Winding conductor device, motor winding, motor and vehicle
By using a tight wire as a conductor in the motor stator winding, the problems of increasing resistance and increasing energy consumption at high speeds are solved, and more efficient motor performance is achieved.
Patent Information
- Application Number
- CN202421427912.2
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-06-20
- Publication Date
- 2025-05-13
- Estimated Expiration
- 2034-06-20
AI Technical Summary
The stator windings of existing new energy vehicle drive motors increase resistance due to skin effect and proximity effect at high speeds, reducing overcurrent capacity, increasing energy consumption, and limiting power output.
The tight-pressed wire is used as the groove entry section of the winding conductor device. The tight-pressed wire is composed of multiple conductors tightly pressed and has a rectangular cross-sectional shape, which reduces the skin effect and proximity effect and improves the groove fullness.
It significantly reduces the skin effect and proximity effect of the winding, improves the motor speed and efficiency at high speeds, and improves the motor's power density and overcurrent capability.
Smart Images
Figure CN222868633U_ABST
Abstract
Description
Technical Field
[0001] The utility model generally relates to the technical field of motors, and more specifically to a winding conductor device, a motor winding, a motor and a vehicle. Background Art
[0002] In the prior art, when an alternating current is passed through the stator winding of a motor, a rotating magnetic field is generated, which can drive the rotor to rotate. Therefore, the stator winding of a motor is an important device in the motor that converts electrical energy into mechanical energy.
[0003] At present, the drive motors of new energy vehicles are developing in the direction of high power density, high speed and low energy consumption. The stator windings of existing new energy vehicle drive motors generally use round copper wires or flat copper wires. The round copper wires are directly wound in the stator slots, and the flat copper wires are prefabricated outside the motor stator and then inserted into the motor stator slots. The round copper wire windings are composed of multiple strands of enameled wire monofilaments that are insulated from each other. The current is uniform, and the skin effect and proximity effect are low at high speeds. Therefore, they are suitable for high-speed motors. However, due to the large gaps between the multiple strands of round copper wire, the slot fill rate in the stator slots is low, resulting in low motor power density.
[0004] The U-shaped flat copper wire hairpin is the smallest unit that makes up the stator winding of the flat copper wire motor. That is, the U-shaped flat copper wire hairpin is manufactured outside the motor stator and then inserted into the motor stator slot. Then, the two ends of the U-shaped hairpin are conductively connected to each other to form a conductor ring. Multiple U-shaped hairpins are interconnected according to a certain rule to form a three-phase winding of the motor.
[0005] In the prior art, the U-shaped flat copper wire hairpin adopts a single-section solid conductor. The motor with the flat copper wire stator winding has a high operating efficiency at medium and low speeds, but at high speeds (i.e., high frequencies), the current is concentrated on the surface of the flat wire. The skin effect and proximity effect generated increase the resistance of the stator winding at high speeds, reduce the overcurrent capacity of the flat copper stator winding, cause the winding to heat up, greatly reduce the operating efficiency of the motor at high speeds, increase the energy consumption of the motor, and further limit the power output of the flat copper wire motor at high speeds.
[0006] Therefore, it is necessary to provide a winding conductor device, a motor winding, a motor and a vehicle to at least partially solve the above problems. Utility Model Content
[0007] A series of simplified concepts are introduced in the utility model content section, which will be further described in detail in the detailed implementation section. The utility model content section of the utility model does not mean to attempt to define the key features and essential technical features of the technical solution claimed for protection, nor does it mean to attempt to determine the scope of protection of the technical solution claimed for protection.
[0008] In order to at least partially solve the above problems, the first aspect of the present invention provides a winding conductor device, comprising:
[0009] The slot entry section is used to be set in the wire slot of the motor rotor or stator. The slot entry section includes a densely pressed wire, which includes a plurality of wires, and the wires are tightly pressed together. The cross-sectional shape of the slot entry section is rectangular.
[0010] Optionally, the cross-sectional shape of the wire is a circle, or the cross-sectional shape of the wire is a regular N-gon, where N≥3.
[0011] Optionally, the winding conductor device further comprises:
[0012] A torsion section, wherein the torsion section is in an inverted V shape and includes two connecting ends;
[0013] There are two groups of slot-entering segments, and two connecting ends of the torsion segment are respectively connected to the first end of one group of slot-entering segments, so that the winding conductor device is U-shaped.
[0014] Optionally, the torsion section is connected to the slot entry section in an overlapping structure, and the connecting end of the torsion section overlaps with the first end of the slot entry section.
[0015] Optionally, the torsion section and the slot entry section are overlapped by reducing the thickness by half at the overlapping position;
[0016] Alternatively, the torsion section and the slot entry section are both provided with oblique cuts at the overlapping positions for overlapping.
[0017] Optionally, the winding conductor device further comprises:
[0018] An extension section, wherein a first end of the extension section is connected to a second end of the slot entry section.
[0019] Optionally, the slot entry section is connected to the extension section in an overlapping structure, and the second end of the slot entry section and the first end of the extension section overlap each other.
[0020] Optionally, the groove entry section and the expansion section are both reduced by half in thickness at the overlapping position for overlapping;
[0021] Alternatively, the slot entry section and the expansion section are both provided with oblique cuts at the overlapping positions for overlapping.
[0022] Optionally, the winding conductor device further comprises:
[0023] A fixing piece, wherein the fixing piece is sleeved on a connecting section between the torsion section and the slot entry section, and / or the fixing piece is sleeved on a connecting section between the slot entry section and the expansion section.
[0024] Optionally, the winding conductor device further comprises:
[0025] An insulating layer at least covers the torsion section and the slot section.
[0026] Optionally, the torsion section and / or the extension section comprises a single or multiple flat copper wires;
[0027] Alternatively, the torsion section comprises a tightly pressed wire, which comprises a plurality of conductive wires which are tightly pressed together.
[0028] Optionally, a plurality of the flat copper wires are arranged along the height direction of the torsion section and / or the expansion section;
[0029] Alternatively, a plurality of the flat copper wires are arranged along the thickness direction of the torsion section and / or the expansion section.
[0030] Optionally, the torsion section comprises:
[0031] a first twisting portion, the first twisting portion connecting the first group of the slot-entering segments;
[0032] a third twisting portion, the third twisting portion being connected to the second group of slot-entering segments;
[0033] a second torsion portion, the second torsion portion connecting the first torsion portion and the third torsion portion;
[0034] The first twisting portion, the second twisting portion, and the third twisting portion are all bent at a preset angle.
[0035] A second aspect of the utility model provides a motor winding, comprising a winding conductor device according to any one of the above technical solutions.
[0036] Optionally, the motor winding comprises:
[0037] There are multiple groups of winding conductor devices, and the second ends of the extended segments of any group of winding conductor devices are connected to the second ends of the extended segments of an adjacent group of winding conductor devices.
[0038] Optionally, the torsion section of the winding conductor arrangement is bent toward the outside of the rotor or stator of the electric machine.
[0039] A third aspect of the utility model provides a motor, comprising the motor winding according to any one of the above technical solutions.
[0040] A fourth aspect of the present invention provides a vehicle, comprising a motor according to any one of the above technical solutions.
[0041] According to a winding conductor device, motor winding, motor and vehicle of the utility model, the winding conductor device sets the conductor segment in the motor slot as a densely pressed wire, and the densely pressed wire is composed of multiple strands of tightly fitted wires. Therefore, the skin effect and proximity effect of the densely pressed wire are significantly reduced, and the slot fill rate in the motor slot is improved, thereby improving the motor speed and efficiency at high speed. BRIEF DESCRIPTION OF THE DRAWINGS
[0042] The following drawings of the embodiments of the present invention are used as part of the present invention for understanding the present invention. The drawings show the embodiments of the present invention and their descriptions, and are used to explain the principles of the present invention. In the drawings,
[0043] Figure 1 is a three-dimensional diagram of a winding conductor device according to a preferred embodiment of the utility model;
[0044] Figure 2 It is a front view of the combined state of the winding conductor device and the motor rotor according to a preferred embodiment of the utility model;
[0045] Figure 3 It is a front view of the combined state of the winding conductor device and the motor rotor according to a preferred embodiment of the utility model;
[0046] Figure 4 for Figure 3 Sectional view along AA;
[0047] Figure 5 for Figure 4 A partial enlarged view of the
[0048] Figure 6 It is a schematic diagram of the step-by-step twisting process of the enameled wire according to a preferred embodiment of the utility model;
[0049] Figure 7 It is a three-dimensional diagram of a compacted wire of a winding conductor device according to a preferred embodiment of the utility model;
[0050] Figure 8 It is a schematic diagram of the connection process of the flat copper wire and the dense pressing wire according to a preferred embodiment of the utility model;
[0051] Fig. 9 It is a schematic diagram of the connection process of the flat copper wire and the dense pressing wire according to a preferred embodiment of the utility model;
[0052] Fig.10 It is a schematic diagram of the connection process of the flat copper wire and the dense pressing wire according to a preferred embodiment of the utility model;
[0053] Fig.11It is a schematic diagram of the connection process of the flat copper wire and the dense pressing wire according to a preferred embodiment of the utility model;
[0054] Fig.12 is a three-dimensional diagram of a winding conductor device according to a preferred embodiment of the utility model;
[0055] Fig.13 is a three-dimensional diagram of a winding conductor device according to a preferred embodiment of the utility model;
[0056] Fig.14 is a three-dimensional diagram of a winding conductor device according to a preferred embodiment of the utility model;
[0057] Fig.15 is a three-dimensional diagram of a winding conductor device according to a preferred embodiment of the utility model;
[0058] Fig.16 It is a partial enlarged view of a winding conductor device according to a preferred embodiment of the utility model;
[0059] Fig.17 for Fig.18 Sectional view along BB;
[0060] Fig.18 A partial top view of a motor rotor according to a preferred embodiment of the utility model;
[0061] Fig.19 It is a partial stereoscopic diagram of a motor rotor according to a preferred embodiment of the utility model;
[0062] Fig. 20 A top view of a motor rotor according to a preferred embodiment of the utility model;
[0063] Fig.21 It is a front view of a motor rotor according to a preferred embodiment of the utility model;
[0064] Fig. 22 is a three-dimensional diagram of a winding conductor device according to a preferred embodiment of the utility model;
[0065] Fig.23 A three-dimensional diagram of a motor rotor according to a preferred embodiment of the utility model;
[0066] Fig.24 It is a three-dimensional diagram of a motor rotor according to a preferred embodiment of the utility model;
[0067] Fig.25 It is a bottom view of a motor rotor according to a preferred embodiment of the utility model.
[0068] Description of reference numerals:
[0069] 1: Winding conductor device 101: Torsion segment
[0070] 102: slot entry section 103: connection section
[0071] 104: Extension section 105: Slot section
[0072] 106: connection segment 107: extension segment
[0073] 108: Fixing piece 109: Connecting section
[0074] 110: connecting section 111: first torsion section
[0075] 112: second twisting portion 113: third twisting portion
[0076] 120: Insulation layer 2: Stator
[0077] 201: Wire slot 3: Twisted wire
[0078] 31: Enameled wire 32: First twisted part
[0079] 32: Second twisting part DETAILED DESCRIPTION
[0080] In the following description, a large number of specific details are given to provide a more thorough understanding of the utility model. However, it is obvious to those skilled in the art that the utility model can be implemented without one or more of these details. In other examples, in order to avoid confusion with the utility model, some technical features known in the art are not described.
[0081] In order to thoroughly understand the utility model, a detailed description will be provided in the following description. It should be understood that these embodiments are provided to make the disclosure of the utility model thorough and complete, and to fully convey the concepts of these exemplary embodiments to those of ordinary skill in the art. Obviously, the implementation of the embodiments of the utility model is not limited to the specific details familiar to those skilled in the art. The preferred embodiments of the utility model are described in detail below, but in addition to these detailed descriptions, the utility model may also have other embodiments.
[0082] Ordinal numbers such as "first" and "second" cited in the present invention are merely identifiers and do not have any other meanings, such as a specific order, etc. Moreover, for example, the term "first component" itself does not imply the existence of the "second component", and the term "second component" itself does not imply the existence of the "first component".
[0083] It should be noted that the terms "upper", "lower", "front", "back", "left", "right", "inside", "outside" and similar expressions used in the present invention are for illustrative purposes only and are not restrictive.
[0084] The utility model discloses a winding conductor device, a motor winding, a motor and a vehicle.
[0085] Now, exemplary embodiments according to the present invention will be described in more detail with reference to the accompanying drawings.
[0086] like Figure 1 , Figure 2 , Figure 3 , Figure 4 As shown, in a preferred embodiment, a winding conductor device 1 comprises:
[0087] The slot-entry sections 102 and 105 are used to be arranged in the wire slot 201 of the motor stator 2, that is, the slot-entry sections 102 and 105 extend into the wire slot 201 of the motor stator 2;
[0088] The slot entry sections 102 and 105 include a densely pressed wire, which includes a plurality of conductors that are tightly pressed together. The cross-sectional shape of the slot entry sections 102 and 105 is a rectangle, which can better fit the space of the wire slot 201 and improve the slot fill rate.
[0089] If the rotor of the motor needs to be excited, the winding conductor device 1 can also be arranged in the wire slots of the motor rotor, that is, the slot sections 102 and 105 extend into the wire slots of the motor rotor.
[0090] When an alternating current is passed through the winding of the motor stator 2, a magnetic field is generated, wherein only the part inside the wire slot 201 of the stator 2 affects the motor power, and this part is the slot entry section 102, 105, which is also called the effective section. Specifically, the densely pressed wire of the slot entry section 102, 105 is different from a single solid flat copper wire and is composed of multiple strands of conductors twisted together. The densely pressed wire has a higher net copper cross-sectional area. Compared with the solid flat copper wire, the densely pressed wire is composed of multiple strands of tightly fitted conductors. Therefore, the skin effect and proximity effect of the densely pressed wire are significantly reduced, which improves the motor speed and efficiency at high speeds. Compared with ordinary round or enameled stranded wire, it has a larger net copper cross-sectional area, which increases the slot fill rate of the winding, thereby improving the power density of the motor.
[0091] Skin effect: When there is alternating current or alternating electromagnetic field in a conductor, the current inside the conductor is unevenly distributed, and the current is concentrated in the "skin" part of the conductor, that is, the current is concentrated in the thin layer on the surface of the conductor. The closer to the surface of the conductor, the greater the current density, and the current inside the conductor is actually smaller. As a result, the resistance of the conductor increases, and its power loss also increases. This phenomenon is called skin effect or skin effect.
[0092] The skin effect causes the current to tend to flow on the surface. So, for a wire with the same cross-sectional area, the larger the surface area, the smaller the equivalent resistance. Therefore, using multiple thin wires instead of a single solid wire can improve the skin effect and reduce the AC resistance of the wire.
[0093] Proximity effect: When high-frequency current flows in opposite directions in two conductors or in a reciprocating conductor, the current will be concentrated on the adjacent side of the conductor. This phenomenon is called proximity effect. For example, when the two conductors of a two-wire transmission line pass alternating currents in opposite directions, the alternating magnetic fields generated by each conductor generate eddy currents on the other adjacent conductor. The eddy currents excited by the current on the adjacent conductor are superimposed on the original working current of the conductor, so that the actual current distribution in the conductor is concentrated on the side (inside) close to the adjacent conductor. As a result, the effective resistance of the conductor increases and the working attenuation increases.
[0094] The proximity effect causes eddy currents in wires. Therefore, for wires with the same cross-sectional area, using multiple thin wires instead of a single solid wire can effectively reduce the eddy currents and improve the proximity effect.
[0095] In summary, the smaller single conductor cross-sectional area of the compacted wire (Litz wire) reduces the skin effect and proximity effect of the winding conductor device (hairpin unit), thereby improving the efficiency and limiting performance of the drive motor over a wide speed range.
[0096] When the motor is working, the main function section of the winding conductor device 1 is the slot entry section. Because the slot entry section of the winding conductor device 1 uses a square compressed wire, the motor stator winding made using the winding conductor device 1 can ensure a slot filling rate comparable to that of a flat copper wire stator, ensuring the working efficiency of the motor at low and medium speeds; at the same time, the skin effect and proximity effect of the winding are reduced at high speeds of the motor, so that the efficiency and limit performance of the drive motor in a wide speed range are improved.
[0097] The compacted wire (Litz wire) can also be used for high-frequency transformer winding, with uniform current distribution. The twisted braided structure of the compacted wire can reduce current concentration and resistance loss at high frequencies. The compacted wire is pressed into a square shape, which is similar to the flat wire. Its advantage is that it has the advantage of uniform current distribution of the compacted wire, and at the same time, it has the advantage of a higher net copper area like the flat copper wire.
[0098] In one embodiment, the cross-sectional shape of the wire is a circle, or the cross-sectional shape of the wire is a regular N-gon, where N≥3.
[0099] The conductor may be a round conductor, which is easy to manufacture or purchase and has a low cost. The conductor may also be a polygonal conductor, such as a quadrilateral, a hexagon, etc.
[0100] In one embodiment, the wire is an enameled wire 31 or a bare wire.
[0101] like Figure 6 , Figure 7 As shown, it is a schematic diagram of the enameled wire 31 being twisted into a round wire in steps. The enameled wire 31 is first twisted into small strands, namely the first twisted portion 32 in the figure, and then the small strands are twisted into large strands, namely the second twisted portion 33 in the figure. The twisting directions of the small strands and the large strands can be the same or opposite; the small strands contain 5 to 15 enameled wires 31, and the number of small strands in the large strand should be greater than 3. The diameter of the single wire of the enameled wire 31 is between 0.5 and 1 mm, and the enameled wire 31 is made of a self-adhesive direct solderable paint film with a paint film thickness of less than 0.04 mm. In some application embodiments, the wire may also be a bare wire (such as Fig.14 embodiment shown).
[0102] The wire diameter of the compressed wire is small and the material is soft. In order to ensure the shape and size accuracy of the winding conductor device 1 and reduce the rebound during processing, the wire has certain rigidity requirements. Therefore, the diameter of the enameled wire conductor used for the square compressed wire should be 0.5 to 1 mm, and the enameled wire film is a self-adhesive film. First, a single enameled wire is twisted into a small strand of compressed wire, and then the small strands of compressed wire are twisted into a large strand of compressed wire.
[0103] In one embodiment, if Figure 5 , Figure 7 As shown, the cross-sectional shape of the slot sections 102 and 105 is a rectangle. The compacted wires of the slot sections 102 and 105 are different from single solid flat copper wires and are composed of multiple strands of mutually insulated wires twisted together and molded and compressed into a certain rectangle. The compression into a certain rectangle is to adapt to the slot shape of the wire slot 201 of the stator 2, and to be compressed as tightly as possible without damaging the insulation performance between the enameled wires 31, so as to eliminate the gaps between the twisted enameled wires 31 and ensure that there are as many copper conductors as possible in the cross-sectional area of the wire slot 201 of the stator 2.
[0104] In one embodiment, if Figure 1 , Figure 2 As shown, the winding conductor device 1 further comprises:
[0105] The torsion section 101 is in an inverted V shape and includes two connecting ends;
[0106] The two groups of slot-entry sections are slot-entry sections 102 and slot-entry sections 105, and the two connecting ends of the torsion section 101 are respectively connected to the first end of the slot-entry section 102 and the first end of the slot-entry section 105, so that the winding conductor device 1 is U-shaped. The U-shaped winding conductor device 1 can span multiple wire slots 201, and the span of the winding conductor device 1 can be designed according to the prior art, for example, spanning a suitable number of wire slots 201.
[0107] In one embodiment, the torsion section 101 is connected and welded with the slot section 102 and the slot section 105 in an overlap structure, and the two connecting ends of the torsion section 101 overlap with the first end of the slot section 102 and the first end of the slot section 105. The overlap structure connection and welding can ensure the firmness of the connection, and the torsion section 101 and the slot sections 102 and 105 are not easy to break.
[0108] The torsion section 101 and the slot section 102 and the slot section 105 are overlapped by reducing the thickness by half at the overlap position, or the torsion section 101 and the slot section 102 and the slot section 105 are overlapped by providing oblique cuts at the overlap position, so that the welding connection is more firm and a rectangular structure is easily formed.
[0109] The end center of the torsion section 101 maintains straightness with the end center of the slot section 102 and the slot section 105. After welding, the weld is compacted so that the cross-sectional dimensions of the weld are the same as the cross-sectional dimensions of the slot section 102 and the slot section 105, ensuring that the connection can be normally set in the wire slot 201 of the stator 2.
[0110] In one embodiment, if Figure 1 , Figure 2 As shown, it also includes:
[0111] The first end of the extension segment 104 is connected to the second end of the slot segment 102, and the first end of the extension segment 107 is connected to the second end of the slot segment 105. The extension segments 104 and 107 extend from the wire slot 201 of the stator 2 for connecting with the adjacent winding conductor device 1.
[0112] The second end of the extension segment 104 can be connected to the extension segment 107 of the adjacent winding conductor device 1, and the second end of the extension segment 107 can be connected to the extension segment 104 of the adjacent winding conductor device 1. The connection can be fixedly connected by laser welding so that the adjacent winding conductor devices 1 are interconnected to form a winding.
[0113] In one embodiment, if Figure 8 As shown, the slot entry section 102 and the expansion section 104 are connected and welded in an overlapping structure, and the second end of the slot entry section 102 and the first end of the expansion section 104 overlap each other.
[0114] The slot entry section 102 and the expansion section 104 are both reduced by half in thickness at the overlap position for overlapping, or the slot entry section 102 and the expansion section 104 are both provided with oblique cuts at the overlap position for overlapping, so that the welding connection is more firm and a rectangular structure is easily formed.
[0115] The end center of the slot entry section 102 and the end center of the expansion section 104 maintain straightness. After welding, the weld is compacted so that the cross-sectional size of the weld is the same as the cross-sectional size of the slot entry section 102 to ensure that the connection can be normally set in the wire slot 201 of the stator 2.
[0116] Similarly, the slot entry section 105 and the extension section 107 are connected and welded in an overlapping structure, and the specific structure of the slot entry section 102 and the extension section 104 may be referred to.
[0117] In one embodiment, if Fig. 9 As shown, it also includes:
[0118] The fixing member 108 is sleeved on the connecting section 103 between the slot entry section 102 and the expansion section 104 . The fixing member 108 can enhance the strength of the connecting section.
[0119] Likewise, the fixing member 108 may be sleeved on the connecting section 106 between the slot section 105 and the expansion section 107 to enhance the strength of the connection.
[0120] Likewise, the fixing member 108 may be disposed at the connection section between the torsion section 101 and the slot section 102 and the slot section 105 to enhance the strength of the connection.
[0121] The fixing member 108 is a rectangular ring structure, and its internal dimensions are slightly larger than those of the slot section 102 and the extension section 104, so that the slot section 102 and the extension section 104 can be inserted into the fixing member 108. The slot section 102 and the extension section 104 are inserted into the fixing member 108 and welded into a solid conductor. The fixing member 108 is used to prevent the compaction line from spreading during the welding process when the combined conductor is connected, to ensure the shape of the welded connection, and to strengthen the rigidity of the connection. The fixing member 108 is not an essential item for welding, and welding can be performed without the fixing member 108.
[0122] In one embodiment, if Fig.16 , Fig.17 As shown, it also includes:
[0123] Insulation layer 120, the insulation layer 120 at least covers the torsion section 101 and the connection section. The insulation layer 120 can effectively isolate the influence of the charge between the conductors. The eddy current and Joule heat inside the winding will generate heat, and the insulation layer 120 can insulate and maintain the stable structure of the winding to avoid damage to the winding due to high temperature. The insulation layer 120 can also prevent water, oil and other liquids from entering the winding to maintain its function and life.
[0124] In one embodiment, the torsion section 101 and the expansion sections 104, 107 include a single or multiple flat copper wires;
[0125] Alternatively, the torsion section 101 and the expansion sections 104, 107 include a tightly pressed wire, which includes a plurality of wires that are tightly pressed together.
[0126] The winding conductor device 1 can have various wire combinations, such as Fig.12 As shown, the torsion section 101 is configured as a close-pressed wire, the slot sections 102 and 105 are integrally formed with the torsion section 101 and are also configured as close-pressed wires, and the extension sections 104 and 107 are configured as single or multiple flat copper wires for easy welding connection with the adjacent winding conductor device 1.
[0127] like Fig.13 As shown, the torsion section 101 is configured as a single or multiple flat copper wires, and the slot sections 102, 105 and the expansion sections 104, 107 are integrally formed and configured as a densely pressed wire.
[0128] like Fig.14 As shown, the torsion section 101 is set as a single or multiple flat copper wires, the slot sections 102 and 105 are set as densely pressed wires, and the expansion sections 104 and 107 are set as a single or multiple flat copper wires. The position where the torsion section 101 is connected to the slot section 102 is the connecting section 109, and the position where the torsion section 101 is connected to the slot section 105 is the connecting section 110, and the structure can refer to the connecting section 103.
[0129] like Fig.15 As shown, the torsion section 101, the slot sections 102, 105 and the expansion sections 104, 107 are integrally made and are all arranged as close pressing lines.
[0130] In one embodiment, a plurality of flat copper wires are arranged along the height direction of the torsion section 101 and / or the expansion sections 104 and 107;
[0131] Alternatively, a plurality of rectangular copper wires are arranged along the thickness direction of the twisting section 101 and / or the expansion sections 104 , 107 .
[0132] like Fig.10 , Fig.11 As shown, the plurality of flat copper wires are arranged along the height direction of the extension section 104, and the thickness of each flat copper wire is the same as the thickness of the extension section 104. The plurality of flat copper wires can also be arranged along the thickness direction of the extension section 104, and the height of each flat copper wire is the same as the height of the extension section 104. With this arrangement, the flat copper wires can be staggered or form a transposition structure to further reduce eddy current losses. For example, when the torsion section 101 is torsionally deformed, the plurality of flat copper wires can change their original positions to form a transposition structure, for example, from the inner side of the torsion section 101 to the outer side of the torsion section 101.
[0133] In one embodiment, if Fig.18 , Fig.19 As shown, the torsion section 101 comprises:
[0134] A first twisting portion 111, the first twisting portion 111 is connected to the first group slot sections 102 and 105;
[0135] A third twisting portion 113, the third twisting portion 113 is connected to the second group of slot segments 102 and 105;
[0136] A second twisting portion 112, the second twisting portion 112 connects the first twisting portion 111 and the third twisting portion 113;
[0137] The first twisting portion 111 , the second twisting portion 112 , and the third twisting portion 113 are all bent at a preset angle.
[0138] When the torsion segment 101 of the winding conductor device 1 is a single flat copper wire or a densely pressed wire, the upper layer of the torsion segment 101 is divided into two sections, and an outward bending angle is added in the middle to connect the two crown sections. The outward bending angle is between 3° and 15°, and the torsion segment 101 cannot be bent outward beyond the outermost layer of the motor stator housing. The upper and lower layers of the torsion segment 101 are each flat, and the upper and lower layers are bent at a certain angle for connection. The lower layer is bent outward by 15° to 60°, and the upper layer is bent inward by 45° to 105°. The required angle for the connection and bending of the upper and lower layers is determined according to the outward bending angle of the upper layer, and there is no special requirement for the shape of the connection between the upper and lower layers. The torsion segment 101 is turned outward so that when the winding conductor device 1 is assembled into the motor slot, the ends of the torsion segments 101 of multiple winding conductor devices 1 are staggered from each other, such as Fig. 20 As shown, the required height of the winding conductor device 1 is reduced while avoiding interference between multiple winding conductor devices 1. When the torsion section 101 uses multiple flat copper wire conductors, the flat copper wires can be staggered or form a transposed structure to further reduce eddy current losses. The winding conductor device 1 can be formed in a single step or multiple steps by expansion, bending, stamping or a variety of forming methods.
[0139] In one embodiment, the conductor is an enameled wire 31, and the outer insulating varnish of the enameled wire 31 is bonded and fixed together.
[0140] In one embodiment, the outer insulating varnish of the enameled wire 31 is a self-adhesive direct-weldable varnish film.
[0141] The function of the self-adhesive paint is to solidify the coil and shape it. In the winding conductor device 1, the self-adhesive paint makes the conductors inside the compact wire bonded and formed during the compact wire forming and curing process, reducing the mutual slippage of the conductors and improving the rigidity of the compact wire. The stronger the viscosity of the self-adhesive paint, the higher the rigidity of the square compact wire. The paint film thickness of the enameled wire should be less than the standard thickness but at the same time meet the insulation requirements between conductors, and the viscosity of the self-adhesive layer paint film should be stronger than that of the standard self-adhesive enameled wire.
[0142] In one embodiment, the length of the slot sections 102 and 105 of the winding conductor device 1 is equal to the length of the motor slot, the length of the torsion section 101 is between 1.7 and 3.5 times the straight-line distance of the slot sections 102 and 105 , and the length of the extension sections 104 and 107 is between 2 and 4 times the spacing of the winding conductor device 1 .
[0143] like Fig.21 , Fig. 22 , Fig.23 , Fig.24 As shown, an embodiment of the utility model further provides a motor winding, comprising the winding conductor device 1 described in any one of the above embodiments.
[0144] The motor winding may be a stator winding, which is arranged in the wire slot 201 of the motor stator 2. If the rotor of the motor needs excitation, the motor winding may also be arranged in the wire slot of the motor rotor to form a rotor winding.
[0145] In one embodiment, if Fig.23 , Fig.24 As shown, the motor winding includes:
[0146] The second ends of the extended segments of any one group of winding conductor devices 1 are connected to the second ends of the extended segments of a group of winding conductor devices.
[0147] Specifically, the first end of the extension segment 104 is connected to the second end of the slot segment 102, and the second end of the extension segment 104 is connected to the second end of the extension segment 107 of the adjacent winding conductor device 1; the first end of the extension segment 107 is connected to the second end of the slot segment 105, and the second end of the extension segment 107 is connected to the second end of the extension segment 104 of the adjacent winding conductor device 1.
[0148] The second end of the extension segment 104 is connected to the extension segment 107 of the adjacent winding conductor device 1, and the second end of the extension segment 107 is connected to the extension segment 104 of the adjacent winding conductor device 1. The connection can be fixedly connected by laser welding so that the adjacent winding conductor devices 1 are connected to each other to form a winding.
[0149] In one embodiment, if Fig.18 , Fig.19 , Fig. 20 , Fig.21 As shown, the torsion section 101 is in an inverted V-shape and can be bent toward the outside of the motor rotor or stator 2 . By bending toward the outside of the motor rotor or stator 2 , multiple groups of winding conductor devices 1 can be sequentially arranged in the line slots 201 .
[0150] The motor assembly space and performance must be considered during the motor winding design process, so the torsion segment 101 should be compressed as much as possible and ensure that there is no interference between the winding conductor devices 1. In order to avoid interference between the winding conductor devices 1 and ensure the possibility of forming the winding conductor device 1, the upper layer of the torsion segment 101 is bent toward the outside of the motor. This structure can increase the gap at the bend of the torsion segment 101 and reduce the feasibility of interference.
[0151] In one embodiment, a method for manufacturing a motor winding comprises the following steps:
[0152] 1) The enameled wire is twisted into large strands of Litz wire in steps, and then pressed and heated through a mold to form a square Litz wire.
[0153] 2) The two ends of the square Litz wire are welded to the flat copper bus conductor to form a combined conductor.
[0154] 3) Process the combined conductor into a U-shaped hairpin.
[0155] 4) Wrap the U-shaped hairpin around the insulation layer.
[0156] 5) Insert the U-shaped hairpin into the iron slot of the motor stator and expand the legs of the hairpin flat copper bar segment.
[0157] 6) Weld the ends of the U-shaped hairpin legs to form the three-phase winding of the motor.
[0158] In particular: steps 2 and 3 can be interchanged in manufacturing order, steps 3 and 4 can be interchanged in manufacturing order, and steps 2 and 4 can be interchanged in order.
[0159] like Fig.23 , Fig.24 , Fig.25 As shown, an embodiment of the utility model further provides a motor, comprising the motor winding according to any one of the above embodiments.
[0160] The motor can be an electric motor, an engine, or an electric generator.
[0161] An embodiment of the utility model further provides a vehicle, comprising the motor according to any one of the above embodiments.
[0162] The utility model provides a winding conductor device, a motor winding, a motor and a vehicle, which have the following characteristics:
[0163] The utility model sets the conductor segment in the motor slot as a densely pressed wire, which is composed of multiple strands of tightly fitted conductors. Therefore, the skin effect and proximity effect of the densely pressed wire are significantly reduced, thereby improving the motor speed and efficiency at high speed.
[0164] The utility model improves the conductor composition and structure of the existing flat copper wire hairpin, so that the conductor segment of the hairpin in the motor slot is a square densely pressed wire. The transposition structure of the densely pressed wire and the smaller single conductor cross-sectional area greatly reduce the skin effect and eddy current loss of the stator winding, thereby improving the efficiency and limit performance of the drive motor in a wide speed range.
[0165] The processes and steps described in all the above preferred embodiments are only examples. Unless adverse effects occur, various processing operations can be performed in a sequence different from the sequence of the above processes. The sequence of steps in the above processes can also be increased, merged or deleted according to actual needs.
[0166] In understanding the scope of the present invention, the term "comprising" and its derivatives as used herein are intended to be open terms, which specify the existence of the recorded features, elements, components, groups, wholes and / or steps, but do not exclude the existence of other unrecorded features, elements, components, groups, wholes and / or steps. This concept also applies to words with similar meanings, such as the terms "including", "having" and their derivatives.
[0167] The term "attached" or "attached" as used herein includes: a configuration in which an element is directly fixed to another element by fixing the element directly to the other element; a configuration in which an element is indirectly fixed to another element by fixing the element to an intermediate member, which in turn is fixed to the other element; and a configuration in which one element is integral with another element, that is, one element is substantially a part of the other element. This definition also applies to words with similar meanings, such as "connect", "connect", "couple", "mount", "bond", "fix" and their derivatives. Finally, the degree terms such as "substantially", "approximately" and "approximately" used herein indicate the amount of deviation that modifies the term so that the end result will not be significantly changed.
[0168] Unless otherwise defined, the technical and scientific terms used herein have the same meaning as those generally understood by those skilled in the art of the present invention. The terms used herein are only for describing specific implementation purposes and are not intended to limit the present invention. The features described herein in one embodiment may be applied to another embodiment alone or in combination with other features, unless the feature is not applicable or otherwise specified in the other embodiment.
[0169] The utility model has been described through the above-mentioned embodiments, but it should be understood that the above-mentioned embodiments are only for the purpose of example and description, and are not intended to limit the utility model to the scope of the described embodiments. In addition, it can be understood by those skilled in the art that the utility model is not limited to the above-mentioned embodiments, and more variations and modifications can be made according to the teachings of the utility model, and these variations and modifications all fall within the scope of protection claimed by the utility model.
Claims
1. A winding conductor device, characterized in that: include: The slot entry section is used to be set in the wire slot of the motor rotor or stator. The slot entry section includes a densely pressed wire, which includes a plurality of wires, and the wires are tightly pressed together. The cross-sectional shape of the slot entry section is rectangular.
2. The winding conductor arrangement according to claim 1, characterized in that The cross-sectional shape of the wire is a circle, or the cross-sectional shape of the wire is a regular N-gon, where N≥3.
3. The winding conductor arrangement according to claim 1, characterized in that Also includes: A torsion section, wherein the torsion section is in an inverted V shape and includes two connecting ends; There are two groups of slot-entering segments, and two connecting ends of the torsion segment are respectively connected to the first end of one group of slot-entering segments, so that the winding conductor device is U-shaped.
4. The winding conductor arrangement according to claim 3, characterized in that The torsion section is connected to the slot section in an overlapping structure, and the connecting end of the torsion section overlaps with the first end of the slot section.
5. The winding conductor arrangement according to claim 4, characterized in that The torsion section and the slot entry section are both reduced by half in thickness at the overlapping position for overlapping; Alternatively, the torsion section and the slot entry section are both provided with oblique cuts at the overlapping positions for overlapping.
6. The winding conductor arrangement according to claim 3, characterized in that Also includes: An extension section, wherein a first end of the extension section is connected to a second end of the slot entry section.
7. The winding conductor arrangement according to claim 6, characterized in that The slot entry section is connected to the expansion section in an overlapping structure, and the second end of the slot entry section and the first end of the expansion section overlap each other.
8. The winding conductor arrangement according to claim 7, characterized in that The groove entry section and the expansion section are both reduced by half in thickness at the overlapping position for overlapping; Alternatively, the slot entry section and the expansion section are both provided with oblique cuts at the overlapping positions for overlapping.
9. The winding conductor arrangement according to claim 6, characterized in that Also includes: A fixing piece, wherein the fixing piece is sleeved on a connecting section between the torsion section and the slot entry section, and / or the fixing piece is sleeved on a connecting section between the slot entry section and the expansion section.
10. The winding conductor arrangement according to claim 3, characterized in that Also includes: An insulating layer at least covers the torsion section and the slot section.
11. The winding conductor arrangement according to claim 6, characterized in that The twisting section and / or the expansion section comprises a single or multiple flat copper wires; Alternatively, the torsion section comprises a tightly pressed wire, which comprises a plurality of conductive wires which are tightly pressed together.
12. The winding conductor arrangement according to claim 11, characterized in that A plurality of the flat copper wires are arranged along the height direction of the torsion section and / or the expansion section; Alternatively, a plurality of the flat copper wires are arranged along the thickness direction of the torsion section and / or the expansion section.
13. The winding conductor arrangement according to claim 3, characterized in that The torsion section comprises: a first twisting portion, the first twisting portion connecting the first group of the slot-entering segments; a third twisting portion, the third twisting portion being connected to the second group of slot-entering segments; a second torsion portion, the second torsion portion connecting the first torsion portion and the third torsion portion; The first twisting portion, the second twisting portion, and the third twisting portion are all bent at a preset angle.
14. A motor winding, characterized in that: Comprising a winding conductor arrangement according to any one of claims 1-13.
15. The motor winding according to claim 14, characterized in that: include: There are multiple groups of winding conductor devices, and the second ends of the extended segments of any group of winding conductor devices are connected to the second ends of the extended segments of an adjacent group of winding conductor devices.
16. The motor winding according to claim 14, characterized in that: The torsion section of the winding conductor arrangement is bent toward the outside of the rotor or stator of the electric machine.
17. A motor, characterized in that: Comprising a motor winding according to any one of claims 14-16.
18. A vehicle, characterized in that: Comprising an electric machine according to claim 17.