Stator assembly, motor and vehicle
By optimizing the span of the card issuer coil of the flat wire motor, reducing the volume of the stator winding and the amount of silver used, the problem of difficulty in miniaturizing the flat wire motor and large amount of copper is solved, and the motor is miniaturized and cost-reduced.
Patent Information
- Application Number
- CN202420122761.3
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-01-17
- Publication Date
- 2025-02-11
- Estimated Expiration
- 2034-01-17
AI Technical Summary
The stator winding of the flat wire motor is large in size, which makes it difficult to miniaturize the motor and uses a large amount of copper, which increases the cost.
By optimizing the span of the issuing coil, the proportion of the issuing coil with a larger span is reduced, and the proportion of the issuing coil with a smaller span is increased, thereby reducing the volume of the stator winding and the amount of copper used.
The volume reduction of the stator assembly is achieved, the miniaturization of the motor is promoted, and the copper consumption of the stator winding is reduced, and the production cost is reduced.
Smart Images
Figure CN222464274U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to the technical field of motors, in particular to a stator assembly, a motor and a vehicle. Background Art
[0002] Compared with round wire motors, flat wire motors are widely used in the field of new energy vehicles due to their higher power density and efficiency, better temperature performance, and lower electromagnetic noise. However, compared with round wire motors, the hairpin coils of flat wire motors have larger cross-layer and cross-slot distances, resulting in a larger stator winding volume, which is not conducive to the miniaturization of the motor. Therefore, there is room for improvement. Utility Model Content
[0003] The utility model aims to solve at least one of the technical problems existing in the prior art. To this end, one purpose of the utility model is to provide a stator assembly, which can reduce the volume of the stator winding wound on the stator core by reducing the span of the hairpin coil, thereby reducing the volume of the stator assembly, which is beneficial to the miniaturization of the motor and can reduce the amount of copper used in the stator winding.
[0004] The utility model also provides a motor with the stator assembly.
[0005] The utility model also provides a vehicle with a motor.
[0006] According to the stator assembly of the embodiment of the first aspect of the utility model, it is used for an M-phase motor with a rotor pole number 2p, and the stator assembly includes: a stator core, having N stator slots arranged at intervals along the circumferential direction of the stator core; a stator winding, which is arranged in the stator slots and forms an L-layer structure arranged radially along the stator core, and the stator winding includes K types of hairpin coils, wherein the span of K1 type of hairpin coils is N / 2p+1, the span of K2 type of hairpin coils is N / 2p-1, K2≥K1 and K1+K2=K, and p, M, N, L, K, K1, and K2 are all positive integers.
[0007] According to the stator assembly of the embodiment of the utility model, by reducing the span of the hairpin coil, the proportion of the hairpin coil with a larger span is reduced, and the proportion of the hairpin coil with a smaller span is increased, so that the volume of the stator winding wound on the stator core is reduced. For example, the volume of the crown end of the stator winding can be reduced, and then the volume of the stator assembly can be reduced, which is beneficial to the miniaturization of the motor, and can reduce the amount of copper used in the stator winding, thereby reducing costs.
[0008] According to some embodiments of the present invention, 2p=8, N=48.
[0009] According to some embodiments of the present invention, K=L / 2+1.
[0010] According to some embodiments of the present invention, L=6, K=4, K1=1, and K2=3.
[0011] According to some embodiments of the utility model, the K types of hairpin coils include a first hairpin coil, a second hairpin coil, a third hairpin coil and a fourth hairpin coil, wherein the span of the first hairpin coil is N / 2p+1, the spans of the second hairpin coil, the third hairpin coil and the fourth hairpin coil are all N / 2p-1, the first hairpin coil is located in the first layer of the stator winding, the second hairpin coil is located in the second layer of the stator winding and the third layer of the stator winding, the third hairpin coil is located in the fourth layer of the stator winding and the fifth layer of the stator winding, and the fourth hairpin coil is located in the sixth layer of the stator winding.
[0012] According to some embodiments of the utility model, the stator assembly includes an outgoing line structure and a neutral point copper bar, the outgoing line structure and the neutral point copper bar are connected to the stator winding, the neutral point copper bar is located between the outer peripheral side of the stator winding and the outgoing line structure, and the neutral point copper bar and the outgoing line structure are coated with an insulating layer.
[0013] According to some embodiments of the utility model, the neutral point copper bar includes a copper bar main body and a plurality of connecting branches, the copper bar main body is in the shape of an elongated strip and extends along the circumferential direction of the stator core, the plurality of connecting branches are connected to a side of the copper bar main body away from the end of the stator core and are arranged at intervals along the extension direction of the copper bar main body, and the plurality of connecting branches are connected to the stator winding; an interval space is defined between adjacent connecting branches, and at least part of the interval space is used to avoid the outgoing line structure.
[0014] According to some embodiments of the utility model, the K types of hairpin coils include a first hairpin coil and a second hairpin coil, the connecting branch is welded to the first hairpin coil, and the wire output structure is welded to the second hairpin coil; the connecting branch includes a first branch segment and a second branch segment arranged along the axial direction of the stator core, the first branch segment is connected to the copper bar body, the second branch segment is connected to the side of the first branch segment away from the copper bar body, the second branch segment is welded to the first hairpin coil, and an avoidance gap is formed on the side of the first branch segment facing the stator winding.
[0015] The motor according to the second embodiment of the utility model includes: the stator assembly according to the first embodiment of the utility model.
[0016] According to the motor of the embodiment of the utility model, by providing the above-mentioned stator assembly, it is beneficial to miniaturize the motor, and the amount of copper used in the stator winding can be reduced, thereby reducing the cost.
[0017] A vehicle according to an embodiment of the third aspect of the utility model includes: a motor according to an embodiment of the second aspect of the utility model.
[0018] According to the vehicle of the embodiment of the utility model, by providing the above-mentioned motor, it is beneficial to reduce the space occupied by the motor in the whole vehicle, and the amount of copper used in the stator winding of the motor is reduced, which can reduce material costs.
[0019] Additional aspects and advantages of the present invention will be given in part in the following description, and in part will become apparent from the following description, or will be learned through the practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The above and / or additional aspects and advantages of the present invention will become apparent and easily understood from the description of the embodiments in conjunction with the following drawings, in which:
[0021] Figure 1 is a schematic diagram of a stator assembly according to some embodiments of the present invention;
[0022] Figure 2 yes Figure 1 A schematic diagram of a first hairpin coil of a stator winding;
[0023] Figure 3 yes Figure 1 A schematic diagram of a second hairpin coil of a stator winding;
[0024] Figure 4 yes Figure 1 A schematic diagram of a third hairpin coil of a stator winding;
[0025] Figure 5 yes Figure 1 A schematic diagram of a fourth hairpin coil of a stator winding;
[0026] Figure 6 yes Figure 1 Schematic diagram of the neutral point copper bus in.
[0027] Reference numerals:
[0028] 100. stator assembly;
[0029] 1. stator winding; 11. first hairpin coil; 12. second hairpin coil; 13. third hairpin coil; 14. fourth hairpin coil; 15. crown end;
[0030] 2. stator core; 21. stator slot;
[0031] 3. Neutral copper bar; 30. Copper bar body; 301. Connecting branch bar; 31. First branch bar section; 311. Avoidance gap; 32. Second branch bar section; 33. Interval space;
[0032] 4. Outlet structure. DETAILED DESCRIPTION
[0033] The embodiments of the present invention are described in detail below, and examples of the embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and cannot be understood as limiting the present invention.
[0034] Reference below Figure 1-Figure 6 A stator assembly 100 according to an embodiment of the present invention is described.
[0035] Reference Figure 1-Figure 6 According to the stator assembly 100 of the embodiment of the utility model, it is used for an M-phase motor with a rotor pole number of 2p, and the stator assembly 100 includes: a stator core 2 and a stator winding 1. The stator core 2 has N stator slots 21 arranged at intervals along the circumferential direction of the stator core 2, the stator winding 1 is arranged in the stator slots 21 and the stator winding 1 forms an L-layer structure arranged along the radial direction of the stator core 2, and the stator winding 1 includes K types of hairpin coils, wherein the span of K1 type of hairpin coil is N / 2p+1, the span of K2 type of hairpin coil is N / 2p-1, K2≥K1 and K1+K2=K, p, M, N, L, K, K1, K2 are all positive integers. Among them, the M-phase motor can be a three-phase motor, in which case M=3.
[0036] By setting K2≥K1, the span of the K1 type hairpin coil is N / 2p+1, and the span of the K2 type hairpin coil is N / 2p-1. Since N / 2p+1>N / 2p-1 (p and N are both positive integers), the span of the K2 type hairpin coil is smaller than the span of the K2 type hairpin coil. When the volume of the stator core 2 is constant and the number of stator slots 21 is constant, the type of hairpin coil with a smaller span is not less than the type of hairpin coil with a larger span, and the volume of a single hairpin coil with a smaller span is smaller than the volume of a single hairpin coil with a larger span. The volume of the stator winding 1 wound on the stator core 2 is reduced. For example, the volume of the crown end 15 of the stator winding 1 can be reduced, and then the volume of the stator assembly 100 can be reduced, which is beneficial to the miniaturization of the motor, and can reduce the copper usage of the stator winding 1 and reduce the cost.
[0037] In addition, when the number of stator slots 21 of the stator core 2 is certain, the hairpin coil with a smaller span can be more flexible in crossing layers and slots, which can make the stator winding 1 smaller and improve the scalability of the winding solution.
[0038] Optionally, the number of rotor poles 2p=8, and the number of stator slots 21 N=48.
[0039] Optionally, the number N of the stator slots 21 may also be 72.
[0040] The number of rotor poles refers to the number of magnetic poles on the motor, which has a certain influence on the performance and control of the motor; the number of stator slots 21 is determined according to different types of stator windings 1 and motor specifications.
[0041] Optionally, the number of types of linear types of the hairpin coil is K=L / 2+1. For example, when the stator winding 1 has 8 layers (L=8), L / 2+1=5, and the number of types of linear types of the hairpin coil can be 5 (K=5); for example, when the stator winding 1 has 6 layers (L=6), L / 2+1=4, and the number of types of linear types of the hairpin coil can be 4 (K=4); when the stator winding 1 has 4 layers (L=4), L / 2+1=3, and the number of types of linear types of the hairpin coil can be 3 (K=3).
[0042] According to the stator assembly 100 of the embodiment of the utility model, by reducing the span of the hairpin coil, the proportion of the hairpin coil with a larger span is reduced, and the proportion of the hairpin coil with a smaller span is increased, so that the volume of the stator winding 1 wound on the stator core 2 is reduced. For example, the volume of the crown end 15 of the stator winding 1 can be reduced, and then the volume of the stator assembly 100 can be reduced, which is beneficial to the miniaturization of the motor, and can reduce the amount of copper used in the stator winding 1, thereby reducing costs.
[0043] According to some embodiments of the present invention, L=6, that is, the stator winding 1 is set to a six-layer structure arranged along the radial direction of the stator core 2, and the six-layer structure of the stator winding 1 is arranged from the first layer to the sixth layer in sequence along the radial direction of the stator core 2 and from the outside to the inside; since K=L / 2+1, K=4, and the number of linear types of the hairpin coil is 4. Among them, K1=1, K2=3 can be set, where the span of one hairpin coil is N / 2p+1, and the spans of the other three hairpin coils are all N / 2p-1. For example, N=48, 2p=8, where the span of one hairpin coil is 7, and the spans of the other three hairpin coils are all 5.
[0044] Obviously, there are more types of wire types for hairpin coils with smaller spans, and fewer types of wire types for hairpin coils with larger spans, so that the volume of the stator winding 1 wound on the stator core 2 can be reduced. For example, the volume of the crown end 15 of the stator winding 1 can be reduced, and then the volume of the stator assembly 100 can be reduced, which is beneficial to the miniaturization of the motor, and can reduce the amount of copper used in the stator winding 1 and reduce costs.
[0045] In addition, there are more types of settings for hairpin coils with smaller spans. When the number of stator slots 21 is constant, hairpin coils with smaller spans can be more flexible in crossing layers and slots, which can make the stator winding 1 smaller and improve the scalability of the winding solution.
[0046] According to some embodiments of the present invention, L=6, K=4, and the K types of card-hairing coils include the first card-hairing coil 11, the second card-hairing coil 12, the third card-hairing coil 13, and the fourth card-hairing coil 14, wherein the span of the first card-hairing coil 11 is N / 2p+1, and the spans of the second card-hairing coil 12, the third card-hairing coil 13, and the fourth card-hairing coil 14 are all N / 2p-1. For example, N=48, 2p=8, the span of the first card-hairing coil 11 is 7, and the spans of the second card-hairing coil 12, the third card-hairing coil 13, and the fourth card-hairing coil 14 are all 5. The card-hairing coil with a larger span can be set to 1 type, and the card-hairing coil with a smaller span can be set to 3 types.
[0047] Among them, the first card-hairing coil 11 is located at the first layer of the stator winding 1, the second card-hairing coil 12 is located at the second layer of the stator winding 1 and the third layer of the stator winding 1, the third card-hairing coil 13 is located at the fourth layer of the stator winding 1 and the fifth layer of the stator winding 1, and the fourth card-hairing coil 14 is located at the sixth layer of the stator winding 1.
[0048] The first card-hairpin coil 11 and the fourth card-hairpin coil 14 are both cross-connections between the same layers, wherein the first card-hairpin coil 11 is the first layer spanning the first layer, for example, the span is 7; the fourth card-hairpin coil 14 is the sixth layer spanning the sixth layer, for example, the span is 5; the second card-hairpin coil 12 and the third card-hairpin coil 13 are cross-layer connections in the stator winding 1, wherein the second card-hairpin coil 12 is the second layer spanning the third layer, for example, the span is 5; the third card-hairpin coil 13 is the fourth layer spanning the fifth layer, for example, the span is 5. Compared with the span of the first card-hairpin coil 11, the spans of the second card-hairpin coil 12 and the third card-hairpin coil 13 are smaller, which can reduce the volume of the card-hairpin coils between the second layer and the third layer, and the fourth layer and the fifth layer of the stator winding 1; compared with the span of the first card-hairpin coil 11, the span of the fourth card-hairpin coil 14 is smaller, which can reduce the volume of the card-hairpin coils between the sixth single layers. Thus, the volume of the stator winding 1 can be reduced, and the amount of copper used can also be reduced.
[0049] According to some embodiments of the present invention, referring to Figure 1 and Figure 6 The stator assembly 100 includes an outlet structure 4 and a neutral copper bar 3. The outlet structure 4 and the neutral copper bar 3 are both connected to the stator winding 1. The neutral copper bar 3 is located between the outer peripheral side of the stator winding 1 and the outlet structure 4. The neutral copper bar and the outlet structure 4 are both coated with an insulating layer. When the motor is a three-phase motor, the outlet structure 4 is correspondingly a three-phase outlet structure 4.
[0050] Since the hairpin coils are all copper wires, and the neutral point copper bar 3 is also made of copper, they are all conductors. In order to avoid short circuit between at least a part of the stator winding 1 that is irrelevant to the neutral point copper bar 3 and the outgoing line structure, and to ensure the safe operation of the motor, an insulating layer is coated on the neutral point copper bar and the outgoing line structure 4 to provide insulation between the neutral point copper bar 3, the outgoing line structure 4, and the stator winding 1. In addition, by arranging the neutral point copper bar 3 between the outer peripheral side of the stator winding 1 and the outgoing line structure 4, compared with the neutral point copper bar 3 being located on the outside of the outgoing line structure 4, the neutral point copper bar 3 can make full use of the space between the outer peripheral side of the stator winding 1 and the outgoing line structure 4, so that the volume of the stator assembly 100 is smaller, which is more conducive to the miniaturization of the motor.
[0051] Reference Figure 6 According to some embodiments of the present invention, the neutral point copper bar 3 includes a copper bar main body 30 and a plurality of connecting branches 301, the copper bar main body 30 is in a long strip shape and extends along the circumferential direction of the stator core 2, a plurality of connecting branches 301 are connected to a side of the copper bar main body 30 away from the end of the stator core 2 and are arranged at intervals along the extension direction of the copper bar main body 30, and the plurality of connecting branches 301 are connected to the stator winding 1; a spacing space 33 is defined between adjacent connecting branches 301, and at least part of the spacing space 33 is used to avoid the outgoing line structure 4. By including the copper bar main body 30 and the plurality of connecting branches 301, the plurality of connecting branches 301 are connected to the stator winding 1, so that the connection between the neutral point copper bar 3 and the stator winding 1 can be facilitated; and a spacing space 33 is defined between adjacent connecting branches 301, and at least part of the spacing space 33 is used to avoid the outgoing line structure 4, so that the structure can be compact, the volume of the stator assembly 100 can be smaller, and it is more conducive to the miniaturization of the motor. In addition, a spacing space 33 is defined between adjacent connecting branches 301, and at least part of the spacing space 33 is used to avoid the outgoing line structure 4, so that there is a certain physical distance between the outgoing line structure 4 and the connecting branch 301, so that there is a safety gap between the outgoing line structure 4 and the connecting branch 301.
[0052] Reference Figure 1 and Figure 6According to some embodiments of the present utility model, the K-type hairpin coil includes a first hairpin coil 11 and a second hairpin coil 12, the connecting branch row 301 is welded to the first hairpin coil 11, and the wire structure 4 is welded to the second hairpin coil 12; the connecting branch row 301 includes a first branch row segment 31 and a second branch row segment 32 arranged along the axial direction of the stator core 2, the first branch row segment 31 is connected to the copper bar body 30, the second branch row segment 32 is connected to the side of the first branch row segment 31 away from the copper bar body 30, the second branch row segment 32 is welded to the first hairpin coil 11, and an avoidance gap 311 is formed on the side of the first branch row segment 31 facing the stator winding 1. By setting the connecting branch 301 to include the above-mentioned first branch segment 31 and second branch segment 32, the second branch segment 32 is welded and connected to the first hairpin coil 11, the electrical connection between the neutral point copper bar and the stator winding 1 is achieved, and an avoidance gap 311 is formed on the side of the first branch segment 31 facing the stator winding 1. The avoidance gap 311 can form a safety gap between the connecting branch 301 and the hairpin coil, and the overall structure is also relatively compact.
[0053] The motor according to the second embodiment of the utility model comprises: the stator assembly 100 according to the first embodiment of the utility model, wherein the motor can be a flat wire motor, that is, a motor using a flat wire hairpin coil as a winding.
[0054] According to the motor of the embodiment of the utility model, by providing the above-mentioned stator assembly 100, it is beneficial to miniaturize the motor, and the amount of copper used in the stator winding 1 can be reduced, thereby reducing the cost.
[0055] A vehicle according to an embodiment of the third aspect of the utility model includes: a motor according to an embodiment of the second aspect of the utility model.
[0056] According to the vehicle of the embodiment of the utility model, by providing the above-mentioned motor, it is beneficial to reduce the space occupied by the motor in the whole vehicle, and the amount of copper used in the stator winding 1 of the motor is reduced, which can reduce material costs.
[0057] In the description of this specification, the description with reference to the terms "one embodiment", "some embodiments", "illustrative embodiments", "examples", "specific examples", or "some examples" means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the utility model. In this specification, the schematic representation of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner.
[0058] Although the embodiments of the present invention have been shown and described, those skilled in the art will appreciate that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the claims and their equivalents.
Claims
1. A stator assembly, characterized in that: For an M-phase motor with a rotor pole number of 2p, the stator assembly comprises: A stator core having N stator slots arranged at intervals along the circumference of the stator core; The stator winding is arranged in the stator slot and forms an L-layer structure arranged radially along the stator core. The stator winding includes K types of hairpin coils, wherein the span of the K1 type of hairpin coils is N / 2p+1, the span of the K2 type of hairpin coils is N / 2p-1, K2≥K1 and K1+K2=K, and p, M, N, L, K, K1, and K2 are all positive integers.
2. The stator assembly according to claim 1, characterized in that: 2p=8,N=48.
3. The stator assembly according to claim 1, characterized in that: K=L / 2+1.
4. The stator assembly according to claim 3, characterized in that: L=6, K=4, K1=1, K2=3.
5. The stator assembly according to claim 4, characterized in that The K types of card-hairing coils include a first card-hairing coil, a second card-hairing coil, a third card-hairing coil and a fourth card-hairing coil, the span of the first card-hairing coil is N / 2p+1, the spans of the second card-hairing coil, the third card-hairing coil and the fourth card-hairing coil are all N / 2p-1, the first card-hairing coil is located in the first layer of the stator winding, the second card-hairing coil is located in the second layer of the stator winding and the third layer of the stator winding, the third card-hairing coil is located in the fourth layer of the stator winding and the fifth layer of the stator winding, and the fourth card-hairing coil is located in the sixth layer of the stator winding.
6. The stator assembly according to claim 1, characterized in that It includes an outgoing line structure and a neutral point copper bar, the outgoing line structure and the neutral point copper bar are connected to the stator winding, the neutral point copper bar is located between the outer peripheral side of the stator winding and the outgoing line structure, and the neutral point copper bar and the outgoing line structure are both coated with an insulating layer.
7. The stator assembly according to claim 6, characterized in that The neutral point copper bar includes a copper bar main body and a plurality of connecting branches. The copper bar main body is in the shape of an elongated strip and extends along the circumference of the stator core. The plurality of connecting branches are connected to a side of the copper bar main body away from the end of the stator core and are arranged at intervals along the extension direction of the copper bar main body. The plurality of connecting branches are connected to the stator winding. An interval space is defined between adjacent connecting branches, and at least part of the interval space is used to avoid the outgoing line structure.
8. The stator assembly according to claim 7, characterized in that The K types of hairpin coils include a first hairpin coil and a second hairpin coil, the connecting branch row is welded to the first hairpin coil, and the wire output structure is welded to the second hairpin coil; the connecting branch row includes a first branch row segment and a second branch row segment arranged along the axial direction of the stator core, the first branch row segment is connected to the copper bar body, the second branch row segment is connected to the side of the first branch row segment away from the copper bar body, the second branch row segment is welded to the first hairpin coil, and an avoidance gap is formed on the side of the first branch row segment facing the stator winding.
9. A motor, characterized in that: include: A stator assembly according to any one of claims 1 to 8.
10. A vehicle, characterized in that: include: The electric machine according to claim 9.