Stator assembly with different conductor layer numbers at two ends and flat wire motor
By designing stator components with different layers of conductors at both ends, using multi-stage stator cores and windings with different layers, the problems of large end welding sizes and complex winding design of flat wire motors are solved, achieving higher flexibility and adaptability. Reduced production costs.
Patent Information
- Application Number
- CN202420373446.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-02-28
- Publication Date
- 2025-02-14
- Estimated Expiration
- 2034-02-28
AI Technical Summary
The end welding size of existing flat wire motors is large, resulting in low overall efficiency of DC resistance and the whole machine. The winding design is complex and the flexibility is poor, making it difficult to match the peak torque and peak power requirements of different customers, resulting in the adaptation of production line equipment. Poor performance and high product cost.
Design a stator assembly with different conductor layers at both ends. By dividing the stator core into multiple segments and setting a gap at the connection, combining the multi-conductor layer-numbered winding and the few-conductor layer-numbered winding, the flexible adjustment of the winding structure is achieved. .
By adjusting the number of conductor layers and turns, flexible adjustment of the number of turns of the entire machine is achieved, improving the flexibility and adaptability of the flat wire motor, and reducing production costs and competitiveness.
Smart Images
Figure CN222484412U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to the technical field of motors, and more specifically to a stator assembly with different numbers of conductor layers at both ends and a flat wire motor. Background Art
[0002] At present, more and more flat wire motors are used in the domestic new energy vehicle industry. Compared with conventional round windings, the most notable feature of flat wire windings is that the pure copper slot full rate is higher, which reduces DC resistance and copper loss, and the winding wire layout is more balanced and symmetrical, which has higher requirements for design and process. According to the conductor forming line shape, whether the end needs to be welded, and the welding process, flat wires can be further divided into I-pin, Hairpin, X-pin and W-pin.
[0003] like Figure 1 As shown, the winding of the existing flat wire motor is axially inserted into the flat wire winding from one end of the stator core 200, and the other side is turned and welded to form a welding point 400. Generally, the non-welding end is called the winding crown end 300, and the corresponding end of the conductor for welding connection is the winding welding end 500. The winding straight section 700 is located inside the stator core. The axial height of the welding end and the length of the conductor crossover are both large. It is not good for the DC resistance and the overall efficiency of the flat wire motor. At present, the focus of the industry is how to reduce the size of the end welding and reduce the end resistance to further improve the efficiency of the flat wire motor.
[0004] At the same time, taking the Hairpin flat wire production process as an example, it involves processes such as paint removal, wire forming, wire embedding, head twisting welding, and paint coating. Different processes correspond to highly automated and intelligent production equipment, resulting in a very large fixed investment in the flat wire production line. However, the existing flat wire winding design is complex and has poor flexibility. The selection range of the number of conductors per layer is very small (such as the common 4, 6, 8, and 10 layers). It is very difficult to match the peak torque and peak power requirements of different customers by adjusting the number of layers or turns, resulting in poor adaptability of production line equipment, high cost of a single flat wire motor product, and poor market competitiveness. Utility Model Content
[0005] In order to solve the above technical problems, the first purpose of the utility model is to provide a stator assembly with different numbers of conductor layers at both ends. The winding structure of the stator assembly is flexible and easy to adjust, which is conducive to reducing costs. The second purpose of the utility model is to provide a flat wire motor.
[0006] In order to achieve the above first utility model purpose, the utility model adopts the following technical solutions:
[0007] A stator assembly with different numbers of conductor layers at both ends, comprising a stator core and a flat wire winding inserted in a stator slot of the stator core, the stator core being at least two sections, comprising a first core section and a second core section, a gap being left between the first core section and the second core section, the flat wire winding comprising a winding on a side with more conductor layers and a winding on a side with fewer conductor layers, the winding on the side with fewer conductor layers comprising a common-layer conductor assembly A, the winding on the side with more conductor layers comprising a common-layer conductor assembly B, a multi-layer conductor welding end assembly and a multi-layer conductor crown end assembly, the common-layer conductor assembly B being inserted in the second core section, the common-layer conductor assembly A being inserted in the first core section, the common-layer conductor assembly B and the common-layer conductor assembly A both comprising a crown segment and a straight segment, and the corresponding straight segments of the common-layer conductor assembly B and the straight segments of the common-layer conductor assembly A being directly or indirectly welded; the multi-layer conductor crown end assemblies are interconnected via a multi-layer conductor welding end assembly, and the multi-layer conductor welding end assembly is located at the gap.
[0008] As a preferred solution, the equivalent number of turns of the flat wire winding is N and satisfies the following conditions:
[0009]
[0010] Among them, Nl is the number of turns of the winding on the side with more conductor layers, Ll is the stacking length of the second core segment, Nr is the number of turns of the winding on the side with fewer conductor layers, Lr is the stacking length of the first core segment, Lg is the width of the gap, and L is the total stacking length of the stator core.
[0011] As a preferred solution, the number of turns N1 of the winding on the side with more conductor layers and the number of turns Nr of the winding on the side with fewer conductor layers are both non-zero integers, and N1 is greater than Nr.
[0012] As a preferred embodiment, when the number of turns Nr of the winding on the side with fewer conductor layers is 6, the number of turns Nl of the winding on the side with more conductor layers is 6, 8 or 10; or, when the number of turns Nr of the winding on the side with fewer conductor layers is 6, the number of turns Nl of the winding on the side with more conductor layers is 8 or 10; or, when the number of turns Nr of the winding on the side with fewer conductor layers is 8, the number of turns Nl of the winding on the side with more conductor layers is 10 or 12.
[0013] As a preferred solution, the width Lg of the gap between the first core segment and the second core segment is 8-10 mm.
[0014] As a preferred solution, the ends of the straight sections of the co-layer conductor assembly A and the co-layer conductor assembly B are flush and are welded to each other to form a welding point.
[0015] As a preferred solution, a groove is provided at the end of the straight segment of the common-layer conductor component A, and a positioning convex strip is provided at the end of the straight segment of the common-layer conductor component B. The positioning convex strips are inserted into the groove and welded to each other to form a welding point.
[0016] As a preferred embodiment, the ends of the straight sections of the common-layer conductor assembly A and the common-layer conductor assembly B are provided with limit bars, and the two limit bars are staggered with each other, and the limit bars and the limit bars and the common-layer conductor assembly A or the common-layer conductor assembly B are welded to each other to form welding points.
[0017] In order to achieve the above second utility model purpose, the utility model adopts the following technical solutions:
[0018] A flat wire motor comprises a housing, a rotor assembly and a stator assembly as described in any one of the above.
[0019] Compared with the prior art, the beneficial effects of the utility model are:
[0020] The utility model designs a stator core into multiple sections, and gaps are provided at the connection places of the multiple sections of the stator core. The number of layers of the flat wire windings in the multiple sections of the stator core is different. The stacking thicknesses of the two stator cores can be designed to be different lengths as needed. Under the premise that the axial length limit of the entire motor is the same, the adjustment of the number of turns of the whole machine is equivalently converted into the proportion of the stacking thickness of the front and rear stators, thereby achieving more flexible adjustment of the number of winding turns, and then better achieving the balance between the peak torque and peak power requirements of the flat wire motor. Without increasing the investment in equipment and production lines, the flexibility and adaptability of the flat wire motor are improved, and the production cost and competitiveness of the product are greatly reduced. BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The drawings in the specification, which constitute a part of the present application, are used to provide a further understanding of the present application. The illustrative embodiments of the present application and their descriptions are used to explain the present application and do not constitute a limitation on the present application.
[0022] Figure 1 This is a schematic diagram of the principle of winding embedding of a traditional flat wire motor;
[0023] Figure 2 This is a schematic diagram of the winding wire embedding principle of the utility model;
[0024] Figure 3 It is a structural schematic diagram of the stator assembly of the motor of the utility model;
[0025] Figure 4 and Figure 5 They are respectively schematic diagrams of the exploded structures of the stator assembly of the motor of the utility model at different angles;
[0026] Figure 6 and Figure 7 They are schematic diagrams of the three-dimensional winding structure of the winding of the utility model (taking the number of turns of the winding on the side with fewer conductor layers as 6 and the number of turns of the winding on the side with more conductor layers as 8 as an example);
[0027] Figure 8This is a schematic diagram of the winding wire axial layout principle of the utility model. DETAILED DESCRIPTION
[0028] It should be noted that the following detailed descriptions are illustrative and are intended to provide further explanation of the present application. Unless otherwise specified, all technical and scientific terms used herein have the same meanings as those commonly understood by those skilled in the art to which the present application belongs.
[0029] It should be noted that the terms used herein are only for describing specific embodiments and are not intended to limit the exemplary embodiments according to the present application. As used herein, unless the context clearly indicates otherwise, the singular form is also intended to include the plural form. In addition, it should be understood that when the terms "comprise" and / or "include" are used in this specification, it indicates the presence of features, steps, operations, devices, components and / or combinations thereof.
[0030] In addition, in the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "clockwise", "counterclockwise" and the like 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 invention and simplifying the description, and do not indicate or imply that the referred device or element 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 invention.
[0031] In addition, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include one or more of the features. In the description of the present utility model, unless otherwise specified, "plurality" means two or more, unless otherwise clearly defined.
[0032] In the present invention, unless otherwise clearly specified and limited, the terms "install", "connect", "connect", "fix" and the like should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be an indirect connection through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.
[0033] In the present utility model, unless otherwise clearly specified and limited, a first feature being "above" or "below" a second feature may include that the first and second features are in direct contact, or may include that the first and second features are not in direct contact but are in contact through another feature between them. Moreover, a first feature being "above", "above" and "above" a second feature includes that the first feature is directly above and obliquely above the second feature, or simply indicates that the first feature is higher in level than the second feature. A first feature being "below", "below" and "below" a second feature includes that the first feature is directly below and obliquely below the second feature, or simply indicates that the first feature is lower in level than the second feature.
[0034] The utility model is further described below in conjunction with the accompanying drawings and embodiments:
[0035] like Figures 1 to 7 As shown, a stator assembly with different conductor layers at both ends includes a stator core 200 and a flat wire winding inserted in a stator slot of the stator core 200, wherein the stator core 200 is at least two sections, including a first core section 3 and a second core section 5, and a gap 13 is left between the first core section 3 and the second core section 5, and the flat wire winding includes a winding 600 on a side with more conductor layers and a winding 100 on a side with fewer conductor layers, wherein the winding 100 on the side with fewer conductor layers includes a common-layer conductor assembly A2, and the winding 600 on the side with more conductor layers includes a common-layer conductor assembly B 6. Multilayer conductor welding end assembly 1 and multilayer conductor crown end assembly 7, the common-layer conductor assembly B6 is inserted in the second core segment 5, and the common-layer conductor assembly A2 is inserted in the first core segment 3. The common-layer conductor assembly B6 and the common-layer conductor assembly A2 both include crown segments and straight segments, and the corresponding straight segments of the common-layer conductor assembly B6 and the straight segments of the common-layer conductor assembly A2 are directly or indirectly welded; the multilayer conductor crown end assembly 7 is interconnected through the multilayer conductor welding end assembly 1, and the multilayer conductor welding end assembly 1 is located at the gap 13. The width of the gap 13 between the first core segment 3 and the second core segment 5 is 8 to 10 mm. The gap at the stator core connection is convenient for laser deep melting welding of the winding conductor straight segment, and on the other hand, it is to reserve the end space position for the winding on the multi-conductor layer side.
[0036] The equivalent number of turns of the flat wire winding is N, which satisfies the following conditions:
[0037]
[0038] Among them, Nl is the number of turns of the winding 600 on the side with more conductor layers, Ll is the stacking length of the second core segment 5, Nr is the number of turns of the winding 100 on the side with fewer conductor layers, Lr is the stacking length of the first core segment 3, Lg is the width of the gap 13, and L is the total stacking length of the stator core 200.
[0039] Once the values of Nl, Nr, and Lg are fixed, the equivalent number of turns N of the whole machine depends on the values of Ll and Lr. The values of Ll, Lr, and Lg meet the following conditions:
[0040] L=Ll+Lr+Lg
[0041] Through the above two formulas, the value of the equivalent number of turns N can be continuously changed. For example, in this example, when Nl=8 and Nr=6, the value of N is between 6 and 8. Therefore, the peak torque and peak power can be better balanced through the selection of the equivalent number of turns, and the needs of different customers can be adapted to improve the flexibility of the flat wire design. The adjustment of the stacking thickness is relatively the easiest and most acceptable in the design and production of flat wires.
[0042] When the number of turns Nr of the winding 100 on the side with fewer conductor layers is 6, the number of turns Nl of the winding 600 on the side with more conductor layers is 6, 8 or 10; or, when the number of turns Nr of the winding 100 on the side with fewer conductor layers is 6, the number of turns Nl of the winding 600 on the side with more conductor layers is 8 or 10; or, when the number of turns Nr of the winding 100 on the side with fewer conductor layers is 8, the number of turns Nl of the winding 600 on the side with more conductor layers is 10 or 12.
[0043] The end welding methods of the common layer conductor assembly in the present invention include the following:
[0044] 1. The ends of the straight segments of the co-layer conductor assembly A2 and the co-layer conductor assembly B6 are flush and welded to each other to form a welding point 400.
[0045] 2. A groove is provided at the end of the straight segment of the co-layer conductor component A2, and a positioning convex strip is provided at the end of the straight segment of the co-layer conductor component B6. The positioning convex strips are inserted into the groove and welded to each other to form a welding point 400.
[0046] 3. The ends of the straight sections of the common-layer conductor assembly A2 and the common-layer conductor assembly B6 are both provided with limiting bars, and the two limiting bars are offset from each other, and the limiting bars and the common-layer conductor assembly A2 or the common-layer conductor assembly B6 are welded to each other to form welding points 400.
[0047] Figure 8Schematic diagram of the winding wire axial layout principle of the utility model (taking the number of turns of the winding on the side with fewer conductor layers as 4 and the number of turns of the winding on the side with more conductor layers as 6 as an example), the winding on the side with fewer conductor layers is respectively the first winding 601 on the side with more conductor layers, the second winding 602 on the side with more conductor layers, the third winding 603 on the side with more conductor layers, the fourth winding 604 on the side with more conductor layers, the fifth winding 605 on the side with more conductor layers and the sixth winding 606 on the side with more conductor layers, and the winding on the side with more conductor layers is respectively the first winding 101 on the side with fewer conductor layers, the second winding 102 on the side with fewer conductor layers, the third winding 603 on the side with more conductor layers, the fourth winding 604 on the side with more conductor layers, the fifth winding 605 on the side with more conductor layers and the sixth winding 606 on the side with more conductor layers. The third layer winding 103 on the side with more conductor layers and the fourth layer winding 104 on the side with fewer conductor layers; the first layer winding 601 on the side with more conductor layers, the second layer winding 602 on the side with more conductor layers, the third layer winding 603 on the side with more conductor layers, and the fourth layer winding 604 on the side with more conductor layers are respectively welded to the first layer winding 101 on the side with fewer conductor layers, the second layer winding 102 on the side with fewer conductor layers, the third layer winding 103 on the side with fewer conductor layers, and the fourth layer winding 104 on the side with fewer conductor layers, and the fifth layer winding 605 on the side with more conductor layers and the sixth layer winding 606 on the side with more conductor layers are directly welded through the multi-layer conductor welding end assembly 1.
[0048] The double-stator iron core flat wire motor with different numbers of conductor layers proposed in the present invention is completely different from any existing flat wire winding design. The total number of conductor layers in the slots of the front and rear single stator iron cores is different, such as a combination of 4&6 or 6&8 layers, but the same number of layers, and the front and rear two sets of windings are welded on the straight section of the conductor. Through the innovation of connecting the double-stator iron cores with different numbers of conductor layers in series, the number of turns of the traditional flat wire motor is adjusted, which is equivalent to the adjustment of the stacking length of the front and rear single stators, thereby achieving more flexible design adjustment of the peak torque and peak power of the whole machine. Without increasing the investment in equipment and production lines, the flexibility and adaptability of the flat wire motor are improved, and the production cost and competitiveness of the product are greatly reduced.
[0049] The common-layer conductor assembly A2 and the common-layer conductor assembly B6 in the present invention can be manufactured according to the existing flat wire design and process, but the front and rear windings are both hairpins and plugged into the stator axial end faces, and then welded on the conductor straight section. When the common-layer winding is finally output, it is connected to the remaining layers of the winding on the multi-conductor layer side to continue winding, so as to realize the physical and electrical connection of different layers of conductors.
[0050] The present invention further provides a flat wire motor, comprising a housing, a rotor assembly and a stator assembly as described in any one of the above items.
[0051] In the description of this specification, the description with reference to the terms "one embodiment", "some embodiments", "example", "specific example", 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.
[0052] Although the embodiments of the present invention have been shown and described above, it can be understood that the above embodiments are exemplary and cannot be understood as limitations on the present invention. Ordinary technicians in the field can change, modify, replace and modify the above embodiments within the scope of the present invention without departing from the principles and purpose of the present invention. Any simple modifications, equivalent changes and modifications made to the above embodiments based on the technical essence of the present invention are still within the scope of the technical solution of the present invention.
Claims
1. A stator assembly with different numbers of conductor layers at both ends, comprising a stator core (200) and a flat wire winding inserted into a stator slot of the stator core (200), characterized in that: The stator core (200) is at least two sections, including a first core section (3) and a second core section (5), a gap (13) being left between the first core section (3) and the second core section (5), the flat wire winding including a winding on the side with more conductor layers (600) and a winding on the side with fewer conductor layers (100), the winding on the side with fewer conductor layers (100) including a common-layer conductor assembly A (2), and the winding on the side with more conductor layers (600) including a common-layer conductor assembly B (6), a multi-layer conductor welding end assembly (1) and a multi-layer conductor crown end assembly (7 ), the common-layer conductor assembly B (6) is inserted in the second core segment (5), and the common-layer conductor assembly A (2) is inserted in the first core segment (3), the common-layer conductor assembly B (6) and the common-layer conductor assembly A (2) both include crown segments and straight segments, and the corresponding straight segments of the common-layer conductor assembly B (6) and the straight segments of the common-layer conductor assembly A (2) are directly or indirectly welded; the multi-layer conductor crown end assemblies (7) are interconnected through the multi-layer conductor welding end assembly (1), and the multi-layer conductor welding end assembly (1) is located at the gap (13).
2. A stator assembly with different numbers of conductor layers at both ends according to claim 1, characterized in that: The equivalent number of turns of the flat wire winding is N, which satisfies the following conditions: Wherein, Nl is the number of turns of the winding (600) on the side with more conductor layers, Ll is the stacking length of the second core segment (5), Nr is the number of turns of the winding (100) on the side with fewer conductor layers, Lr is the stacking length of the first core segment (3), Lg is the width of the gap (13), and L is the total stacking length of the stator core (200).
3. A stator assembly with different numbers of conductor layers at both ends according to claim 2, characterized in that: The number of turns N1 of the winding (600) on the side with more conductor layers and the number of turns Nr of the winding (100) on the side with fewer conductor layers are both non-zero integers, and N1 is greater than Nr.
4. A stator assembly with different numbers of conductor layers at both ends according to claim 3, characterized in that: When the number of turns Nr of the winding (100) on the side with fewer conductor layers is 6, the number of turns Nl of the winding (600) on the side with more conductor layers is 6, 8 or 10; or, when the number of turns Nr of the winding (100) on the side with fewer conductor layers is 6, the number of turns Nl of the winding (600) on the side with more conductor layers is 8 or 10; or, when the number of turns Nr of the winding (100) on the side with fewer conductor layers is 8, the number of turns Nl of the winding (600) on the side with more conductor layers is 10 or 12.
5. A stator assembly with different numbers of conductor layers at both ends according to claim 2, characterized in that: The width Lg of the gap (13) between the first core segment (3) and the second core segment (5) is 8 to 10 mm.
6. A stator assembly with different numbers of conductor layers at both ends according to claim 1, characterized in that: The ends of the straight sections of the common-layer conductor component A (2) and the common-layer conductor component B (6) are flush with each other and are welded to form a welding point (400).
7. A stator assembly with different numbers of conductor layers at both ends according to claim 1, characterized in that: The end of the straight section of the common-layer conductor component A (2) is provided with a groove, and the end of the straight section of the common-layer conductor component B (6) is provided with a positioning convex strip, the positioning convex strips are inserted into the groove and welded to each other to form a welding point (400).
8. The stator assembly with different numbers of conductor layers at both ends according to claim 1, characterized in that: The ends of the straight sections of the common-layer conductor assembly A (2) and the common-layer conductor assembly B (6) are both provided with limit bars, and the two limit bars are mutually offset, and the limit bars, and the limit bars and the common-layer conductor assembly A (2) or the common-layer conductor assembly B (6) are mutually welded to form welding points (400).
9. A flat wire motor, characterized in that: It comprises a casing (12), a rotor assembly and a stator assembly as claimed in any one of claims 1 to 8.