Stator winding structure of flat wire automobile driving motor

Abstract

The stator winding structure of the flat wire automobile driving motor comprises a stator iron core, a plurality of stator grooves are distributed on the stator iron core along the circumferential direction at intervals, concentric flat wire windings are arranged in the stator grooves, the concentric flat wire windings comprise conductors distributed in the stator grooves, and the conductors are arranged in the stator grooves. Any stator slot is internally provided with an odd number or an even number of conductors, the end part of any conductor is provided with a torsion head structure, and the maximum gap between the bevel edges of the torsion head structures of any two adjacent conductors on the same layer is smaller than or equal to 0.6 mm. On the basis of the existing Hair-pin process, by optimizing winding forming, head twisting, welding and the like, namely U-mini-PIN technology, the height of the welding end of the winding is greatly reduced, compared with a Hair-pin motor of the same model, the height of the welding end is reduced by 10-30%, the height of the corolla end is reduced by 10-20%, the use amount of copper wires is reduced, the manufacturing cost is reduced, and the production efficiency is improved. And the light-weight manufacturing requirement of the product is met.

Description

Technical Field

[0001] The utility model relates to the field of machinery, in particular to motors, and especially to a stator winding structure of a flat wire automotive drive motor. Background Art

[0002] With the rapid development of the new energy vehicle industry, the continuous update and iteration of technology have always been the main driving force for the rapid development of the new energy vehicle industry. As the core component of new energy vehicles, the drive motor provides the power source for the whole vehicle and has received extensive attention.

[0003] The main requirements of the whole vehicle for the drive motor are high efficiency, high power density, low cost, and low NVH. The flat wire winding technology meets the above four requirements in terms of slot fill factor, thermal conductivity, armature rigidity, and automated production. Currently, the three winding methods of I-PIN winding, Hair-pin winding, and W-PIN winding are commonly used in the industry. Among them, the I-PIN winding forming method is the simplest, but both ends of the winding need to be welded, which requires high welding technology and manufacturing beat. Compared with Hair-pin, the beat is doubled. The W-PIN winding adopts the method of continuous winding of the winding, eliminating the welding of the end windings, but also greatly increasing the process difficulty of winding forming and wire insertion.

[0004] The Hair-pin winding is in the form of one-end forming and the other-end welding, inheriting the advantages of I-PIN and W-pin windings, and at the same time reducing the technical difficulty of winding forming and welding. Therefore, it is widely used in new energy flat wire motors. However, the windings in the prior art have the following problems:

[0005] 1. In the existing Hair-pin manufacturing technology, the straight section of the welded end is relatively long, resulting in a high height of the welded end of the winding, high copper wire material cost, and large product size, which does not meet the future requirements of lightweight motor manufacturing;

[0006] 2. In the X-PIN type products on the market, the straight section of the stator winding end is removed, resulting in a smaller electrical clearance and creepage distance of the winding, poorer product reliability and durability, and increasing the failure risk in the application of high-voltage platform products;

[0007] 3. The winding connection form is not flexible enough, and the complexity of winding bridging is relatively large;

[0008] 4. The arrangement of the winding in the motor stator is not tight enough. Summary of the Invention

[0009] The utility model aims to provide a flat wire automobile drive motor stator winding structure, which solves the technical problems in the prior art that the height of the winding welding end is high, the electrical clearance and creepage distance are small, the winding cross-connection is complex, and the winding is not arranged tightly enough in the motor stator.

[0010] The utility model discloses a flat wire automobile drive motor stator winding structure, comprising a stator core, wherein a plurality of stator slots are spaced apart along a circumferential direction on the stator core, and concentric flat wire windings are arranged in the stator slots. The concentric flat wire windings include conductors distributed in the stator slots, and an odd number or an even number of conductors are arranged in any stator slot, and a twist structure is arranged at the end of any conductor, and the maximum gap between the oblique sides of the twist structures of any two adjacent conductors in the same layer is less than or equal to 0.6 mm.

[0011] Furthermore, the bare copper length of any one conductor welding end is 2-5 mm.

[0012] Furthermore, the penetration depth of the solder joint at the soldered end of the conductor is at least 0.7 times the thickness of the bare copper.

[0013] Furthermore, the gap between the two conductor ends at the same welding point in the radial direction of the iron core is less than or equal to 0.3 mm, and the offset distance in the circumferential direction is less than or equal to 0.3 mm.

[0014] Furthermore, the pins of the conductor are provided with a paint film.

[0015] Furthermore, the paint film covers the bend of the molding, and takes the junction of the bend of the molding and the straight line segment as the starting point, and extends along the straight line segment to a length of 0.5 to 1.5 mm.

[0016] Compared with the prior art, the utility model has positive and obvious effects.

[0017] 1. Based on the existing Hair-pin process, the utility model optimizes the winding forming, twisting and welding, i.e., the U-mini-PIN technology, to achieve a significant reduction in the height of the winding welding end. Compared with the same type of Hair-pin motor, the height of the welding end is reduced by 10-30%, and the height of the corolla end is reduced by 10-20%, which reduces the amount of copper wire used, reduces the production cost, and meets the purpose of lightweight manufacturing of products;

[0018] 2. The utility model reduces the phase resistance of the flat wire drive motor by about 3% by reducing the height of the winding end, improves the maximum efficiency by about 0.03%, and improves the high efficiency range of ≥90% by about 0.5%;

[0019] 3. Products using the above-mentioned U-mini-PIN technology have larger electrical clearance and creepage distance, which is more suitable for high-voltage products of 800V and above. At the same time, the solder joint penetration depth and fusion area are larger, and the solder joint strength is 20~40% higher than that of general solder joints, which improves product reliability;

[0020] 4. The welding pass rate of the product of the utility model is more than 90%. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 The utility model is a schematic diagram of a stator winding structure of a flat wire automobile drive motor.

[0022] Figure 2 The utility model is a schematic diagram of a conductor and welding tooling in a stator winding structure of a flat wire automobile drive motor.

[0023] Figure 3 The utility model is a schematic diagram of a twisting head structure in a stator winding structure of a flat wire automobile drive motor.

[0024] Figure 4 The utility model is a schematic diagram of a straight bare copper in a stator winding structure of a flat wire automobile drive motor.

[0025] Figure 5 for Figure 4 A partial enlarged schematic diagram of .

[0026] Figure 6 This is a first schematic diagram of the end of a twisting structure in a stator winding structure of a flat wire automobile drive motor of the utility model.

[0027] Figure 7 This is a second schematic diagram of the end of the twisting head structure in the stator winding structure of a flat wire automobile drive motor of the utility model.

[0028] Figure 8 The utility model is a schematic diagram of welding points of a flat wire automobile drive motor stator winding structure.

[0029] Figure 9 The utility model is a schematic diagram of conductor welding misalignment in a stator winding structure of a flat wire automobile drive motor. DETAILED DESCRIPTION

[0030] The present invention is further described below in conjunction with an embodiment, but the present invention is not limited to the embodiment. Any similar structure and similar changes of the present invention should be included in the protection scope of the present invention. The use of directions such as up, down, front, back, left, and right in the present invention is only for the convenience of clear description and is not a limitation on the technical solution of the present invention.

[0031] likeFigures 1-9 As shown, a flat wire automobile drive motor stator winding structure of the utility model comprises a stator core 1, a plurality of stator slots are spaced apart along the circumferential direction on the stator core 1, a concentric flat wire winding 5 is arranged in the stator slot, the concentric flat wire winding 5 comprises conductors 2 distributed in each stator slot, an odd or even number of conductors 2 are respectively arranged in any stator slot, a twist structure 11 is arranged at the end of any conductor 2, and the maximum gap 10 between the oblique sides of the twist structure 11 of any two adjacent conductors 2 in the same layer is less than or equal to 0.6 mm.

[0032] Concentric winding 5 is a type of arrangement of motor stator windings, which arranges the conductors of all stator slots in circles with the same center and different radii to form a multi-layer concentric circle structure;

[0033] This embodiment shows that the winding connection form of the utility model is more flexible, reduces the complexity of the winding cross-connection, achieves a reduction in the height and cost of the winding ends, and also reduces the size of the motor to meet the needs of lightweight manufacturing; the utility model optimizes the existing line type and twist head parameters, so that the winding is arranged more closely in the motor stator, which helps to improve the overall performance of the motor.

[0034] During welding, a straight bare copper 3 of 2-5 mm in length is reserved at the welding end of any conductor 2. After welding, a welding point 6 with a penetration depth 12 ≥ 0.7 times the bare copper thickness 13 can be obtained, which ensures welding strength and a sufficiently large conduction area. At the same time, the larger electrical clearance and creepage distance of the original U-PIN winding are retained. The product reliability and durability are higher than those of the same model X-PIN.

[0035] The wire feet of the conductor 2 are provided with a paint film 4. The paint film 4 can increase the creepage distance and improve the insulation performance of the motor.

[0036] The paint film 4 should completely cover the bend of the copper wire without any damage. The paint film 4 starts at the junction of the bend 14 of the wire leg and the straight line segment 15 and extends along the straight line segment 15 for 0.5 to 1.5 mm, and the remaining straight line segment is bare copper.

[0037] Effects of paint film 4: 1. Ensure uniformity of gaps between solder joints along the circumferential direction of the winding; 2. Prevent paint film 4 from being too low, which may reduce creepage distance of wire pins; 3. Ensure reliability of insulation performance of the motor from the perspective of product manufacturing.

[0038] Specifically, the stator core 1, stator slots, conductors 2, twist structure 11, straight bare copper 3, paint film 4, etc. in this embodiment all adopt well-known solutions in the prior art, which are well understood by those skilled in the art and will not be described in detail here.

[0039] Manufacturing process of this embodiment:

[0040] 1. Wire forming: Automatically make U-PIN through wire forming die and equipment;

[0041] 2. Wire insertion: Automatically insert PIN wire into the iron core through equipment;

[0042] 3. Twisting: Twist the welded end of the PIN wire through twisting equipment;

[0043] 4. Flattening: Flatten the welded end of the PIN wire through flattening equipment. After flattening, the surface of the wire foot is smooth and free of burrs;

[0044] 5. Welding: Clamp the PIN wire with welding tooling 7 and achieve self-fusion connection between the PIN wires through laser welding to obtain qualified laser solder joints.

[0045] The utility model can be paired with customized welding tooling 7 and adopts two manufacturing methods: first flatten the wire feet, then install the fixture and weld, or first install the welding fixture and then flatten the wire feet and weld, which reduces the welding manufacturing difficulty. As Figure 9 shown, the welding fixture clamps and aligns the wire feet of the conductor 2 in the radial and circumferential directions, ensuring that the gap 9 between the ends of the two conductors along the radial direction of the iron core is ≤ 0.3 mm, and the misalignment distance 8 along the circumferential direction is ≤ 0.3 mm.

[0046] Advantages of the utility model:

[0047] 1. Based on the existing Hair-pin process, the utility model optimizes winding forming, twisting, welding, etc., that is, U-mini-PIN technology, realizes a significant reduction in the height of the welding end of the winding. Compared with the Hair-pin motor of the same model, the height of the welding end is reduced by 10 - 30%, and the height of the corolla end is reduced by 10 - 20%, reducing the copper wire consumption, achieving the purpose of reducing the manufacturing cost, and meeting the requirements of product lightweight manufacturing;

[0048] 2. By reducing the height of the winding end, the utility model reduces the phase resistance of the flat wire drive motor by about 3%, increases the maximum efficiency by about 0.03%, and increases the high-efficiency interval of ≥ 90% by about 0.5%;

[0049] 3. The product adopting the above U-mini-PIN technology has larger electrical clearance and creepage distance, is more suitable for the requirements of high-voltage products of 800V and above. At the same time, the melt depth and fusion area of the solder joint are larger, and the solder joint strength is 20 - 40% higher than that of general solder joints, improving the product reliability;

[0050] 4. The first-pass welding qualification rate of the product of the utility model reaches more than 90%.

Claims

1. A flat wire automobile drive motor stator winding structure, characterized in that: The invention comprises a stator core, wherein a plurality of stator slots are spaced apart along the circumferential direction on the stator core, and concentric flat wire windings are arranged in the stator slots. The concentric flat wire windings comprise conductors distributed in the stator slots, and an odd number or an even number of conductors are arranged in any stator slot, and a twist structure is arranged at the end of any conductor, and the maximum gap between the oblique sides of the twist structures of any two adjacent conductors in the same layer is less than or equal to 0.6 mm.

2. The flat wire automobile drive motor stator winding structure according to claim 1 is characterized in that: The bare copper length of any conductor welding end is 2-5mm.

3. The flat wire automobile drive motor stator winding structure according to claim 1, characterized in that: The penetration depth of the solder joint at the end of the conductor shall be at least 0.7 times the thickness of the bare copper.

4. The flat wire automobile drive motor stator winding structure according to claim 1, characterized in that: The gap between the two conductor ends at the same welding point along the radial direction of the iron core is less than or equal to 0.3 mm, and the offset distance along the circumferential direction is less than or equal to 0.3 mm.

5. The flat wire automobile drive motor stator winding structure according to claim 1, characterized in that: The pins of the conductor are provided with a paint film.

6. A flat wire automobile drive motor stator winding structure according to claim 5, characterized in that: The paint film covers the bend of the molding, and takes the junction of the bend of the molding and the straight line segment as the starting point, and extends along the straight line segment for a length of 0.5 to 1.5 mm.

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