and a plurality of teeth are evenly distributed along the circumferential direction on the outer side of the annular structure; an open slot is formed between two adjacent teeth;

[0007] The vertical winding coil group of each phase is composed of A groups of vertical winding coil units and A-1 bridge wires; each group of vertical winding coil units includes multiple vertical winding coils; the vertical winding coils are sleeved on the teeth; the magnetic slot wedges are arranged on the teeth; and a bridge wire is arranged between two adjacent groups of vertical winding coil units.

[0008] The vertical winding coil is wound into an O-shaped structure using a flat wire.

[0009] The O-shaped structure includes an O-shaped winding part, and a starting end vertical flat wire and a tail end vertical flat wire are respectively arranged on the O-shaped winding part; the starting end vertical flat wire and the tail end vertical flat wire are arranged axially along the tooth part, and the O-shaped winding part is arranged circumferentially along the tooth part.

[0010] The tooth portion and the magnetic slot wedge are connected via a mortise and tenon structure.

[0011] The vertical winding coil unit is formed by connecting a plurality of vertical winding coils end to end in sequence.

[0012] The ends of the vertical winding coil are respectively provided with an incoming twist end and an outgoing twist end on the starting end vertical flat wire and the ending end vertical flat wire. The outgoing twist ends and the incoming twist ends of adjacent vertical winding coils are connected by welding after twisting in opposite directions.

[0013] The bridge wire is arranged on the inner side of the three-phase vertical winding coil group.

[0014] The bridge line includes a first axial vertical flat wire, a concave arc flat wire, a first circumferential arc flat wire, a second circumferential arc flat wire, a third circumferential arc flat wire and a second axial vertical flat wire which are connected in sequence.

[0015] The first connecting part of the concave circular arc flat wire and the first axial vertical flat wire and the second connecting part of the first circumferential circular arc flat wire are both bent inward; the third connecting part of the second circumferential circular arc flat wire and the first circumferential circular arc flat wire and the fourth connecting part of the third circumferential circular arc flat wire are both bent downward; the fifth connecting part of the third circumferential circular arc flat wire and the second axial vertical flat wire is first bent downward and then inward.

[0016] The beneficial effects of the utility model are:

[0017] 1. Compared with the armature winding formed by the hairpin type in the prior art, the utility model adopts a combination of vertical winding coils and bridge wires to form a three-phase vertical winding coil group, which not only reduces the number of end welding points and reduces the difficulty of winding, but also improves reliability and automated production efficiency, while effectively reducing the waste of winding ends, which is conducive to improving motor efficiency and torque density, and reducing material and process costs;

[0018] 2. Different bridge wires are arranged in radial staggered layers and axial stepped arrangements. Only one type of bridge wire can be used to achieve series connection between vertically wound coil units, effectively reducing the types of bridge wires and mold opening costs, and avoiding unbalanced three-phase resistance values;

[0019] 3. The magnetic slot wedge is connected to the tooth part through the mortise and tenon structure, which can not only effectively reduce the harmonic loss of the motor, but also improve the reliability of the slot wedge. The arc structure has a positioning effect and can also place self-locking points. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 It is a three-dimensional diagram of a flat wire vertically wound armature with magnetic slot wedges and 42 slots provided by an embodiment of the utility model;

[0021] Figure 2 A top view of a flat wire vertically wound armature with magnetic slot wedges having 42 open slots provided in an embodiment of the utility model;

[0022] Figure 3 This is a schematic diagram of the vertical winding coil structure of the utility model;

[0023] Figure 4 It is a schematic diagram of the magnetic slot wedge structure of the utility model;

[0024] Figure 5 This is a schematic diagram of the core tooth structure of the utility model;

[0025] Figure 6 It is a schematic diagram of the structure formed by connecting the tooth portion and the magnetic slot wedge of the utility model through the mortise and tenon structure;

[0026] Figure 7 This is a schematic diagram of the structure of the first group of vertically wound coil units of each phase of this embodiment;

[0027] Figure 8 This is a schematic diagram of the bridge wiring structure of the utility model;

[0028] Fig. 9 It is a schematic diagram of the structure after different bridge wirings are assembled according to the embodiment of the utility model;

[0029] In the figure: 1-iron core, 2-vertical winding coil group, 3-magnetic slot wedge, 4-tooth portion, 5-open slot, 6-vertical winding coil unit, 7-bridge wire, 8-vertical winding coil, 9-O-type winding part, 10-starting end vertical flat wire, 11-ending end vertical flat wire, 12-first axial vertical flat wire, 13-concave arc flat wire, 14-first circumferential arc flat wire, 15-second circumferential arc flat wire, 16-third circumferential arc flat wire, 17-second axial vertical flat wire, 18-first connecting part, 19-second connecting part, 20-third connecting part, 21-fourth connecting part, 22-fifth connecting part; 1001-inlet twist end, 1102-outlet twist end. DETAILED DESCRIPTION

[0030] The technical solution of the utility model is further described below, but the scope of protection required is not limited to the description.

[0031] The utility model provides a flat wire vertically wound armature with magnetic slot wedges, such as Figure 1 The figure shows a three-dimensional diagram of a flat wire vertically wound armature with magnetic slot wedges and 42 slots provided by an embodiment of the utility model. Figure 2 The figure shows a top view of a flat wire vertically wound armature with magnetic slot wedges and 42 open slots provided by an embodiment of the utility model;

[0032] Combination Figure 1 to Figure 2 The flat wire vertically wound armature comprises an iron core 1, a three-phase vertically wound coil group 2 and a magnetic slot wedge 3; the iron core 1 is an annular structure, and a plurality of teeth 4 are evenly distributed along the circumferential direction on the outer side of the annular structure; an open slot 5 is formed between two adjacent teeth 4;

[0033] Specifically, the number of the open slots 5 in this embodiment is 42.

[0034] Furthermore, each phase of the vertical winding coil group 2 is composed of A groups of vertical winding coil units 6 and A-1 bridge wires 7; each group of vertical winding coil units 6 includes multiple vertical winding coils 8; the vertical winding coils 8 are sleeved on the tooth portion 4; the magnetic slot wedge 3 is arranged on the tooth portion 4; and a bridge wire 7 is arranged between two adjacent groups of vertical winding coil units 6.

[0035] Furthermore, if Figure 3 The figure shows a schematic diagram of the vertical winding coil structure of the utility model, wherein the vertical winding coil 8 is wound into an O-shaped structure using a flat wire;

[0036] Furthermore, the O-shaped structure includes an O-shaped winding portion 9, and a starting end vertical flat wire 10 and a tail end vertical flat wire 11 are respectively arranged on the O-shaped winding portion 9; the starting end vertical flat wire 10 and the tail end vertical flat wire 11 are arranged axially along the tooth portion 4, and the O-shaped winding portion 9 is arranged circumferentially along the tooth portion 4;

[0037] Specifically, the O-shaped winding portion 9 is composed of N turns of coils. In this embodiment, N is 6, that is, the O-shaped winding portion 9 is composed of 6 turns of coils.

[0038] Furthermore, combined with Figure 4 The magnetic slot wedge structure diagram of the utility model shown in FIG. Figure 5 The schematic diagram of the core tooth structure of the utility model shown in FIG. Figure 4 It can be seen that the magnetic slot wedge 3 is a convex structure. Figure 5 It can be seen that the tooth portion 4 is a concave structure, such as Figure 6 The figure shows a schematic diagram of a structure formed after the tooth portion and the magnetic slot wedge of the utility model are connected by a mortise and tenon structure, wherein the tooth portion 4 and the magnetic slot wedge 3 are connected by a mortise and tenon structure;

[0039] The mortise and tenon structure is used for connection, which can not only effectively reduce the harmonic loss of the motor and facilitate the vertical winding coil 8 to be directly embedded in the slot, but also make the magnetic slot wedge 3 not easy to fall off, thereby improving the reliability of the magnetic slot wedge 3. The arc structure has a positioning effect and can also place self-fastening points.

[0040] Furthermore, the vertical winding coil unit 6 is formed by connecting a plurality of vertical winding coils 8 end to end in sequence.

[0041] Furthermore, the ends of the vertical winding coil 8 are respectively provided with an incoming twist end 1001 and an outgoing twist end 1102 on the starting end vertical flat wire 10 and the ending end vertical flat wire 11, and the outgoing twist end 1102 and the incoming twist end 1001 of the adjacent vertical winding coil 8 are connected by welding after twisting in opposite directions;

[0042] Specifically, Figure 7The schematic diagram of the structure of the first group of vertical winding coil units of each phase of the present embodiment is shown, wherein the vertical winding coil unit 6 is composed of 7 vertical winding coils 8; the outgoing twisted end 1102 of the vertical flat wire 11 at the end of the first vertical winding coil 8 is connected to the incoming twisted end 1001 of the vertical flat wire 10 at the starting end of the second vertical winding coil 8, the outgoing twisted end 1102 of the vertical flat wire 11 at the end of the second vertical winding coil 8 is connected to the incoming twisted end 1001 of the vertical flat wire 10 at the starting end of the third vertical winding coil 8, the outgoing twisted end 1102 of the vertical flat wire 11 at the end of the third vertical winding coil 8 is connected to the incoming twisted end 1001 of the vertical flat wire 10 at the starting end of the fourth vertical winding coil 8 The incoming twisted end 1001 of the wire 10, the outgoing twisted end 1102 of the vertical flat wire 11 at the end of the fourth vertical winding coil 8 and the incoming twisted end 1001 of the vertical flat wire 10 at the starting end of the fifth vertical winding coil 8, the outgoing twisted end 1102 of the vertical flat wire 11 at the end of the fifth vertical winding coil 8 and the incoming twisted end 1001 of the vertical flat wire 10 at the starting end of the sixth vertical winding coil 8, and the outgoing twisted end 1102 of the vertical flat wire 11 at the end of the sixth vertical winding coil 8 and the incoming twisted end 1001 of the vertical flat wire 10 at the starting end of the seventh vertical winding coil 8 are all connected by twisting in opposite directions and then being welded;

[0043] Further, the incoming twisted end 1001 of the vertical flat wire 10 at the starting end of the first vertical winding coil 8 serves as the lead-in wire of the vertical winding coil group 2 of each phase, and the outgoing twisted end 1102 of the vertical flat wire 11 at the ending end of the seventh vertical winding coil 8 is welded and connected to the incoming twisted end 1001 of the vertical flat wire 10 at the starting end of the first vertical winding coil 8 of the second group of the vertical winding coil units 6 through the bridge wire 7; the outgoing twisted end 1102 of the vertical flat wire 11 at the ending end of the seventh vertical winding coil 8 of the second group of the vertical winding coil units 6 serves as the lead-out wire of the vertical winding coil group 2 of each phase;

[0044] Compared with the armature formed by embedding hairpin-shaped flat wires or the armature formed by continuous winding in the prior art, the utility model forms the winding by combining a vertically wound coil with a bridge wire, which not only reduces the number of end welding points and reduces the difficulty of winding, but also improves reliability and automated production efficiency, while effectively reducing the waste of winding ends, which is beneficial to improving motor efficiency and reducing material and process costs.

[0045] Furthermore, the bridge wire 7 is arranged on the inner side of the three-phase vertical winding coil group 2;

[0046] The bridge wire can realize long-distance connection between adjacent vertical winding coil units 6 of the same phase, that is, in this embodiment, the outgoing twisted end 1102 of the vertical flat wire 11 at the tail end of the seventh vertical winding coil 8 of the first group of vertical winding coil units 6 and the incoming twisted end 1001 of the vertical flat wire 10 at the starting end of the first vertical winding coil 8 of the second group of vertical winding coil units 6 are connected through the bridge wire 7. It can be applied to the connection scheme of multiple groups of vertical winding coil units. Compared with the existing copper wire forming and then injection molding and welding the starting and tail ends of two coil groups, the length of the bridge wire can be effectively shortened and the manufacturing cost can be reduced.

[0047] Furthermore, if Figure 8 The figure shows a schematic diagram of the bridge wire structure of the utility model; the bridge wire 7 comprises a first axial vertical flat wire 12, a concave arc flat wire 13, a first circumferential arc flat wire 14, a second circumferential arc flat wire 15, a third circumferential arc flat wire (16) and a second axial vertical flat wire 17 connected in sequence;

[0048] Furthermore, the first connection portion 18 of the concave circular arc flat wire 13 and the first axial vertical flat wire 12 and the second connection portion 19 of the first circumferential circular arc flat wire 14 are both bent inwardly; the third connection portion 20 of the second circumferential circular arc flat wire 15 and the first circumferential circular arc flat wire 14 and the fourth connection portion 21 of the third circumferential circular arc flat wire 16 are both bent downwardly; the fifth connection portion 22 of the third circumferential circular arc flat wire 16 and the second axial vertical flat wire 17 is first bent downwardly and then inwardly;

[0049] The structural type of the bridge wire 7 facilitates radial staggering and axial step arrangement between different bridge wires to avoid spatial interference. Only one type of bridge wire can be used to achieve series connection between the same-phase vertically wound coil units, effectively reducing the types of bridge wires and mold opening costs, and avoiding unbalanced three-phase resistance values.

[0050] Furthermore, A≥2, where A is an integer.

[0051] Specifically, in this embodiment, A is set to 2, that is, each phase vertical winding coil group 2 is composed of 2 sets of vertical winding coil units 6 and 1 bridge wire, and the three phases are composed of 6 sets of vertical winding coil units 6 and 3 bridge wires, and the 3 bridge wires 7 are defined as bridge wire 7a, bridge wire 7b and bridge wire 7c; Fig. 9The figure shows a schematic diagram of the structure of different bridge wires of the embodiment of the utility model. A part of the second circumferential circular arc flat wire 15, the fourth connecting part 21, the third circumferential circular arc flat wire 16 and the downward bending part of the fifth connecting part 22 of the bridge wire 7a are arranged in an axial stepped manner corresponding to the first connecting part 18, the second connecting part 19 and the third connecting part 20 of the bridge wire 7b, and another part of the second circumferential circular arc flat wire 15 and the inward bending part of the fifth connecting part 22 are arranged in a radial staggered manner corresponding to the concave circular arc flat wire 13 and a part of the second circumferential circular arc flat wire 15 of the bridge wire 7b; the first connecting part 18, the second connecting part 19 and the third connecting part 20 of the bridge wire 7c are arranged in a radial staggered manner. The connecting portion 19 and the third connecting portion 20 are arranged in an axial stepped manner corresponding to a portion of the second circumferential circular arc flat wire 15 of the bridging wire 7b, the fourth connecting portion 21, the third circumferential circular arc flat wire 16 and the downwardly bent portion of the fifth connecting portion 22; the concave circular arc flat wire 13 and a portion of the second circumferential circular arc flat wire 15 are arranged in a radially staggered manner corresponding to another portion of the second circumferential circular arc flat wire 15 of the bridging wire 7b and the inwardly bent portion of the fifth connecting portion 22; the second axial vertical flat wire 17 of the bridging wire 7a is embedded in the hollow position of the radially staggered portion formed by the second circumferential circular arc flat wire 15 of the bridging wire 7b and the concave circular arc flat wire 13 of the bridging wire 7c.

[0052] The beneficial effects of the utility model are: 1. Compared with the armature winding formed by the hairpin type in the prior art, the utility model adopts a combination of a vertical winding coil and a bridge wire to form a three-phase vertical winding coil group, which not only reduces the number of end welding points and reduces the difficulty of winding, but also improves reliability and automated production efficiency, while effectively reducing the waste of winding ends, which is beneficial to improving motor efficiency and torque density, and reducing material and process costs; 2. Different bridge wires are arranged by radial staggered layers and axial stepped arrangements, and only one type of bridge wire can be used to achieve series connection between the same-phase vertical winding coil units, effectively reducing the types of bridge wires and mold opening costs, and avoiding unbalanced three-phase resistance values; 3. The magnetic slot wedge and the tooth portion are connected by a mortise and tenon structure, which can not only effectively reduce the harmonic loss of the motor, but also improve the reliability of the slot wedge. The arc structure has a positioning effect, and self-locking points can also be placed.

[0053] The above embodiments are merely descriptions of preferred implementations of the present invention and cannot be used as limitations of the present invention. Various modifications and alterations made to the technical solution of the present invention should fall within the protection scope of the claims of the present invention.

Claims

1. A flat wire vertically wound armature with magnetic slot wedges, characterized in that: It comprises an iron core (1), a three-phase vertically wound coil group (2) and a magnetic slot wedge (3); the iron core (1) is an annular structure, and a plurality of teeth (4) are evenly distributed along the circumferential direction on the outer side of the annular structure; an open slot (5) is formed between two adjacent teeth (4); The vertical winding coil group (2) of each phase is composed of A groups of vertical winding coil units (6) and A-1 bridge wires (7); each group of vertical winding coil units (6) includes a plurality of vertical winding coils (8); the vertical winding coils (8) are sleeved on the teeth (4); the magnetic slot wedges (3) are arranged on the teeth (4); and a bridge wire (7) is arranged between two adjacent groups of vertical winding coil units (6).

2. A flat wire vertically wound armature with magnetic slot wedges as claimed in claim 1, characterized in that: The vertical winding coil (8) is wound into an O-shaped structure using a flat wire.

3. A flat wire vertically wound armature with magnetic slot wedges as claimed in claim 2, characterized in that: The O-shaped structure comprises an O-shaped winding portion (9), and a starting end vertical flat wire (10) and a tail end vertical flat wire (11) are respectively arranged on the O-shaped winding portion (9); the starting end vertical flat wire (10) and the tail end vertical flat wire (11) are arranged axially along the tooth portion (4), and the O-shaped winding portion (9) is arranged circumferentially along the tooth portion (4).

4. A flat wire vertically wound armature with magnetic slot wedges as claimed in claim 1, characterized in that: The tooth portion (4) and the magnetic slot wedge (3) are connected via a mortise and tenon structure.

5. A flat wire vertically wound armature with magnetic slot wedges as claimed in claim 1, characterized in that: The vertical winding coil unit (6) is formed by connecting a plurality of vertical winding coils (8) end to end in sequence.

6. A flat wire vertically wound armature with magnetic slot wedges as claimed in claim 5, characterized in that: The ends of the vertical winding coil (8) are respectively provided with an incoming twist end (1001) and an outgoing twist end (1102) on a starting end vertical flat wire (10) and an ending end vertical flat wire (11); the outgoing twist ends (1102) and the incoming twist ends (1001) of adjacent vertical winding coils (8) are connected by welding after twisting in opposite directions.

7. A flat wire vertically wound armature with magnetic slot wedges as claimed in claim 1, characterized in that: The bridge wire (7) is arranged on the inner side of the three-phase vertically wound coil group (2).

8. A flat wire vertically wound armature with magnetic slot wedges as claimed in claim 1, characterized in that: The bridge wire (7) comprises a first axial vertical flat wire (12), a concave circular arc flat wire (13), a first circumferential circular arc flat wire (14), a second circumferential circular arc flat wire (15), a third circumferential circular arc flat wire (16) and a second axial vertical flat wire (17) which are connected in sequence.

9. A flat wire vertically wound armature with magnetic slot wedges as claimed in claim 8, characterized in that: The first connection part (18) of the concave circular arc flat wire (13) and the first axial vertical flat wire (12) and the second connection part (19) of the first circumferential circular arc flat wire (14) are both bent inwards; the third connection part (20) of the second circumferential circular arc flat wire (15) and the first circumferential circular arc flat wire (14) and the fourth connection part (21) of the third circumferential circular arc flat wire (16) are both bent downwards; the fifth connection part (22) of the third circumferential circular arc flat wire (16) and the second axial vertical flat wire (17) is first bent downwards and then bent inwards.

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