Winding outgoing line connecting structure of flat wire motor
By twisting the lead wire in a flat wire motor and setting the busbar along the radial distribution of the windings, the problem of excessive motor volume caused by the large radial size of the busbar in the prior art is solved, and a more compact motor design is achieved, simplifying the space layout on the vehicle.
Patent Information
- Application Number
- CN202420358581.5
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-02-27
- Publication Date
- 2025-03-07
- Estimated Expiration
- 2034-02-27
AI Technical Summary
The lead-out wire connection structure of the existing flat wire motor results in a large radial size of the busbar, resulting in an excessively large motor volume, which in turn affects the spatial layout of the motor on the vehicle.
By twisting the lead wire toward the inner circumference of the stator, its ends are in contact with the busbar, and the axial and radial dimensions of the busbar are compressed through the first busbar and the second busbar in the radial direction of the winding.
It effectively reduces the axial and radial dimensions of the flat wire motor, reduces the space required for installation, and makes the space arrangement of the flat wire motor on the vehicle simpler.
Smart Images
Figure CN222582148U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to a winding lead-out wire connection structure of a flat wire motor, belonging to the technical field of flat wire motors. Background Art
[0002] As a key component of the drive motor, the motor stator generally adopts the round copper wire motor stator solution. However, due to its slot fill rate and power density, it is difficult to make a big breakthrough in the round copper wire motor stator. Flat copper wire motor stators have gradually become the new favorite of motor companies. Compared with round wire motors, flat wire motors have the characteristics of high slot fill rate, small size, high power density, and suitable for automated production. They have become the development direction of drive motors. Flat wire motors use flat copper wire in the stator winding. The winding is first made into a shape similar to a hairpin, inserted into the stator slot, and then the end of the hairpin is welded at the other end.
[0003] However, as the number of parallel branches and layers of the flat wire stator increases, its lead wires become more and more complicated. In order to reduce the difficulty of the process, reduce the frequency of welding errors, and improve the appearance quality of the motor stator assembly, and also to achieve automated production, flat wire motors often use buses to organize their lead wires. However, in related technologies, each bus is stacked axially, resulting in a large axial dimension, and the lead wires are generally located on the outer and inner circumferences of the windings. If the lead wires are directly connected to the bus, then the radial dimension of the bus is required to be large, resulting in a complex bus structure and a large volume, which can easily lead to an excessively large motor volume, which in turn makes it difficult to arrange the motor space on the vehicle. Utility Model Content
[0004] The utility model aims to provide a winding lead-out wire connection structure of a flat wire motor which can reduce the radial size of the busbar in view of the shortcomings of the prior art.
[0005] To achieve the purpose, the technical solution adopted by the utility model is:
[0006] A flat wire motor winding lead wire connection structure comprises a stator, wherein the stator comprises a winding and a busbar connected to a plurality of lead wires of the winding, wherein the lead wires are twisted toward the inner circumference of the stator so that the ends of the lead wires are in contact with the busbar.
[0007] As a further optimization of the above technical solution: the end of the lead wire is in contact with a side surface of the bus bar close to the inner circumference of the stator.
[0008] As a further optimization of the above technical solution: the lead-out wires of the winding include a starting end and an ending end of several phase lines, the bus includes a first bus connected to the ending end and a plurality of second bus connected to the starting end, the first bus and the second bus are distributed along the radial direction of the winding, and the three second bus are distributed in an arc shape.
[0009] As a further optimization of the above technical solution: the first bus is provided with a plurality of first weld legs protruding along the axial direction, the tail end is welded to the first weld legs, both ends of the second bus are provided with second weld legs protruding along the axial direction, and the starting end is welded to the second weld legs.
[0010] As a further optimization of the above technical solution: the first bus is bent in the radial direction, so that a plurality of approximately U-shaped connection blocks are formed on the first bus, and part of the first welding legs are located on the connection blocks.
[0011] As a further optimization of the above technical solution: an installation space is formed between the inner walls of the U-shaped connecting block, and one end of the second bus is bent in the radial direction and extends into the installation space, so that the second welding leg is in contact with the starting end.
[0012] As a further optimization of the above technical solution: it also includes an insulating plate, the first bus and the second bus are located on the insulating plate, a plurality of positioning holes are formed on the insulating plate, the positioning holes and the first welding legs and the second welding legs are arranged correspondingly, and the starting end and the ending end are passed through the positioning holes.
[0013] Compared with the prior art, the first bus and the second bus of the utility model are distributed along the radial direction of the winding. Compared with the traditional axially stacked arrangement of the bus, the utility model compresses the axial dimension, so that after the bus is installed on the stator, the axial dimension of the stator can be effectively reduced, and the space required for the installation of the flat wire motor is reduced, making the spatial arrangement of the flat wire motor on the vehicle simpler; after the lead wire is twisted, the second welding leg can be arranged closer to the inner circumference of the stator, thereby compressing the radial dimension of the second bus; at the same time, the three second busbars are distributed in an arc shape rather than radially in parallel, which also compresses the radial dimension, so that after the bus is installed on the stator, the radial dimension of the stator can be effectively reduced, and the space required for the installation of the flat wire motor is greatly reduced, making the spatial arrangement of the flat wire motor on the vehicle simpler; the insulating plate is used to strengthen the insulation and voltage resistance between the winding and the bus to avoid short circuit between the first bus and the second bus. BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Figure 1 It is a three-dimensional structural schematic diagram of the utility model.
[0015] Figure 2 It is a schematic diagram of the three-dimensional structure of the utility model after the insulating plate is hidden. DETAILED DESCRIPTION
[0016] The present invention will be further described below in conjunction with the accompanying drawings and specific implementations. Figure 1-2 As shown, the stator 1 includes a winding 2 and a busbar connected to the lead-out wire of the winding 2. The lead-out wire of the winding includes the starting end and the ending end of several phase lines, and the busbar includes a first busbar 3 connected to the ending end and three second busbars 4 connected to the starting end. The first busbar 3 and the second busbar 4 are distributed along the radial direction of the winding 2, and the three second busbars 4 are distributed in an arc shape. In the utility model, the first busbar 3 and the second busbar 4 are distributed along the radial direction of the winding 2. Compared with the traditional axially stacked arrangement of the busbar, the utility model compresses the axial dimension, so that after the busbar is installed on the stator 1, the axial dimension of the stator 1 can be effectively reduced, and the space required for the installation of the flat wire motor can be reduced, so that the space layout of the flat wire motor on the vehicle is simpler. The "radial" mentioned in this patent refers to the diameter direction of the winding, and the "axial" refers to the motor shaft direction of the motor, and the motor shaft is penetrated in the stator 1.
[0017] In the above technical solution: the first busbar 3 is provided with a plurality of first welding legs 31 protruding in the axial direction, and the tail end is welded to the first welding leg 31. Both ends of the second busbar 4 are provided with second welding legs 41 protruding in the axial direction, and the head end is welded to the second welding leg 41. The first welding leg 31 and the second welding leg 41 are both protruding in the axial direction, so that the extension direction of the first welding leg 31 and the second welding leg 41 is consistent with the extension direction of the lead wire, thereby increasing the contact area between the first welding leg 31 and the second welding leg 41 and the lead wire, thereby improving the welding stability of the first welding leg 31 and the second welding leg 41 and the lead wire.
[0018] In the above technical solution: the first busbar 3 is bent in the radial direction, so that a plurality of U-shaped connection blocks 32 are formed on the first busbar 3, and part of the first welding legs 31 are located on the connection blocks 32. An installation space is formed between the inner walls of the U-shaped connection blocks 32, and one end of the second busbar 4 is bent in the radial direction and extends into the installation space, so that the second welding leg 41 contacts the starting end. The U-shaped connection block 32 not only makes the structure of the first busbar 3 reasonable, facilitates the connection of the first busbar 3 with the lead-out wire, but also provides space for the connection of the second welding leg 41 with the starting end.
[0019] In the above technical solution: part of the lead wire is twisted toward the inner circumference of the stator 1, and the end of the lead wire is approximately C-shaped after twisting, so that part of the starting end can contact the side of the second welding leg 41 close to the inner circumference of the stator, or part of the ending end can contact the first welding leg 31, so as to reduce the radial size of the busbar. After the lead wire is twisted, the second welding leg 41 can be set closer to the inner circumference of the stator, so as to compress the radial size of the second busbar 4; at the same time, the three second busbars 4 are distributed in an arc shape instead of radially parallel, which also compresses the radial size, so that after the busbar is installed on the stator 1, the radial size of the stator 1 can be effectively reduced, and the space required for the installation of the flat wire motor is greatly reduced, making the spatial arrangement of the flat wire motor on the vehicle simpler.
[0020] When the outer diameter of the stator core is less than 155 mm, the installation positions of the first bus 3 and the second bus 4 can be moved toward the inner circumference of the stator 1 to enhance the turn-to-turn voltage resistance and improve the insulation level of the winding, while also ensuring that the second bus 4 is located within the curved surface of the outer circumference of the stator 1, avoiding the motor casing and maintaining a sufficient creepage safety distance.
[0021] In the above technical solution: it also includes an insulating plate 5, the first busbar 3 and the second busbar 4 are located on the insulating plate 5, and a plurality of positioning holes 51 are formed on the insulating plate 5, and the positioning holes 51 are arranged corresponding to the first welding leg 31 and the second welding leg 41. The end of the lead wire of the motor winding 2 is inserted into the positioning hole 51 and is welded and fixed to the first welding leg 31 and the second welding leg 41, so as to avoid misalignment during the welding operation and ensure the accuracy of the lead wire connection. The insulating plate 5 is used to strengthen the insulation and withstand voltage between the winding 2 and the busbar, and avoid short circuit between the first busbar 3 and the second busbar 4.
[0022] The preferred specific embodiments of the present utility model are described in detail above. It should be understood that ordinary technicians in this field can make many modifications and changes based on the concept of the present utility model without creative work. Therefore, all technical solutions that can be obtained by technicians in this technical field based on the concept of the present utility model through logical analysis, reasoning or limited experiments on the basis of the existing technology should fall within the protection scope of the present utility model.
Claims
1. A winding lead wire connection structure for a flat wire motor, comprising a stator (1), wherein the stator (1) comprises a winding (2) and a busbar for connecting to a plurality of lead wires of the winding (2), characterized in that The lead wire is twisted toward the inner circumference of the stator (1) so that the end of the lead wire is in contact with the bus bar.
2. The winding lead wire connection structure of a flat wire motor according to claim 1, characterized in that The end of the lead wire contacts a side surface of the bus bar close to the inner peripheral surface of the stator (1).
3. The flat wire motor winding lead wire connection structure according to claim 1, characterized in that The lead-out wires of the winding (2) include a plurality of starting ends and an ending end of a phase line, the busbar includes a first busbar (3) connected to the ending end and a plurality of second busbars (4) connected to the starting end, the first busbar (3) and the second busbar (4) are distributed along the radial direction of the winding (2), and the three second busbars (4) are distributed in an arc shape.
4. A flat wire motor winding lead wire connection structure according to claim 3, characterized in that The first busbar (3) is provided with a plurality of first welding legs (31) protruding along the axial direction, and the tail end is connected to the first welding legs (31) by welding, and both ends of the second busbar (4) are provided with second welding legs (41) protruding along the axial direction, and the starting end is connected to the second welding legs (41) by welding.
5. A winding lead connection structure for a flat wire motor according to claim 4, characterized in that The first busbar (3) is bent in the radial direction so that a plurality of approximately U-shaped connection blocks (32) are formed on the first busbar (3), and part of the first welding legs (31) are located on the connection blocks (32).
6. A flat wire motor winding lead wire connection structure according to claim 5, characterized in that An installation space is formed between the inner walls of the U-shaped connection block (32), and one end of the second busbar (4) is bent in the radial direction and extends into the installation space, so that the second welding leg (41) is in contact with the starting end.
7. The flat wire motor winding lead wire connection structure according to claim 4, characterized in that It also includes an insulating plate (5), the first busbar (3) and the second busbar (4) are located on the insulating plate (5), a plurality of positioning holes (51) are formed on the insulating plate (5), the positioning holes (51) and the first welding legs (31) and the second welding legs (41) are arranged correspondingly, and the starting end and the ending end are inserted into the positioning holes (51).