Flat wire motor stator, flat wire motor, power assembly and electric vehicle

Abstract

The utility model relates to the technical field of motors, in particular to a flat wire motor stator with ends converged through flat wires, a flat wire motor, a power assembly and an electric vehicle. The flat wire motor stator comprises a stator core and a flat wire winding, the stator core comprises two axial end faces, the flat wire winding comprises a plurality of flat wires, and each flat wire comprises more than four straight line segments, at least one cross line segment and two lead segments. One ends of the two lead wire sections are respectively used for connecting one ends of the two straight line sections in the two different winding grooves or the other ends of the two straight line sections in the two different winding grooves, and the other end of each lead wire section is used for directly welding the other end of one lead wire section in the other flat wire to form a confluence end; and each confluence end is used for transmitting one phase of alternating current or is used as a neutral connecting end of the flat wire winding. The end windings of the flat wire motor are converged through the flat wires, an automatic process and low-cost manufacturing can be realized, the axial size of the flat wire motor can be reduced, and the safety is improved.

Description

Technical Field

[0001] The present application relates to the technical field of motors, and particularly to a flat wire motor stator, a flat wire motor, a power assembly, and an electric vehicle in which the ends are connected by flat wire busbars. Background Art

[0002] At present, the drive motors of electric vehicles usually adopt flat wire windings to improve the slot fill factor. During the manufacturing process of flat wire windings, the I-pin and U-pin methods are generally used to insert into the stator core along the axial direction of the stator and then turn and weld, and are connected by busbars for busbar connection. This busbar connection structure will occupy the axial dimension of the motor, the manufacturing process is complex and difficult, and there are certain safety risks due to the large weight. Summary of the Utility Model

[0003] The present application provides a flat wire motor stator, a flat wire motor, a power assembly, and an electric vehicle in which the ends of the flat wire windings are connected by flat wire busbars, which can realize automated processes and low-cost manufacturing, and can also reduce the axial dimension of the flat wire motor and improve safety.

[0004] In a first aspect, the present application provides a flat wire motor stator in which the ends of the flat wire windings are connected by flat wire busbars. The flat wire motor stator includes a stator core and flat wire windings. The stator core includes two axial end faces. The flat wire windings include multiple flat wires. Each flat wire includes: more than four straight segments, at least one cross segment, and two lead segments. Among them, each straight segment is used to be embedded in a winding slot of the stator core. One end of each straight segment faces one axial end face of the stator core, and the other end of each straight segment faces the other axial end face of the stator core; each cross segment exposes one or the other axial end face of the stator core, and both ends of each cross segment are respectively used to connect one end of two straight segments in two different winding slots or the other ends of two straight segments in two different winding slots. The two lead segments expose one axial end face of the stator core. The axial length of each lead segment exposed on one axial end face is greater than the axial length of each cross segment exposed on one or the other axial end face. One end of each of the two lead segments is respectively used to connect one end of two straight segments in two different winding slots or the other ends of two straight segments in two different winding slots. The other end of each lead segment is used to directly weld the other end of a lead segment in another flat wire to form a busbar connection end. Each busbar connection end is used to transmit a three-phase alternating current or to be used as a neutral connection end of the flat wire windings.

[0005] In the above-mentioned flat wire motor stator, each lead segment of the flat wire winding is used to weld the lead segments of other flat wires to achieve the current collection connection of the flat wire winding, saving the current collection structure and eliminating the need for additional workstations for assembly and welding. This can improve the degree of manufacturing automation and reduce production costs. At the same time, this flat wire motor stator has a smaller axial dimension and weight, making it easier to miniaturize the motor. The reliability of the flat wire solder joints is less affected by vibration and shock, and the safety of the flat wire motor is also improved.

[0006] In some embodiments, each lead segment includes a radial segment and an axial segment, and the axial segment is used to connect the radial segment and the straight segment; along the axial direction of the stator, the radial segments of each lead segment exposed on the same axial end face of the stator core are arranged at intervals from any one of the crossover segments. The radial segment avoiding the crossover segment of the flat wire allows the lead segment to extend along the radial and circumferential directions of the flat wire motor stator to connect to other lead segments.

[0007] In some embodiments, one end of the radial segment of the lead segment away from the axial segment includes a welding end protruding along the axial direction of the stator, and the welding end is used to weld other lead segments. Among them, the welding end includes a welding surface, the welding surface is parallel to the axial direction of the stator and perpendicular to the radial direction of the stator, and the two lead segments can be welded along the radial direction of the stator, which can reduce the influence of the welding of the two lead segments on the axial dimension of the stator.

[0008] Among them, along the axial direction of the stator, the axial dimension of the welding surface is smaller than the axial dimension of the welding end; along the circumferential direction of the stator, the circumferential dimension of the welding surface is smaller than the circumferential dimension of the welding end. The welding surface is a part of the surface of the welding end, and the smaller welding surface can reduce the influence of vibration and shock.

[0009] In some embodiments, the lead segment further includes a bending segment, and the bending segment is connected between the axial segment and the straight segment; along the radial direction of the stator, the axial segment is arranged at intervals from any one of the crossover segments. The bending segment can lead the lead segment to the radial outside of the flat wire winding to avoid the crossover segment.

[0010] In some embodiments, with one axial end face as a reference, along the axial direction of the stator, the axial length of the exposed axial segment is greater than the axial length of any one of the crossover segments, so as to lead the lead segment to the axial outside of the flat wire winding to avoid the crossover segment.

[0011] In some embodiments, along the radial direction of the stator, the straight segment connected to one of the two lead segments is arranged on the bottom layer of a winding slot of the stator core, and the straight segment connected to the other of the two lead segments is arranged on the top layer of another winding slot of the stator core.

[0012] In some embodiments, the layers of the two straight segments connected by each crossover segment in the two winding slots of the stator core are different, which can achieve the crossover of the flat wire. The two winding slots where the two straight segments connected by each crossover segment are located are spaced 8 winding slots apart.

[0013] In some embodiments, the flat wire winding includes a multi-phase winding, each phase winding corresponding to one phase of electricity, and each phase winding includes a plurality of parallel flat wires; along the circumferential direction of the stator, the straight segments of the plurality of flat wires of the same phase are arranged in a staggered manner, and the cross segments of the plurality of flat wire windings of the same phase are arranged in a staggered manner; along the radial direction of the stator, a plurality of straight segments are arranged adjacent to each other in each winding slot of the stator core; along the axial direction of the stator, the two lead segments of the plurality of flat wires of the multi-phase winding are exposed on the same axial end face of the stator core. The multi-phase windings of the flat wire winding can be circuit-connected by flat wire busbar connection on one side of the same axial end face.

[0014] In some embodiments, along the radial direction of the stator, the other end of a lead segment of a flat wire is arranged adjacent to and connected to the other end of a lead segment of another flat wire of the same phase to form a busbar end for connecting the phase electricity, and the other end of another lead segment of a flat wire winding is arranged adjacent to and connected to the other end of a lead segment of a flat wire of another phase to form a busbar end for neutral connection. Among them, the busbar end for neutral connection can be used for star connection or delta connection.

[0015] Among them, in the same phase winding, the straight segment connected by a lead segment of a flat wire and the straight segment connected by a lead segment of another flat wire connected thereto are located in the same winding slot and are arranged at intervals along the radial direction of the stator.

[0016] In some embodiments, along the circumferential direction of the stator, the different winding slots where the two lead segments of each flat wire are respectively connected are separated by 8 winding slots.

[0017] In a second aspect, the present application provides a flat wire motor. The flat wire motor provided by the present application includes a motor rotor, a motor shaft, and a flat wire motor stator as provided in the first aspect. The stator core is sleeved on the motor rotor, and the motor rotor is sleeved and fixed on the motor shaft. The flat wire motor has a smaller axial dimension and weight, can be automated in the manufacturing process, and also has a lower manufacturing cost.

[0018] In a third aspect, the present application provides a powertrain. The powertrain provided by the present application can be applied to an electric vehicle to provide power for the electric vehicle. The powertrain includes any one of a reducer or a transmission and a flat wire motor as in the second aspect and any of its embodiments, and the motor shaft of the flat wire motor is used for driving connection with the input shaft of the reducer or the input shaft of the transmission. For the beneficial effects of the powertrain provided by the present application, please refer to the descriptions of the first aspect and the second aspect and their embodiments above, and will not be elaborated here.

[0019] Fourthly, the present application provides an electric vehicle, which includes wheels, a transmission mechanism, and a power assembly as provided in the above third aspect. The power assembly drives the wheels to rotate through the transmission mechanism. For the beneficial effects of the electric vehicle provided in the present application, please refer to the descriptions of the above first aspect to the third aspect and their embodiments, and details will not be repeated here. Description of the Drawings

[0020] Figure 1 Schematic structural diagram of an electric vehicle provided by an embodiment of the present application;

[0021] Figure 2 Schematic structural diagram of a power assembly provided by an embodiment of the present application;

[0022] Figure 3a Schematic structural diagram of a flat wire motor stator provided by an embodiment of the present application;

[0023] Figure 3b Schematic structural diagram of a flat wire motor stator provided by an embodiment of the present application;

[0024] Figure 3c Exploded view of a flat wire motor stator provided by an embodiment of the present application;

[0025] Figure 4 Schematic structural diagram of the flat wire of a flat wire motor stator provided by an embodiment of the present application;

[0026] Figure 5a Partial schematic structural diagram of a flat wire motor stator provided by an embodiment of the present application;

[0027] Figure 5b is Figure 5a Detail enlarged view at V1 in;

[0028] Figure 5c Partial schematic structural diagram of a flat wire motor stator provided by an embodiment of the present application;

[0029] Figure 6 Schematic structural diagram of the lead segment of a flat wire motor stator provided by an embodiment of the present application;

[0030] Figure 7a Schematic structural diagram of the wire section of a flat wire motor stator provided by an embodiment of the present application;

[0031] Figure 7b Schematic structural diagram of the lead section of a flat wire motor stator provided by an embodiment of the present application;

[0032] Figure 7c Schematic structural diagram of the flat wire of a flat wire motor stator provided by an embodiment of the present application;

[0033] Figure 8a Schematic diagram of the structure of the same-phase winding of a flat wire motor stator provided by an embodiment of the present application;

[0034] Figure 8b Partial schematic diagram of the structure of a flat wire motor stator provided by an embodiment of the present application;

[0035] Figure 8c Partial schematic diagram of the structure of a flat wire motor stator provided by an embodiment of the present application;

[0036] Figure 8d Partial schematic diagram of the structure of a flat wire motor stator provided by an embodiment of the present application;

[0037] Figure 9a Partial schematic diagram of the structure of a flat wire motor stator provided by an embodiment of the present application;

[0038] Figure 9b Partial schematic diagram of the structure of a flat wire motor stator provided by an embodiment of the present application;

[0039] Figure 10a Schematic diagram of the structure of the flat wire winding of a flat wire motor stator provided by an embodiment of the present application;

[0040] Figure 10b For Figure 10a Detail enlarged view at V2 in;

[0041] Figure 10c For Figure 10a Detail enlarged view at V3 in;

[0042] Figure 11 Partial schematic diagram of the structure of the flat wire winding of a flat wire motor stator provided by an embodiment of the present application.

[0043] Reference numerals:

[0044] 1000 - Powertrain; 2000 - Transmission mechanism; 3000 - Wheel; 100 - Flat wire motor; 200 - Reducer; 10 - Flat wire motor stator; 20 - Rotor; 30 - Motor shaft; 40 - Housing; 1 - Stator core; 11 - Stator tooth; 12 - Winding slot; 13 - Outer ring; 2 - Flat wire winding; 21 - Straight segment; 22 - Cross segment; 23, 23a, 23b, 23m, 23m1, 23m2, 23n, 23n1, 23n2 - Lead segment; 231 - Bending segment; 232 - Axial segment; 233 - Radial segment; 201 - Conductor section; 2011 - Conductor cross-over part; 2012 - Conductor straight part; 2013 - Conductor connection part; 202 - Lead section; 2021 - Lead cross-over part; 2022 - Lead straight part; 2023 - Lead connection part; 2024 - Lead extraction part; 3 - Insulating paper. Detailed implementation manners

[0045] The flat wire winding of the flat wire motor in an electric vehicle has a relatively large end height, which will increase the axial dimension of the flat wire motor. In the traditional technology, the end windings of the flat wire winding of the flat wire motor are collected and welded by a bus bar. During the manufacturing process, the shape of the bus bar is complex and requires manual installation, and additional workstations and equipment are needed for welding, making it difficult to achieve automation. The manufacturing of the bus bar itself involves processes such as stamping and injection molding, which will increase the weight of the flat wire motor and the manufacturing cost is relatively high. For the stator winding collected by the bus bar, the solder joints are prone to breakage when the flat wire motor is subjected to vibration and impact, posing a safety risk.

[0046] Based on this, the embodiments of the present application provide a flat wire motor stator, a flat wire motor, a power assembly and an electric vehicle with the end of the flat wire winding collected by a flat wire. The end of the flat wire winding of the flat wire motor stator is collected by a flat wire, which can realize an automated process and low-cost manufacturing, and can also reduce the axial dimension of the flat wire motor and improve safety.

[0047] In order to make the objectives, technical solutions and advantages of the present application clearer, the present application will be further described in detail below with reference to the accompanying drawings.

[0048] Figure 1 It is a schematic diagram of the electric vehicle provided by the embodiment of the present application. Referring to Figure 1 , the electric vehicle provided by the embodiment of the present application includes a power assembly 1000, a transmission mechanism 2000 and a wheel 3000. The power assembly 1000 drives the wheel 3000 through the transmission mechanism 2000. Among them, the power assembly 1000 is used to convert electrical energy into mechanical energy. The transmission mechanism 2000 is used to transmit and connect the power assembly 1000 and the wheel 3000.

[0049] Figure 2 It is a schematic diagram of the power assembly provided by the embodiment of the present application. As Figure 2 shown, the power assembly 1000 provided by the embodiment of the present application includes a flat wire motor 100 and a reducer 200. Among them, the flat wire motor 100 and the reducer 200 are transmission-connected. The flat wire motor 100 is used to drive the transmission mechanism 2000 of the electric vehicle through the reducer 200. In the embodiment of the present application, the reducer 200 is also replaced by a transmission. As Figure 2 shown, the flat wire motor 100 includes a flat wire motor stator 10, a rotor 20, a motor shaft 30 and a housing 40. The motor shaft 30 is used to transmit and connect the reducer 200. The flat wire motor stator 10 includes a flat wire winding 2 and a stator core 1. The flat wire winding 2 is wound around the stator core 1. When the flat wire winding 2 is energized, a magnetic field can be formed in the central hole of the stator core 1, and the rotor 20 can rotate around the axis of the motor shaft 30 in the magnetic field. The power assembly 1000 further includes a controller, and the controller is electrically connected to the flat wire motor 100 and is used to adjust the working state of the flat wire motor 100.

[0050] Figure 3a And Figure 3b are respectively schematic structural diagrams of a flat wire motor stator 10 provided by an embodiment of the present application as observed along the axial direction of the stator. As Figure 3a and Figure 3b shown, the flat wire motor stator 10 includes a stator core 1 and a flat wire winding 2. Along the axial direction of the stator, the stator core 1 includes two axially opposite axial end faces, which are exemplarily the first end face d1 and the second end face d2 respectively. The stator core 1 is annular, and the inner wall of the stator core 1 includes a plurality of stator teeth 11 arranged at intervals along the circumferential direction of the stator. A winding slot 12 is formed between any two adjacent stator teeth 11 along the circumferential direction of the stator, and the flat wire winding 2 is wound around the winding slot 12. An insulating paper 3 is provided in each winding slot 12 to isolate the flat wire winding 2 from the winding slot 12. A part of the flat wire winding 2 is accommodated in a plurality of winding slots 12, and a part protrudes axially from the two axial end faces of the stator core 1 along the axial direction of the stator. Generally, the flat wire winding 2 protruding axially from the axial end face of the stator core 1 along the axial direction of the stator is called an end winding, and the height of the end winding affects the axial dimension of the flat wire motor stator 10.

[0051] Figure 3c shows a partial exploded view of the flat wire motor stator 10. As Figure 3c shown, the flat wire winding 2 and the stator core 1 are arranged along the axial direction of the stator. The stator core 1 is exemplified as an assembled core structure, including an annular outer ring 13 and a plurality of stator teeth 11. The plurality of stator teeth 11 are installed on the inner wall of the outer ring 13 along the circumferential direction of the stator, and a winding slot 12 is formed between any two stator teeth 11. An insulating paper 3 can be provided in each winding slot 12, and the insulating paper 3 is used to isolate the flat wire accommodated in the winding slot 12 from the inner wall of the winding slot 12.

[0052] Among them, the flat wire winding 2 includes a multi-phase winding, and each phase winding includes a plurality of flat wires. Each flat wire can be considered as a continuous wire. The plurality of flat wires included in the flat wire winding 2 need to be connected in parallel at the axial end of the stator core 1 to achieve circuit connection. Referring together to Figure 3a and Figure 3bAs shown in the figure, in the flat wire motor stator 10 provided by the embodiment of the present application, the end winding of the flat wire winding 2 protruding from the first end face d1 is used to lead out the end of the flat wire, and the ends of different flat wires are all led out at the first end face d1 to be connected to other flat wires to achieve current collection. The end winding of the flat wire winding 2 protruding from the second end face d2 is used for cross-wire connection. Specifically, a plurality of flat wires of the flat wire winding 2 are current-collected by welding at the first end face d1, and no other current-collecting structural members are used to realize the circuit connection, which can reduce the connection structure of the end winding of the flat wire winding 2 at the axial end face, thereby being beneficial to reducing the axial dimension of the flat wire motor stator 10 and also reducing the weight of the flat wire motor stator 10. Of course, it is only one implementation manner that a plurality of flat wires of the flat wire winding 2 all lead out wire ends at the first end face d1 for circuit current-collection connection. In the specific winding routing, a part of the flat wires can also lead out wire ends at the second end face d2, which is not shown and described here.

[0053] Next, the structure of the flat wire winding 2 in the embodiment of the present application will be introduced in detail. Among them, the axial direction of the stator, the axial direction of the flat wire motor stator 10, the axial direction of the stator core 1, and the axial direction of the flat wire motor 100 refer to the same direction, the circumferential direction of the stator, the circumferential direction of the flat wire motor stator 10, the circumferential direction of the stator core 1, and the circumferential direction of the flat wire motor 100 refer to the same direction, and the radial direction of the stator, the radial direction of the flat wire motor stator 10, the radial direction of the stator core 1, and the radial direction of the flat wire motor 100 refer to the same direction.

[0054] The above-mentioned flat wire winding 2 includes a plurality of flat wires as Figure 4 shown. A plurality of flat wires are wound around the stator core 1 according to a certain winding rule to form the flat wire motor stator 10. As Figure 4 shown, each flat wire includes more than four straight segments 21, at least one cross segment 22, and two lead segments 23. Each straight segment 21 is used to be embedded in a winding slot 12 of the stator core 1, and both ends of each cross segment 22 are respectively connected to two straight segments 21. A plurality of straight segments 21 are alternately connected by a plurality of cross segments 22. The two lead segments 23 are respectively connected to both ends of the flat wire, and one of the lead segments 23 is used for current introduction, and the other lead segment 23 is used for current export. Taking the two lead segments 23 of a flat wire as an example, one ends of the two lead segments 23 are respectively used to connect one ends of two straight segments 21 in two different winding slots 12 or the other ends of two straight segments 21 in two different winding slots 12. The other end of each lead segment 23 is used to be directly welded to the other end of a lead segment 23 in another flat wire to form a current-collection end, and each current-collection end is used to transmit a three-phase alternating current or be used as the neutral connection end of the flat wire winding 2. The neutral connection end is the end of the flat wire winding 2 for star connection or delta connection.

[0055] Figure 5a An example of the structure of a flat wire wound around the stator core 1 is shown.Figure 5b for Figure 5a A detailed enlarged picture of V1 in the figure. Figure 5a As shown, each straight line segment 21 is embedded in a winding slot 12 of the stator core 1, and the straight line segment 21 is isolated from the winding slot 12 by the insulating paper 3, wherein the straight line segment 21 is hidden and not shown. One end of each straight line segment 21 faces one axial end face of the stator core 1, and the other end of each straight line segment 21 faces another axial end face of the stator core 1. The two ends of each cross-line segment 22 are respectively used to connect one end of two straight line segments 21 in two different winding slots 12 facing the same axial end face. With the first end face d1 of the stator core 1 as a reference, the two lead segments 23 of the flat wire are both exposed to the first end face d1 of the stator core 1. The end of each lead segment 23 away from the straight line segment 21 includes a welding end T for welding other lead segments 23.

[0056] like Figure 5b As shown, two lead segments 23 are exposed from the first end face d1 of the stator core 1 along the axial direction of the stator. Taking one of the lead segments 23 as an example, the lead segment 23 exemplarily includes a bending segment 231, an axial segment 232, and a radial segment 233 connected in sequence, and the bending segment 231 is used to connect one end of a straight segment 21 connected to the lead segment 23 toward the first end face d1. Among them, the axial segment 232 extends along the axial direction of the stator and is arranged adjacent to a plurality of cross-line segments 22 along the radial direction of the stator. The radial segment 233 is arranged adjacent to a plurality of cross-line segments 22 along the axial direction of the stator. One end of the bending segment 231 is connected to the straight segment 21, and the other end extends along the radial direction of the stator toward the outer peripheral surface of the flat wire motor stator 10 to connect to the axial segment 232. The welding end T protrudes from the radial segment 233 along the axial direction of the stator, and the welding end T is used to connect other lead segments 23 to form a bus terminal, or the welding end T can also be used to independently connect the circuit. In the radial direction of the stator, the radial segment 233 can extend in a direction perpendicular to the axial direction of the stator, so that the radial segment 233 occupies as little axial space of the flat wire motor stator 10 as possible. The two straight segments 21 connected by each cross-line segment 22 have different numbers of layers in the two winding slots 12 of the stator core 1, and specifically can differ by 1 layer.

[0057] Please continue to refer to Figure 5b , along the radial direction of the stator, the straight line segment 21 connected to one lead segment 23 of the two lead segments 23 of a flat wire is arranged at the bottom layer of a winding slot 12 of the stator core 1, and the straight line segment 21 connected to the other lead segment 23 is arranged at the notch layer of another winding slot 12 of the stator core 1. Since the straight line segment 21 is embedded in the winding slot 12 and is hidden and cannot be shown, c1 is used to point to the notch layer, and c2 is used to point to the bottom layer of the slot.

[0058] Further references Figure 5cThe structures of the two lead segments 23 shown and the stator core 1 are such that the structures of the two lead segments 23 are different, and there are 8 winding slots 12 arranged between the winding slots 12 where the two straight segments 21 to which the two lead segments 23 are connected are located. For example, if the winding slot 12 where the straight segment 21 connected by one lead segment 23 is located is the No. 1 winding slot, then the winding slot 12 where the straight segment 21 connected by the other lead segment 23 is located is the No. 10 winding slot.

[0059] Of course, the structure of the lead segment 23 may also have other forms and does not necessarily need to include the bent segment 231, the axial segment 232, and the radial segment 233. For example, the lead segment 23 can extend along the axial direction of the stator so that the welding end T protrudes from the cross segment 22, or the lead segment 23 includes the axial segment 232 and the radial segment 233, and the axial segment 232 is connected between the radial segment 233 and the straight segment 21, and the end of the radial segment 233 away from the axial segment 232 forms the welding end T. That is to say, the specific form of the lead segment 23 in the flat wire winding 2 is not limited as long as the welding end T of the lead segment 23 protrudes from the cross segment 22 along the axial direction of the stator. The connection between the multiple flat wires included in the flat wire winding 2 is only achieved by connecting and collecting through the lead segments 23 of each flat wire, saving the current collecting structure, eliminating the need for additional workstations for assembly and welding, improving the degree of manufacturing automation, and reducing production costs. The solder joints between the flat wires are less affected by the vibration and impact of the flat wire motor 100, which can improve the safety of the flat wire motor 100.

[0060] In some embodiments, as Figure 6 shown in a structure of the lead segment 23, the welding end T of the lead segment 23 includes a welding surface t. After the flat wire winding 2 is assembled to the stator core 1, the welding surface t is parallel to the axial direction of the stator. The welding end T of the lead segment 23 is welded to the welding end T of another lead segment 23 along the radial direction of the stator, and the welding surface t on the welding segment T is perpendicular to the radial direction of the stator, which can reduce the influence of the welding of the two lead segments 23 on the axial dimension of the flat wire motor stator 10. Along the axial direction of the stator, the axial dimension of the welding surface t is smaller than the axial dimension of the welding end T. Along the circumferential direction of the stator, the circumferential dimension of the welding surface t is smaller than the circumferential dimension of the welding end T. That is to say, the welding surface t is a part of the outer surface of the welding end T, and the smaller welding surface t can reduce the influence of vibration and impact.

[0061] The flat wire provided in the embodiments of the present application can be formed by bending a single wire, or can be formed by sequentially connecting multiple wire segments. In some embodiments, each flat wire can be obtained by connecting a plurality of Figure 7a shown wire sections 201 and two Figure 7b shown lead sections 202 to form the Figure 7c shown structure.

[0062] As Figure 7aAs shown in the figure, the wire section 201 includes a wire jumper section 2011, two wire straight sections 2012, and two wire connection sections 2013. The two wire straight sections 2012 are respectively connected to both ends of the wire jumper section 2011, and each wire straight section 2012 is connected between the wire jumper section 2011 and a wire connection section 2013. The wire straight section 2012 is used to be embedded in the winding slot 12 of the stator core 1, and the wire straight section 2012 is equivalent to the straight segment 21 of the flat wire winding 2. The wire jumper section 2011 is used to expose the axial end face of the stator core 1, and the wire jumper section 2011 is equivalent to the jumper segment 22 of the flat wire winding 2.

[0063] As Figure 7b shown in the figure, the lead section 202 includes a lead jumper section 2021, two lead straight sections 2022, a lead connection section 2023, and a lead extraction section 2024. The two lead straight sections 2022 are respectively connected to both ends of the lead jumper section 2021. One of the lead straight sections 2022 is connected between the lead jumper section 2021 and a lead connection section 2023, and the other lead straight section 2022 is connected between the lead jumper section 2021 and a lead extraction section 2024. The lead connection section 2023 is used to connect to a wire section 201. The lead straight section 2022 is used to be embedded in the winding slot 12 of the stator core 1, and the lead straight section 2022 is equivalent to the straight segment 21 of the flat wire winding 2. The lead jumper section 2021 is used to expose the axial end face of the stator core 1, and the lead jumper section 2021 is equivalent to the jumper segment 22 of the flat wire winding 2. The end of the lead extraction section 2024 away from the lead straight section 2022 forms a welding end T, and this welding end T is the welding end T of the lead segment 23 of the flat wire winding 2.

[0064] A flat wire formed after connecting two lead sections 202 and multiple wire sections 201 is as Figure 7c shown in the figure. As Figure 7cAs shown, multiple wire segments 201 are connected end to end, and two lead segments 202 are respectively connected to both ends of the flat wire. Between two connected wire segments 201, referring to the area within the virtual coil R1, a wire connection portion 2013 of one wire segment 201 and a wire connection portion 2013 of another wire segment 201 are welded along the radial direction of the stator. These two wire connection portions 2013 are connected to form a cross segment 22 of the flat wire. Taking one of the lead segments 202 as an example, referring to the area within the virtual coil R2, the lead connection portion 2023 of this lead segment 202 and a wire connection portion 2013 of one wire segment 201 are welded along the radial direction of the stator. This wire connection portion 2013 and this lead connection portion 2023 are connected to form a cross segment 22 of the flat wire. For the entire flat wire, the wire cross segments 2011 of all wire segments 201 and the lead cross segments 2021 of the two lead segments 202 all face the same end of the stator core 1 along the axial direction of the stator. The two wire connection portions 2013 are connected to form a cross segment 22 of the flat wire, and the wire connection portion 2013 and the lead connection portion 2023 are connected to form a cross segment 22 of the flat wire, which then face the other end of the stator core 1 along the axial direction of the stator.

[0065] In some embodiments, the flat wire winding 2 includes multi-phase windings, each phase winding corresponding to one phase of electricity, and each phase winding includes multiple parallel flat wires.

[0066] Figure 8a A phase winding included in the flat wire winding 2 is shown, and this phase winding includes two parallel flat wires. As Figure 8a shown, along the axial direction of the stator, the four lead segments 23 of the two flat wires are all on the same side. Exemplarily, the two lead segments 23 at both ends of each flat wire are respectively the lead segment 23a and the lead segment 23b. One lead segment 23a of each flat wire is for current introduction, and the other lead segment 23b is for current export. One lead segment 23a of one flat wire and one lead segment 23a of another flat wire are connected to form a bus bar end, and this bus bar end can be used to connect the phase electricity. The other lead segments 23b of the two flat wires are for star connection or delta connection. Along the circumferential direction of the stator, the multiple straight segments 21 of the multiple flat wires in the same phase are arranged in a staggered manner, and the multiple cross segments 22 of the multiple flat wires in the same phase are arranged in a staggered manner.

[0067] Figure 8b For Figure 8a the structural schematic diagram of assembling the shown phase winding onto the stator core 1. Combining Figure 8a and Figure 8bAs shown, multiple straight segments 21 are embedded in the winding slots 12 of the stator core 1 and are hidden from view. A part of the cross segment 22 exposes one axial end face of the stator core 1 and is connected to one end of two straight segments 21 facing this axial end face, and another part of the cross segment 22 exposes the other axial end face of the stator core 1 and is connected to one end of two straight segments 21 facing this axial end face. The two straight segments 21 connected by each cross segment 22 are respectively embedded in two different winding slots 12 of the stator core 1. Exemplarily, the four lead segments 23 of the two flat wires both expose the first end face d1 of the stator core 1, and the lead segment 23a of one flat wire is welded to the lead segment 23a of the other flat wire to form a bus bar end for connecting the phase electricity. Along the circumferential direction of the stator, each cross segment 22 spans 9 winding slots 12 and is connected to two straight segments 21, and there are 8 winding slots 12 arranged between the winding slots 12 where the two straight segments 21 connected by this cross segment 22 are located.

[0068] In some embodiments, referring to Figure 8c the partial structure of the flat wire winding 2 shown, the welding end T of the lead segment 23m of one flat wire is welded to the welding end T of the lead segment 23n of the other flat wire along the radial direction of the stator. The welding surfaces t of the two welding ends T face each other along the radial direction of the stator and are welded, and the welding surface t is not shown. From Figure 8c it can also be seen that the structures of the lead segments 23 included in the flat wire winding 2 can be different. Exemplarily, the lead segment 23m of one flat wire includes an axial segment 232 and a radial segment 233, and the lead segment 23m of the other flat wire includes a radial segment 233. The specific structure of the lead segment 23 is not limited, as long as the circuit bus bar of the flat wire winding 2 is realized by connecting the lead segments 23 of different flat wires at the axial end of the flat wire motor stator 10.

[0069] As Figure 8d shown in the structure of the lead-out segments 23 of two flat wires of the same phase and the stator core 1, the two lead-out segments 23 of one flat wire are respectively the lead-out segment 23m1 and the lead-out segment 23m2, and the two lead-out segments 23 of the other flat wire are respectively the lead-out segment 23n1 and the lead-out segment 23n2. The lead-out segment 23m1 is welded to the lead-out segment 23n1, and the straight segment 21 connected to the lead-out segment 23m1 and the straight segment 21 connected to the lead-out segment 23n1 are located in the same winding slot 12 and are arranged at intervals along the radial direction of the stator.

[0070] Figure 9a It is a schematic structural diagram of a phase winding wound around the stator core 1 when observing along the radial direction of the stator. As Figure 9a shown, along the axial direction of the stator, with reference to the first end face d1, the axial length H2 of each lead segment 23 exposed on the first end face d1 is greater than the axial length H1 of each cross segment 22 exposed on the first end face d2. The axial lengths H2 of each lead segment 23 exposed on the first end face d1 can be the same or different.Figure 9a The axial lengths H2 of different lead segments 23 in Figure 9a exposed on the first end face d1 are different. Taking the circumferential length H2 of one lead segment 23 exposed on the first end face d1 as an example, it is compared with the axial length H1 of the cross segment 22 exposed on the first end face d1. Such a structural design enables the lead segment 23 of a flat wire to span multiple cross segments 22 along the radial or circumferential direction of the stator to connect the lead segment 23 of another flat wire to form a current collecting end, realizing the current collection of different flat wire windings 2. For the flat wire motor 100 provided by the embodiments of the present application, the flat wire windings 2 can be directly connected through the end windings to realize current collection, without the need to rely on an additional current collecting structure, reducing the structural components of the stator 10 of the flat wire motor. The direct welding of the flat wires occupies less space, and the end size of the flat wire winding 2 can be reduced in the axial direction of the stator 1, and thus the axial size of the flat wire motor 100 can be reduced.

[0071] Figure 9b shows Figure 9a partial detailed structures in Figure 9a . As Figure 9b shown, one lead segment 23 of one flat wire includes a bent segment 231, an axial segment 232, and a radial segment 233. Along the radial direction of the stator, the axial segment 232 is arranged outside the cross segment 22. Along the axial direction of the stator, the radial segment 233 is arranged on the side of the multiple cross segments 22 away from the first end face d1. One end of the bent segment 231 is connected to the straight segment 21 embedded in the winding slot 12 of the stator core 1, and the other end extends along the radial direction of the stator to the outer peripheral surface of the stator core 1 and is connected to the axial segment 232, so that the axial segment 232 can avoid the cross segment 22. Along the axial direction of the stator, the end of the axial segment 232 away from the first end face d1 protrudes from the end of the cross segment 22 away from the first end face d1, so that the radial segment 233 can avoid the cross segment 22.

[0072] Taking a three-phase two-branch star-connected motor 100 as an example, the flat wire winding 2 of the motor 100 is as Figure 10a shown in Figure 10a . The flat wire winding 2 includes 6 flat wires, each flat wire includes two lead-out segments 23, a total of 12 lead-out segments 23, and the 12 lead-out segments 23 are located on the same side along the axial direction of the stator. Each phase winding includes two parallel flat wires, and the lead segment 23 of one flat wire is welded to the lead segment 23 of the other flat wire for connecting the phase electricity.

[0073] Figure 10b is Figure 10a a detailed enlarged view of the V2 position in Figure 10a . As Figure 10b shown, the straight segments 21 included in multiple flat wires are arranged at intervals along the circumferential direction of the stator into multiple groups, and each group includes 6 straight segments 21 arranged along the radial direction of the stator, and the 6 straight segments 21 are used to be embedded in the same winding slot 12. Figure 10bSix straight segments 21 for being embedded in the same winding slot 12 are exemplified. Among them, the straight segment 21 located at the bottom of the winding slot 12 is in the first layer, and the straight segments 21 located at the slot opening of the winding slot 12 are arranged in the sixth layer. The direction from the bottom of the winding slot 12 to the slot opening, that is, the direction in which the six straight segments 21 point from the first layer to the sixth layer. Along the axial direction of the stator, in some structures of the end part of the flat wire winding 2, for one flat wire, among the multiple wire segments 201 it includes, one wire connection part 2013 is welded to another wire connection part 2013 along the radial direction of the stator, and the two wire connection parts 2013 are connected to form a cross-wire part 22 of one flat wire. After winding the flat wire winding 2 around the stator core 1, along the radial direction of the stator, six straight segments 21 are arranged adjacent to each other in each winding slot 12 of the stator core 1. Along the axial direction of the stator, all the lead segments 23 included in the multiple flat wires of the polyphase winding are exposed on the same axial end face of the stator core 1.

[0074] Figure 10c It is Figure 10a a detailed enlarged view at V3 in. As Figure 10c shown, taking two parallel flat wires of one-phase winding as an example, the welding end T11 of the lead segment 23 of one flat wire is welded to the welding end T12 of the lead segment 23 of another flat wire along the radial direction of the stator, and the welding end T11 and the welding end T12 are welded to form a busbar end, which realizes the parallel busbar connection between the flat wires of the same phase. This busbar end is used to connect the phase electricity. For a three-phase winding, the welding end T21 of a lead segment 23 of the first-phase winding, the welding end T22 of a lead segment 23 of the second-phase winding, and the welding end T23 of a lead segment 23 of the third-phase winding are arranged and welded in sequence along the radial direction of the stator to form a busbar end, and this busbar end can realize the star connection of the three-phase winding.

[0075] Figure 11 It shows a busbar structure of a three-phase two-branch star-connected flat wire winding 2. As Figure 11As shown, the flat wire winding 2 includes six flat wires in three phases, each flat wire includes two lead wire segments 23, and each lead wire segment 23 includes a welding end T, that is, each phase winding includes four welding ends T. A plurality of lead wire segments 23 of the flat wire winding 2 are located on the same side of the flat wire winding 2 in the axial direction. Due to the limitation of the viewing angle, some lead wire segments 23 are blocked and not shown. Exemplarily, the winding in the U direction includes two parallel flat wires, one of which includes a welding end T11a and a welding end T11b, and the other includes a welding end T12a and a welding end T12b. The welding end T12a and the welding end T11a are welded to form a busbar end for connecting the U-phase electricity. The winding in the W direction includes two parallel flat wires, one of which includes a welding end T21a and a welding end T21b, and the other includes a welding end T22a and a welding end T22b. The welding end T22a and the welding end T21a are welded to form a busbar end for connecting the W-phase electricity. The winding in the V direction includes two parallel flat wires, one of which includes a welding end T31a and a welding end T31b, and the other includes a welding end T32a and a welding end T32b. The welding end T32a and the welding end T31a are welded to form a busbar end for connecting the V-phase electricity. The welding end T12b, the welding end T22b, and the welding end T32b are welded to form a star connection busbar end, and the welding end T11b, the welding end T21b, and the welding end T31b are welded to form another star connection busbar end. In some embodiments, the welding ends T11b, T21b, T31b, T12b, T22b, and T32b of the three-phase winding can be arranged adjacent to each other in the radial direction of the stator and welded to form a star connection busbar end. It should be understood that in order to achieve the circuit busbar connection of the above welding end T, the structural shape of the lead wire segment 23 can be adjusted as needed.

[0076] In summary, for the flat wire motor stator 10 provided by the embodiments of the present application, the ends of the flat wire winding 2 are welded by the flat wire itself for busbar connection, without additional structures such as busbars, and without additional workstations for assembly and welding. The process is simpler and easier to implement, which helps to realize automated production. At the same time, this busbar connection method of the flat wire winding 2 can reduce the occupied space of the end winding, and further reduce the axial dimension of the flat wire motor stator 10, which is beneficial to the miniaturization of the flat wire motor 100 and reduces the manufacturing cost. The flat wire winding 2 uses flat wire busbar welding, which can also reduce the weight of the flat wire motor stator 10. When the flat wire motor 100 is subjected to vibration and impact, the solder joints between the flat wires are less affected, which can improve the safety of the flat wire motor.

[0077] The above is only the specific implementation manner of the present application, but the protection scope of the present application is not limited thereto. Any person skilled in the art within the technical scope disclosed by the present application can easily think of changes or substitutions, which should be covered within the protection scope of the present application. Therefore, the protection scope of the present application should be subject to the protection scope of the claims.

Claims

1. A flat wire motor stator, characterized in that, The flat wire motor stator includes a stator core and a flat wire winding. The stator core includes two axial end faces. The flat wire winding includes a plurality of flat wires, and each flat wire includes: More than four straight segments, each straight segment is for being embedded in a winding slot of the stator core. One end of each straight segment faces one of the axial end faces of the stator core, and the other end of each straight segment faces the other axial end face of the stator core; At least one cross segment, each cross segment exposes one or the other axial end face of the stator core. Both ends of each cross segment are respectively for connecting one end of two straight segments in two different winding slots or the other ends of two straight segments in two different winding slots; Two lead segments, the two lead segments expose one axial end face of the stator core. The axial length of each lead segment exposed on the one axial end face is greater than the axial length of each cross segment exposed on the one or the other axial end face. One ends of the two lead segments are respectively for connecting one end of two straight segments in two different winding slots or the other ends of two straight segments in two different winding slots. The other end of each lead segment is for directly welding the other end of a lead segment in another flat wire to form a busbar end, and each busbar end is for transmitting a phase of alternating current or for being used as the neutral connection end of the flat wire winding.

2. The flat wire motor stator according to claim 1, characterized in that, Along the axial direction of the stator, each lead segment includes a radial segment and an axial segment, and the axial segment is for connecting the radial segment and the straight segment; Along the axial direction of the stator, the radial segments of each lead segment exposing the same axial end face of the stator core are arranged at intervals with any one cross segment.

3. The flat wire motor stator according to claim 2, wherein One end of the radial segment away from the axial segment includes a welding end protruding along the axial direction of the stator; The welding end includes a welding surface, and the welding surface is parallel to the axial direction of the stator and perpendicular to the radial direction of the stator.

4. The flat wire motor stator according to claim 3, wherein Along the axial direction of the stator, the axial dimension of the welding surface is smaller than the axial dimension of the welding end; Along the circumferential direction of the stator, the circumferential dimension of the welding surface is smaller than the circumferential dimension of the welding end.

5. The flat wire motor stator according to claim 2, characterized in that The lead segment further includes a bent segment, and the bent segment is connected between the axial segment and the straight segment; Along the radial direction of the stator, the axial segment is arranged at intervals with any one cross segment.

6. The flat wire motor stator according to claim 5, characterized in that, Along the axial direction of the stator, the axial length of the axial segment exposed on the one axial end face is greater than the axial length of any one cross segment.

7. The flat wire motor stator according to claim 1, characterized in that, Along the radial direction of the stator, the straight segment connected by one of the two lead segments is arranged in one layer at the bottom of a winding slot of the stator core, and the straight segment connected by the other lead segment of the two lead segments is arranged in one layer at the notch of another winding slot of the stator core.

8. The flat wire motor stator according to claim 1, wherein, The layers of the two straight segments connected by each cross segment in the two winding slots of the stator core are different; The different winding slots where the two straight line segments connected by each cross-line segment are located are spaced apart by 8 winding slots.

9. The flat wire motor stator according to claim 1, characterized in that, The flat wire winding includes multi-phase windings, each phase winding corresponding to one phase of electricity, and each phase winding including a plurality of parallel flat wires; Along the circumferential direction of the stator, the four or more straight line segments of the flat wires of the same phase are arranged in a staggered manner, and at least one cross-line segment of the flat wire windings of the same phase is arranged in a staggered manner; Along the radial direction of the stator, a plurality of the straight line segments are arranged adjacent to each other in each winding slot of the stator core; Along the axial direction of the stator, the two lead segments of the flat wires of the multi-phase windings are exposed from the same axial end face of the stator core.

10. The flat wire motor stator according to claim 9, wherein Along the radial direction of the stator, the other end of one lead segment of a flat wire is arranged adjacent to and connected to the other end of one lead segment of another flat wire of the same phase to form a busbar end for connecting the phase electricity, and the other end of the other lead segment of a flat wire winding is arranged adjacent to and connected to the other end of one lead segment of a flat wire of another phase to form a busbar end for neutral connection.

11. The flat wire motor stator according to claim 10, characterized in that, In the same phase winding, the straight line segment connected by one lead segment of a flat wire and the straight line segment connected by one lead segment of another flat wire connected thereto are located in the same winding slot and are arranged at intervals along the radial direction of the stator.

12. The flat wire motor stator according to any one of claims 1-11, characterized in that, Along the circumferential direction of the stator, the different winding slots where the two straight line segments respectively connected by the two lead segments of each flat wire are located are separated by 8 winding slots.

13. A flat wire motor, characterized in that, The flat wire motor includes a motor rotor, a motor shaft, and a flat wire motor stator as described in any one of claims 1-12. The stator core is sleeved on the motor rotor, and the motor rotor is sleeved and fixed on the motor shaft.

14. A powertrain, characterized in that, It includes a speed reducer and a flat wire motor as described in claim 13. The motor shaft of the flat wire motor is in transmission connection with the power input shaft of the speed reducer, and the flat wire motor is used to drive the power input shaft to rotate.

15. An electric vehicle, characterized in that, The electric vehicle includes wheels, a transmission mechanism, and a power assembly as described in claim 14. The power assembly drives the wheels to rotate through the transmission mechanism.

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