A stator, a motor and a vehicle
By using a composite insulating film to wrap the turns in the motor stator slot, the problem of space occupancy of insulating materials is solved, and the conductor floor area ratio and motor performance are improved.
Patent Information
- Application Number
- CN202421468127.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-06-25
- Publication Date
- 2025-04-04
- Estimated Expiration
- 2034-06-25
AI Technical Summary
In existing motors, the insulating paper or insulating film in the stator groove occupies space, affecting the conductor floor area ratio, and thus limiting the power and torque density of the motor.
A composite insulating film is used to wrap the turns line, including an insulating film layer and a support layer. The turns line abuts with the inner wall of the stator groove through the composite insulating film, eliminating the insulating paper or insulating film in the stator groove.
The floor area ratio of the conductors in the groove is increased, the power and torque density of the motor is enhanced, and the use of insulating materials is reduced.
Smart Images
Figure CN222721197U_ABST
Abstract
Description
Technical Field
[0001] The present application relates to the field of motor technology, and in particular to a stator, a motor and a vehicle. Background Art
[0002] With the development of new energy technologies, the use of new energy vehicles is becoming more and more widespread, and the requirements for the insulation performance of motors are becoming higher and higher.
[0003] In existing motors, insulating paper is often provided in the slots of the stator core or an insulating film is provided on the inner slot wall of the stator slot to achieve insulation between the turns and the core. However, the above insulation structures will occupy space in the slot, affecting the further improvement of the conductor occupancy rate in the slot. Utility Model Content
[0004] The embodiments of the present application provide a stator, a motor and a vehicle, which can increase the conductor occupancy rate in the slot and improve the power and torque density of the motor.
[0005] In a first aspect, an embodiment of the present application provides a stator, comprising: an iron core, provided with a plurality of stator slots spaced apart around the axis of the iron core; a coil, comprising a plurality of wire turns embedded in the stator slots, each of the wire turns comprising a conductor and a composite insulating film wrapped around the outer circumference of the conductor, the composite insulating film comprising an insulating film layer and a supporting layer arranged from the inside to the outside, the wire turns abutting against the inner wall of the stator slot through the composite insulating film.
[0006] In some embodiments, the insulating film layer is at least one of a mica tape layer and an imide film mica tape layer.
[0007] In some embodiments, the support layer is at least one of a glass fiber layer and an aramid fiber layer.
[0008] In some embodiments, the insulating film layer is combined with the supporting layer to form an integrated film layer.
[0009] In some embodiments, the insulating film layer is configured as the imide film mica tape layer, the supporting layer is configured as at least one of a glass fiber layer and an aramid fiber layer, and the thickness of the composite insulating film is 0.19 mm to 0.21 mm.
[0010] In some embodiments, the insulating film layer is configured as the mica tape layer, the supporting layer is configured as an aramid fiber layer, and the thickness of the composite insulating film is 0.23 mm to 0.26 mm.
[0011] In some embodiments, there is an assembly gap between two adjacent turns and / or between the turns and the stator slots, and the stator further includes an auxiliary insulating portion, and the auxiliary insulating portion is filled in the assembly gap.
[0012] In some embodiments, the assembly gap between two adjacent turns is less than or equal to 0.01 mm, and / or the assembly gap between the turn and the stator slot is less than or equal to 0.01 mm.
[0013] In a second aspect, an embodiment of the present application further provides a motor, comprising a stator and a rotor rotatably matched with each other, wherein the stator is the stator described in the first aspect.
[0014] In a third aspect, an embodiment of the present application further provides a vehicle, comprising the motor described in the second aspect.
[0015] The stator provided in the embodiment of the present application includes an iron core and a coil, the iron core includes a plurality of stator slots spaced apart around the axis of the iron core, the coil includes a plurality of turns embedded in the stator slots, each turn includes a conductor and a composite insulating film wrapped around the outer circumference of the conductor to form a film-wrapped wire structure. The composite insulating film includes an insulating film layer and a supporting layer arranged from the inside to the outside to simultaneously ensure the insulation performance and mechanical strength of the turns, so when the turns are arranged in the stator slots, the insulating paper or insulating film in the stator slots can be omitted, and the turns are directly abutted against the inner wall of the stator slots through the composite insulating film, thereby increasing the conductor occupancy rate in the slots and improving the power and torque density of the motor.
[0016] The above description is only an overview of the technical solution of the present application. In order to more clearly understand the technical means of the present application, it can be implemented in accordance with the contents of the specification. In order to make the above and other purposes, features and advantages of the present application more obvious and easy to understand, the specific implementation methods of the present application are listed below. BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The features, advantages and technical effects of exemplary embodiments of the present application will be described below with reference to the accompanying drawings.
[0018] Figure 1 is a structural schematic diagram of a stator provided by an embodiment of the present application;
[0019] Figure 2 is a cross-sectional view of a stator provided by an embodiment of the present application;
[0020] Figure 3 It is a partial enlarged view of a stator slot provided in one embodiment of the present application;
[0021] Figure 4 It is a cross-sectional view of a turn provided by an embodiment of the present application.
[0022] Description of Figure Numbers:
[0023] 10- stator;
[0024] 1-iron core; 11-stator slot; 2-coil; 21-turn wire; 211-conductor; 212-composite insulating film; 3-auxiliary insulating part.
[0025] In the drawings, the same reference numerals are used for the same components. The drawings are not drawn to scale. DETAILED DESCRIPTION
[0026] The features and exemplary embodiments of various aspects of the present application will be described in detail below. In the detailed description below, many specific details are proposed to provide a comprehensive understanding of the present application. However, it is obvious to those skilled in the art that the present application can be implemented without the need for some of these specific details. The following description of the embodiments is only to provide a better understanding of the present application by illustrating examples of the present application. In the accompanying drawings and the following description, at least some of the known structures and technologies are not shown to avoid unnecessary ambiguity in the present application; and, for clarity, the size of some structures may be exaggerated. In addition, the features, structures or characteristics described below may be combined in one or more embodiments in any suitable manner.
[0027] The directional words appearing in the following description are all directions shown in the figures, and do not limit the specific structure of this application. In the description of this application, it should also be noted that, unless otherwise clearly specified and limited, the terms "installation" and "connection" 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 directly connected or indirectly connected. For ordinary technicians in this field, the specific meanings of the above terms in this application can be understood according to the specific circumstances.
[0028] The stator of the motor includes an iron core and a coil embedded in the iron core. Since the motor needs to be controlled by a frequency converter when working, the opening and closing of the insulated gate bipolar transistor switch in the frequency converter will generate a high-order pulse voltage of MHz level. When the high-order pulse voltage is transmitted in the coil of the winding assembly, it will affect the corresponding coil in the same branch, so the motor generally adds an insulation structure to withstand the electrical stress generated by the high-order pulse voltage when it is transmitted.
[0029] In order to achieve insulation between the iron core and the coil, the turns of the existing coil are often set to an enameled wire structure, that is, at least one layer of insulating paint is coated on the conductor, and the insulating paint is cured in an oven to form an insulating structure of the enameled wire. At the same time, insulating paper is set on the inner slot wall of the stator core, or an insulating film is formed on the inner slot wall of the stator core by injection molding or spraying, and the insulation performance is improved by the combination of the two.
[0030] However, the above-mentioned insulating paper and insulating film will occupy the space in the slot, and due to considerations of processability and mechanical strength, the insulating paper needs to have a certain thickness, which often reaches 0.3 mm, which affects the occupancy rate of the conductor in the stator and is not conducive to further increasing the power density of the motor.
[0031] Based on the above considerations, in order to solve this problem, the present application proposes a new stator. The stator, motor and vehicle in the embodiments of the present application are described in detail below with reference to the accompanying drawings.
[0032] See also Figures 1 to 3 , Figure 1 and Figure 2 The structure diagram and cross-sectional diagram of the stator 10 provided in one embodiment of the present application are respectively shown. Figure 3 A local enlarged view of a stator slot 11 provided in an embodiment of the present application is shown.
[0033] An embodiment of the present application provides a stator 10, including an iron core 1 and a coil 2, the iron core 1 is provided with a plurality of stator slots 11 spaced apart around the axis of the iron core 1, the coil 2 includes a plurality of turns 21 embedded in the stator slots 11, each turn 21 includes a conductor 211 and a composite insulating film 212 wrapped around the outer periphery of the conductor 211, the composite insulating film 212 includes an insulating film layer and a supporting layer arranged from the inside to the outside, and the turn 21 is in contact with the inner wall of the stator slot 11 through the composite insulating film 212.
[0034] The stator 10 in the embodiment of the present application includes an iron core 1 and a plurality of turns 21 embedded in the stator slot 11 of the iron core 1, each turn 21 includes a conductor 211 and a composite insulating film 212 wrapped around the outer periphery of the conductor 211, forming a film-wrapped wire structure. The composite insulating film 212 includes an insulating film layer and a supporting layer arranged from the inside to the outside, so as to simultaneously ensure the insulation performance and mechanical strength of the turns 21. Therefore, when the turns 21 are arranged in the stator slot 11, the insulating paper or insulating film in the stator slot 11 can be omitted, and the turns 21 are directly abutted against the inner wall of the stator slot 11 through the composite insulating film 212, thereby increasing the occupancy rate of the conductor 211 in the slot and improving the power and torque density of the motor.
[0035] It can be understood that the stator 10 in the embodiment of the present application can save part of the space in the stator slot 11 after eliminating the insulating paper or insulating film in the stator slot 11, and this part of the space can be used to set the conductor 211, so that under the condition of limited cross-sectional area of the stator slot 11, the filling area of the conductor 211 can be increased, that is, the occupancy rate of the conductor 211 in the slot is increased, thereby further improving the power density of the motor.
[0036] Optionally, the conductor 211 can be set as a copper flat wire. The flat wire refers to a conductor structure with a rectangular cross section, which can improve the thermal conductivity between windings at a high slot fill rate and has higher efficiency. The conductor 211 is set as copper, which has lower cost. For ease of description, the following description is based on the example of the conductor 211 being set as a copper flat wire.
[0037] Optionally, multiple coils 2 may be distributed along the circumference of the core 1 and may be located in different stator slots 11. The stator slots 11 may be provided as strip slots, which may extend a predetermined length along the radial direction of the core 1. The turns 21 of the coils 2 are radially stacked and embedded in the strip slots. The number of turns 21 may be adjusted according to actual needs, and the number of turns 21 may be provided as 6, or may be provided as less or more.
[0038] In some optional embodiments, the insulating film layer is at least one of a mica tape layer and an imide film mica tape layer, so as to improve the insulation resistance of the turns 21 through the insulating film layer and improve the corona resistance life of the coil 2, so that the insulation performance of the core 1 and the coil 2 meets the motor requirements.
[0039] It is understandable that the material of the insulating film layer can be adjusted according to the maximum withstand voltage of the motor. For a voltage level of 500V, the insulating film layer can be set as a mica tape layer to reduce costs while meeting insulation requirements. For a voltage level of 800V, since the PDIV (Partial Discharge Inception Voltage) of the turn 21 is relatively high, the insulating film layer can be set as an imide film mica tape layer to prevent the coil 2 from being broken down by the imide film.
[0040] Optionally, during the preparation of the wire turns 21 , the imide film mica tape layer may be directly wrapped around the conductor 211 , or the mica tape layer and the imide film may be wrapped separately, so as to form an insulating material structure having the mica tape layer and the imide film outside the conductor 211 .
[0041] Optionally, the imide film may be an imide film with a low dielectric constant. By reducing the dielectric constant of the imide film, the insulation structure of the stator 10 can be made more reasonable, the thickness of the composite insulating film 212 on the turns 21 can be reduced, and the copper filling rate in the stator slot 11 can be increased.
[0042] In some optional embodiments, the support layer is at least one of a glass fiber layer and an aramid fiber layer, so that the support layer can have both mechanical and electrical properties and be resistant to chemical corrosion.
[0043] The composite insulating film 212 in the embodiment of the present application can reduce the scratches or scratches on the wire turns 21 caused by bending the wire turns 21 or clamping the coil 2 to be embedded in the stator slot 11. In addition, since the iron core 1 is formed by stacking multiple silicon steel sheets, the wire turns 21 can also be protected by the composite insulating film 212 to protect the conductor 211, thereby reducing the damage to the wire turns 21 caused by any silicon steel sheet protruding relative to other silicon steel sheets, so that after the coil 2 is embedded in the stator slot 11, the insulation performance can still meet the actual use requirements.
[0044] It is understandable that glass fibers have a lower cost and aramid fibers have better insulation performance and mechanical strength, so the support layer can be set to a glass fiber layer or an aramid fiber layer according to actual needs, so that the performance of the composite insulating film 212 can meet the use requirements.
[0045] It should be noted that the above-mentioned insulating film layer and supporting layer can be arbitrarily combined, for example, the insulating film layer can be set as a mica tape, and the supporting layer can be set as an aramid fiber layer, or the insulating film layer can be set as an imide film mica tape layer, and the supporting layer can be set as a glass fiber layer, or the insulating film layer can be set as an imide film mica tape layer, and the supporting layer can be set as an aramid fiber layer. In addition, the supporting layer can be set as one of a glass fiber layer and an aramid fiber layer, or can be set with an aramid fiber layer and a glass fiber layer at the same time, which can be adjusted according to actual needs, and this application does not make specific restrictions on this.
[0046] Optionally, the thickness of the insulating film layer is greater than the thickness of the supporting layer to better balance the insulation performance and mechanical strength of the wire turns 21. The thicknesses of the insulating film layer and the supporting layer can be adjusted separately according to actual needs. Specifically, on the basis of satisfying the insulation performance and mechanical strength, the thicknesses of the insulating film layer and the supporting layer can be reduced as much as possible to further increase the filling area of the conductor 211, that is, to increase the copper filling rate in the stator slot 11.
[0047] See also Figure 3 and Figure 4 In some optional embodiments, the insulating film layer and the supporting layer are combined to form an integrated film layer. The composite insulating film 212 combines the performance of the insulating film layer and the supporting layer, and has better durability and stability, thereby increasing the service life of the coil 2.
[0048] Optionally, the insulating film layer and the supporting layer may be sintered to form an integrated composite insulating film 212. The sintering method can make the sintered composite insulating film 212 more uniform and dense, which is beneficial to improving the stability of the composite insulating film 212. Of course, in some other implementations, other methods may be used, such as pressing or gluing to form the integrated composite insulating film 212.
[0049] The structure of the composite insulating film 212 is described below with reference to specific embodiments.
[0050] In an embodiment of the present application, the winding 21 is provided, wherein the insulating film layer is configured as an imide film mica tape layer, the supporting layer is configured as at least one of a glass fiber layer and an aramid fiber layer, and the thickness of the composite insulating film 212 is 0.19 mm to 0.21 mm.
[0051] For example, when preparing the turn wire 21, you can first fold the conductor 211 by 1 / 2, that is, half-press and half-fold a layer of imide film mica tape with a thickness of 0.08mm, and then flatly wrap a layer of glass fiber layer with a thickness of 0.02mm~0.03mm to form a film-wrapped wire, and then prepare the sintering raw materials, and place the sintering raw materials into the sintering machine, start the sintering machine to sinter the film-wrapped wire, and obtain the turn wire 21 wrapped with a composite insulating film 212. The thickness of the composite insulating film 212 can be set to 0.19mm~0.21mm.
[0052] Optionally, the sintering raw material may be set to FEP glue (Fluorinated ethylene propylene, perfluoroethylene propylene copolymer), so as to perform high-temperature sintering with the FEP glue to form the composite insulating film 212 .
[0053] For the 800V voltage level, the effective value of the ground main insulation PDIV measured by the power frequency method of GB / T7354 must be greater than 1300V, and the peak value measured by the phase-to-phase pulse method must be at least greater than 3500V. After testing, the effective value of the turns 21 formed by the above embodiment can meet more than 1600V, and even reach 1800V, which can effectively meet the use requirements of the 800V voltage level while eliminating the insulation paper. At the same time, since the thickness of the composite insulating film 212 is only 0.19mm~0.21mm, compared with the existing stator 10, the copper filling rate in the stator slot 11 can be increased by about 7%, thereby effectively improving the power and torque density of the motor.
[0054] It can be understood that the thickness of the composite insulating film 212 can be adjusted according to the accuracy of the turn wire 21 forming equipment. For example, on the basis of the high accuracy of the turn wire 21 forming equipment, the thickness of the composite insulating film 212 can be set to 0.19 mm to further improve the copper filling rate in the stator slot 11. When the accuracy of the turn wire 21 forming equipment is not high, the thickness of the composite insulating film 212 can be set to 0.21 mm to form a forming margin to better meet the insulation requirements of the motor.
[0055] In the turn wire 21 provided in an embodiment of the present application, the insulating film layer is set as a mica tape layer, the supporting layer is set as an aramid fiber layer, and the thickness of the composite insulating film 212 is 0.23 mm to 0.26 mm.
[0056] Optionally, the mica tape layer and the aramid fiber layer can be combined to form an aramid mica tape. When preparing the turn wire 21, a layer of aramid mica tape with a thickness of 0.11mm to 0.13mm is folded 1 / 2 on the conductor 211, that is, half-pressed and half-folded to form a film-wrapped wire. The thickness of the composite insulating film 212 can be set to 0.23mm to 0.26mm. Compared with the existing stator 10, the copper filling rate in the stator slot 11 can still be increased by about 2%, and the power and torque density of the motor can also be effectively improved.
[0057] See also Figures 1 to 4 In some optional embodiments, there is an assembly gap between two adjacent turns 21 and / or between the turn 21 and the stator slot 11, and the stator 10 further includes an auxiliary insulating portion 3, and the auxiliary insulating portion 3 is filled in the assembly gap.
[0058] After the coil 2 is embedded in the stator slot 11 , the auxiliary insulating part 3 is filled in the assembly gap between the stator slot 11 and the wire turns 21 and between multiple wire turns 21 , so that the insulation performance can be further improved without affecting the copper filling rate in the stator slot 11 .
[0059] Optionally, the insulating material of the auxiliary insulating part 3 may be set to unsaturated polyester imide resin or epoxy resin with a temperature resistance grade of 200° C. or 220° C.
[0060] In some optional embodiments, the assembly gap between two adjacent turns 21 is less than or equal to 0.01 mm, and / or the assembly gap between the turn 21 and the stator slot 11 is less than or equal to 0.01 mm.
[0061] By reducing the above-mentioned assembly gap, the coil 2 can be embedded in the stator slot 11 while increasing the proportion of the turns 21 as much as possible, thereby further improving the copper filling rate in the stator slot 11 to improve the power and torque density of the motor.
[0062] Optionally, the coil 2 has a straight portion and an end portion, the straight portion of the coil 2 is embedded in the stator slot 11, and the end portion of the coil 2 is provided with a reinforced insulating portion, which is epoxy-coated powder.
[0063] The embodiment of the present application also provides a motor, including a stator 10 and a rotor that are rotatably matched, and the stator 10 is the stator 10 in the above embodiment. Since the turns 21 of the coil 2 of the stator 10 include a conductor 211 and a composite insulating film 212 wrapped around the outer periphery of the conductor 211, taking the composite insulating film 212 as an example of an imide film mica aramid fiber sintered integrally, the formed stator 10 has a low cost and can meet the requirements of the 800V insulation system without the need for insulating paper, thereby saving space for insulating paper, significantly improving the occupancy rate of the conductor 211 in the slot, and thus improving the power and torque density of the motor.
[0064] The embodiment of the present application also provides a vehicle, including the motor in the above embodiment, so it also has the advantages of low cost and high occupancy rate of the conductor 211 in the slot, and is more convenient for promotion and application.
[0065] Although the present application has been described with reference to preferred embodiments, various modifications may be made thereto and parts thereof may be replaced with equivalents without departing from the scope of the present application. In particular, the various technical features mentioned in the various embodiments may be combined in any manner as long as there are no structural conflicts. The present application is not limited to the specific embodiments disclosed herein, but includes all technical solutions falling within the scope of the claims.
Claims
1. A stator (10), characterized in that: include: An iron core (1) provided with a plurality of stator slots (11) spaced apart and distributed around an axis of the iron core (1); The coil (2) comprises a plurality of wire turns (21) embedded in the stator slot (11), each of the wire turns (21) comprising a conductor (211) and a composite insulating film (212) wrapped around the outer periphery of the conductor (211), the composite insulating film (212) comprising an insulating film layer and a supporting layer arranged from the inside to the outside, and the wire turns (21) are in contact with the inner wall of the stator slot (11) through the composite insulating film (212).
2. The stator (10) according to claim 1, characterized in that: The insulating film layer is at least one of a mica tape layer and an imide film mica tape layer.
3. The stator (10) according to claim 1, characterized in that: The support layer is at least one of a glass fiber layer and an aramid fiber layer.
4. The stator (10) according to claim 1, characterized in that The insulating film layer is combined with the supporting layer to form an integrated film layer.
5. The stator (10) according to claim 4, characterized in that The insulating film layer is an imide film mica tape layer, the supporting layer is at least one of a glass fiber layer and an aramid fiber layer, and the thickness of the composite insulating film (212) is 0.19 mm to 0.21 mm.
6. The stator (10) according to claim 4, characterized in that The insulating film layer is configured as a mica tape layer, the supporting layer is configured as an aramid fiber layer, and the thickness of the composite insulating film (212) is 0.23 mm to 0.26 mm.
7. The stator (10) according to any one of claims 1 to 6, characterized in that: An assembly gap is provided between two adjacent turns (21) and / or between the turns (21) and the stator slot (11), and the stator (10) further comprises an auxiliary insulating portion (3), wherein the auxiliary insulating portion (3) is filled in the assembly gap.
8. The stator (10) according to claim 7, characterized in that The assembly gap between two adjacent turns (21) is less than or equal to 0.01 mm, and / or the assembly gap between the turns (21) and the stator slot (11) is less than or equal to 0.01 mm.
9. A motor, characterized in that: The invention comprises a stator (10) and a rotor which are rotationally matched, wherein the stator (10) is the stator (10) according to any one of claims 1 to 8.
10. A vehicle, characterized in that: Comprising the motor as claimed in claim 9.