Stator thread end forming module

Abstract

The utility model relates to a stator wire end forming module which comprises a stator iron core, 80 slots are arranged on the radial inner surface of the stator iron core in an annular array mode, and the 80 slots are sequentially defined as the first slot to the 80th slot. A first layer to a sixth layer are defined in the slot along the radius direction of the stator core from outside to inside, an outer layer wire is bridged between the first layer and the second layer, a middle layer wire is bridged between the third layer and the fourth layer, and an inner layer wire is bridged between the fifth layer and the sixth layer; an outer same-layer overline is inserted in the first layer, an outer outgoing line is inserted in the first layer, an outer reverse overline is inserted between the third layer and the second layer, an inner outgoing line is inserted in the sixth layer, an inner reverse overline is inserted between the fifth layer and the fourth layer, and an inner same-layer overline is inserted in the accommodating part of the sixth layer. According to the utility model, under the condition that the performance of the stator is not changed, the number of the slots is redesigned, the use amount of copper is reduced, and materials are saved.

Description

Technical Field

[0001] The utility model relates to the technical field of motor manufacturing, in particular to a stator lead forming module. Background Art

[0002] In the prior art, half of the copper wire of the stator winding is threaded into the slots of the stator core according to a certain layout method, and then the ends of the hairpins are welded according to the design. The stator winding generally uses flat wire. By using flat wire motors, the slot fill factor of the motor can be increased, and the power density of the motor can be improved. However, at the same time, more copper flat wire will be used, increasing the manufacturing cost. Summary of the Utility Model

[0003] The purpose of the utility model is to provide a stator lead forming module, which can reduce the use of copper wire without reducing the output power of the stator, save copper materials and manufacturing costs.

[0004] To achieve the above object, the utility model provides the following technical solution: A stator lead forming module includes a stator core. 80 slots are annularly and arrayedly opened on the radial inner surface of the stator core, and are defined as the 1st - 80th slots in sequence; in the slots, from outside to inside along the radial direction of the stator core, it is defined as the first to sixth layers. An outer layer wire is bridged between the first and second layers, a middle layer wire is bridged between the third and fourth layers, and an inner layer wire is bridged between the fifth and sixth layers; an outer same - layer cross - wire is inserted into the first layer, an outer lead - out wire is inserted into the first layer, an outer reverse cross - wire is inserted between the third and second layers, an inner lead - out wire is inserted into the sixth layer, an inner reverse cross - wire is inserted between the fifth and fourth layers, and an inner same - layer cross - wire is inserted into the accommodating part of the sixth layer.

[0005] Further, there are 2 outer same - layer cross - wires in total, and the two ends are respectively used for inserting into the 29th and 34th slots, the 47th and 52nd slots of the first layer;

[0006] There are 3 inner same - layer cross - wires in total, and the two ends are respectively used for inserting into the 25th and 30th slots, the 43rd and 48th slots, the 61st and 66th slots of the sixth layer.

[0007] Further, there are 6 outer lead - out wires in total, which are respectively inserted into the 20th, 61st, 25th, 38th, 43rd, 56th slots of the first layer;

[0008] There are 4 inner lead - out wires in total, which are respectively inserted into the 39th, 34th, 52nd, 57th slots of the sixth layer.

[0009] Further, a total of 10 outer reverse jumper wires are provided, and the two ends are respectively used to jumper across the 25th slot of the third layer and the 30th slot of the second layer, the 20th slot of the third layer and the 25th slot of the second layer, the 29th slot of the third layer and the 34th slot of the second layer, the 38th slot of the third layer and the 43rd slot of the second layer, the 56th slot of the third layer and the 61st slot of the second layer, the 43rd slot of the third layer and the 57th slot of the second layer, the 61st slot of the third layer and the 66th slot of the second layer, the 34th slot of the third layer and the 39th slot of the second layer, the 52nd slot of the third layer and the 57th slot of the second layer, the 47th slot of the third layer and the 52nd slot of the second layer;

[0010] A total of 10 inner reverse jumper wires are provided, and the two ends are respectively used to jumper across the 25th slot of the fifth layer and the 30th slot of the fourth layer, the 20th slot of the fifth layer and the 25th slot of the fourth layer, the 29th slot of the fifth layer and the 34th slot of the fourth layer, the 38th slot of the fifth layer and the 43rd slot of the fourth layer, the 56th slot of the fifth layer and the 61st slot of the fourth layer, the 43rd slot of the fifth layer and the 48th slot of the fifth layer, the 61st slot of the fifth layer and the 66th slot of the fourth layer, the 34th slot of the fifth layer and the 39th slot of the fourth layer, the 52nd slot of the fifth layer and the 57th slot of the fourth layer, the 47th slot of the fifth layer and the 52nd slot of the fourth layer.

[0011] Further, the two ends of the outer layer wire are respectively inserted into the first layer and the second layer at intervals of 4 slots, and the remaining positions of the first layer and the second layer are filled;

[0012] The two ends of the middle layer wire are respectively inserted into the third layer and the fourth layer at intervals of 4 slots, and the remaining positions of the third layer and the fourth layer are filled;

[0013] The two ends of the inner layer wire are respectively inserted into the fifth layer and the sixth layer at intervals of 4 slots, and the remaining positions of the fifth layer and the sixth layer are filled.

[0014] Further, the 20th slot of the first layer is connected in parallel with the 61st slot of the first layer; the 25th slot of the first layer is connected in parallel with the 34th slot of the sixth layer; the 38th slot of the first layer is connected in parallel with the 39th slot of the sixth layer; the 43rd slot of the first layer is connected in parallel with the 52nd slot of the sixth layer; the 40th slot of the second layer is connected in parallel with the 26th slot of the third layer; the 57th slot of the first layer is connected in parallel with the 57th slot of the sixth layer.

[0015] Further, the inner wall of the slot is covered with insulating paper.

[0016] The beneficial effects of the present utility model: By redesigning the positions of the lead wires and the number and positions of the inner and outer reverse jumper wires, etc., while the function of the output power of the stator remains unchanged, the number of slots is reduced, so that the use of copper wires can be reduced, the copper material can be saved, and the manufacturing cost can be saved. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 It is a schematic structural diagram of a three-row wire motor stator.

[0018] Figure 2 It is a schematic diagram showing only the installation of inner and outer reverse jumper wires inside the stator core.

[0019] Figure 3 It is a schematic diagram of the distribution state after each inner reverse jumper wire is installed in the stator core.

[0020] Figure 4 It is a schematic diagram of the distribution state of the inner and outer reverse jumper wires removed from the stator core.

[0021] Figure 5 It is a schematic diagram showing the installation of only inner and outer reverse jumper wires and lead wires inside the stator core.

[0022] Figure 6 It is Figure 5 A schematic diagram of the state after removing the stator core.

[0023] Figure 7 It is a schematic diagram of the usage distribution state of inner same-layer jumper wires.

[0024] Figure 8 It is a schematic diagram of the usage distribution state of outer same-layer jumper wires.

[0025] Figure 9 It is a schematic diagram of the relative positions of the usage distribution states of inner and outer same-layer jumper wires.

[0026] Figure 10 It is a schematic diagram of the relative positions of lead wires, inner and outer same-layer jumper wires installed in the slots of the stator core.

[0027] Figure 11 It is a schematic diagram of the relative positions of inner and outer reverse jumper wires, inner and outer same-layer jumper wires, and lead wires during installation and use.

[0028] Figure 12 It is Figure 1 A schematic diagram of the state after removing the stator core.

[0029] Figure 13 Schematic diagram of the structure of the outer layer wires.

[0030] Figure 14 It is a partial schematic diagram after the combination of each wire is unfolded.

[0031] Figure 15 It is a schematic diagram of removing a single group of wires after the combination of each wire is unfolded.

[0032] Wherein: 1. Stator core; 2. Outer same-layer jumper wire; 31. Inner lead wire; 32. Outer lead wire; 4. Inner same-layer jumper wire; 41. Bending part; 42. Inserting arm; 43. Pin; 5. Outer layer wire; 51. Turning part; 52. Connecting arm; 53. Contact pin; 6. Connecting pin; 7. Inner layer wire; 8. Inner reverse jumper wire; 9. Outer reverse jumper wire; 11. Slot. Detailed implementation mode

[0033] The following further describes the present utility model in conjunction with the attached drawings. For better understanding, the orientation of the present utility model is described according to the orientation shown in the drawings, and it cannot be construed as a limitation to this application; the following terms "first", "second", etc. are only for descriptive purposes and cannot be construed as indicating or implying relative importance.

[0034] Please refer to Figures 1 to 15 , the present utility model provides an embodiment: a stator lead forming module, including a stator core 1, 80 slots 11 are annularly and arrayedly opened on the radial inner surface of the stator core 1, and are sequentially defined as the 1st - 80th slots; the slots 11 are defined as the first to sixth layers from the outside to the inside along the radial direction of the stator core 1, an outer layer wire 5 is bridged between the first and second layers, a middle layer wire is bridged between the third and fourth layers, and an inner layer wire 7 is bridged between the fifth and sixth layers; an outer same-layer jumper wire 2 is inserted into the first layer, an outer lead wire 32 is inserted into the first layer, an outer reverse jumper wire 9 is inserted between the third and second layers, an inner lead wire 31 is inserted into the sixth layer, an inner reverse jumper wire 8 is inserted between the fifth and fourth layers, and an inner same-layer jumper wire 4 is inserted into the accommodating part of the sixth layer. The present utility model can reduce the number of slots 11 on the radial inner surface of the stator core 1 and reduce the use of copper material under the same output power.

[0035] Please continue to refer to Figure 7 , Figure 8 , Figure 9 As shown, in an embodiment of the present utility model, a total of 2 outer same-layer jumper wires 2 are provided, and the two ends are respectively used for inserting into the 29th slot and the 34th slot, the 47th slot and the 52nd slot of the first layer;

[0036] A total of 3 inner same-layer jumper wires 4 are provided, and the two ends are respectively used for inserting into the 25th slot and the 30th slot, the 43rd slot and the 48th slot, the 61st slot and the 66th slot of the sixth layer.

[0037] Please continue to refer to Figure 5 , Figure 11 As shown, in an embodiment of the present utility model, a total of 6 outer lead wires 32 are provided, and are respectively inserted into the 20th slot, the 61st slot, the 25th slot, the 38th slot, the 43rd slot, and the 56th slot of the first layer;

[0038] A total of 4 inner lead wires 31 are provided, and are respectively inserted into the 39th slot, the 34th slot, the 52nd slot, and the 57th slot of the sixth layer.

[0039] Please continue to refer to Figures 2 to 5 、 Figure 11 As shown, in an embodiment of the present utility model, a total of 10 outer reverse jumper wires 9 are provided, and the two ends are respectively used for cross-connecting the 25th slot of the third layer and the 30th slot of the second layer, the 20th slot of the third layer and the 25th slot of the second layer, the 29th slot of the third layer and the 34th slot of the second layer, the 38th slot of the third layer and the 43rd slot of the second layer, the 56th slot of the third layer and the 61st slot of the second layer, the 43rd slot of the third layer and the 57th slot of the second layer, the 61st slot of the third layer and the 66th slot of the second layer, the 34th slot of the third layer and the 39th slot of the second layer, the 52nd slot of the third layer and the 57th slot of the second layer, the 47th slot of the third layer and the 52nd slot of the second layer;

[0040] A total of 10 inner reverse jumper wires 8 are provided, and the two ends are respectively used for cross-connecting the 25th slot of the fifth layer and the 30th slot of the fourth layer, the 20th slot of the fifth layer and the 25th slot of the fourth layer, the 29th slot of the fifth layer and the 34th slot of the fourth layer, the 38th slot of the fifth layer and the 43rd slot of the fourth layer, the 56th slot of the fifth layer and the 61st slot of the fourth layer, the 43rd slot of the fifth layer and the 48th slot of the fifth layer, the 61st slot of the fifth layer and the 66th slot of the fourth layer, the 34th slot of the fifth layer and the 39th slot of the fourth layer, the 52nd slot of the fifth layer and the 57th slot of the fourth layer, the 47th slot of the fifth layer and the 52nd slot of the fourth layer. The inner same-layer jumper wire 4 structurally includes a bent portion 41 with the top bent and protruding to one side, plugging arms 42 integrally connected to both ends of the bent portion 41 and bent in the opposite direction to the bent portion 41, and pins 43 integrally connected to the lower ends of the plugging arms 42; the structure of the inner same-layer jumper wire 4 is mirror-symmetric to the structure of the outer same-layer jumper wire 2, and the sizes of the inner same-layer jumper wire 4 and the outer same-layer jumper wire 2 are based on the radius size of the layer where the stator core 1 is located.

[0041] Please continue to refer to Figures 6 to 9 As shown, in an embodiment of the present utility model, both ends of the outer layer wire 5 are respectively inserted into the first layer and the second layer at intervals of 4 slots 11, filling the remaining positions of the first layer and the second layer; for example, one end of the outer layer wire 5 is inserted into the 31st slot of the second layer, and the other end is inserted into the 36th slot of the first layer, and so on;

[0042] Both ends of the middle layer wire are respectively inserted into the third layer and the fourth layer at intervals of 4 slots 11, filling the remaining positions of the third layer and the fourth layer; for example, one end of the middle layer wire is inserted into the 31st slot of the third layer, and the other end is inserted into the 36th slot of the fourth layer, and so on;

[0043] Both ends of the inner layer wire 7 are respectively inserted into the fifth layer and the sixth layer with an interval of 4 slots 11, filling the remaining positions of the fifth layer and the sixth layer. For example, one end of the inner layer wire 7 is inserted into the 31st slot of the fifth layer, and the other end is inserted into the 36th slot of the sixth layer. The outer layer wire 5 structurally includes a turning portion 51 integrally shaped like a U, two connecting arms 52 integrally connected to both ends of the turning portion 51, and pins 53 integrally connected to the outer ends of the connecting arms 52; the electrical connection between two adjacent outer layer wires 5 is achieved by welding on the end face of the pins 53; the middle layer wire 6, the inner layer wire 7 and the outer layer wire 5 have the same structure; the structure of the outer reverse jumper wire 9 and the inner reverse jumper wire 8 is mirror-symmetrical to the structure of the outer layer wire 5; the dimensions of various wires are adapted to the radius of the layer where they are located.

[0044] Please continue to refer to Figure 1 、 Figure 5 、 Figure 11 and Figure 12 As shown, in an embodiment of the present invention, the 20th slot of the first layer is connected in parallel with the 61st slot of the first layer; the 25th slot of the first layer is connected in parallel with the 34th slot of the sixth layer; the 38th slot of the first layer is connected in parallel with the 39th slot of the sixth layer; the 43rd slot of the first layer is connected in parallel with the 52nd slot of the sixth layer; the 40th slot of the second layer is connected in parallel with the 26th slot of the third layer; the 57th slot of the first layer is connected in parallel with the 57th slot of the sixth layer. The star lead-out wire connection method is adopted.

[0045] Please continue to refer to Figures 1 to Figure 15 As shown, the inner wall of the slot 11 is covered with insulating paper. The insulating paper can isolate the conductors between phases.

[0046] The working principle of the present invention is as follows: The inner reverse jumper wire is inserted into the fourth and fifth layers to connect the middle layer (the third and fourth layers) and the inner layer (the fifth and sixth layers), and the outer reverse jumper wire is inserted into the third and second layers to connect the middle layer (the third and fourth layers) and the outer layer (the first and second layers), so that the lead-out wire can be inserted into the inner layer and the outer layer of the stator core 1. By optimizing the layout of the copper wires in the stator, the number of slots in the stator core can be reduced, and the use of copper materials can be reduced.

[0047] The above is only a preferred embodiment of the present invention and should not be construed as a limitation to the present application. Any equivalent changes and modifications made within the scope of the patent application of the present invention shall fall within the scope covered by the present invention.

Claims

1. A stator lead forming module, characterized in that: It includes a stator core. 80 slots are annularly arrayed on the radial inner surface of the stator core and are defined as the 1st - 80th slots in sequence. In the slots, from the outside to the inside along the radius direction of the stator core, there are defined six layers, namely the first to the sixth layers. An outer layer wire is bridged between the first and the second layers, a middle layer wire is bridged between the third and the fourth layers, and an inner layer wire is bridged between the fifth and the sixth layers. An outer same - layer cross - wire is inserted into the first layer, an outer lead - out wire is inserted into the first layer, an outer reverse cross - wire is inserted between the third and the second layers, an inner lead - out wire is inserted into the sixth layer, an inner reverse cross - wire is inserted between the fifth and the fourth layers, and an inner same - layer cross - wire is inserted into the accommodating part of the sixth layer.

2. The stator lead - end forming module according to claim 1, wherein: There are a total of 2 outer same - layer cross - wires, and the two ends are respectively used for inserting into the 29th slot and the 34th slot, the 47th slot and the 52nd slot of the first layer. There are a total of 3 inner same - layer cross - wires, and the two ends are respectively used for inserting into the 25th slot and the 30th slot, the 43rd slot and the 48th slot, the 61st slot and the 66th slot of the sixth layer.

3. The stator lead - end forming module according to claim 2, wherein: There are a total of 6 outer lead - out wires, which are respectively inserted into the 20th slot, the 61st slot, the 25th slot, the 38th slot, the 43rd slot, and the 56th slot of the first layer. There are a total of 4 inner lead - out wires, which are respectively inserted into the 39th slot, the 34th slot, the 52nd slot, and the 57th slot of the sixth layer.

4. The stator lead - end forming module according to claim 3, wherein: There are a total of 10 outer reverse cross - wires, and the two ends are respectively used for bridging between the 25th slot of the third layer and the 30th slot of the second layer, between the 20th slot of the third layer and the 25th slot of the second layer, between the 29th slot of the third layer and the 34th slot of the second layer, between the 38th slot of the third layer and the 43rd slot of the second layer, between the 56th slot of the third layer and the 61st slot of the second layer, between the 43rd slot of the third layer and the 57th slot of the second layer, between the 61st slot of the third layer and the 66th slot of the second layer, between the 34th slot of the third layer and the 39th slot of the second layer, between the 52nd slot of the third layer and the 57th slot of the second layer, between the 47th slot of the third layer and the 52nd slot of the second layer. There are a total of 10 inner reverse cross - wires, and the two ends are respectively used for bridging between the 25th slot of the fifth layer and the 30th slot of the fourth layer, between the 20th slot of the fifth layer and the 25th slot of the fourth layer, between the 29th slot of the fifth layer and the 34th slot of the fourth layer, between the 38th slot of the fifth layer and the 43rd slot of the fourth layer, between the 56th slot of the fifth layer and the 61st slot of the fourth layer, between the 43rd slot of the fifth layer and the 48th slot of the fifth layer, between the 61st slot of the fifth layer and the 66th slot of the fourth layer, between the 34th slot of the fifth layer and the 39th slot of the fourth layer, between the 52nd slot of the fifth layer and the 57th slot of the fourth layer, between the 47th slot of the fifth layer and the 52nd slot of the fourth layer.

5. The stator lead - end forming module according to claim 4, wherein: The two ends of the outer layer wire are respectively inserted into the first layer and the second layer at an interval of 4 slots, filling the remaining positions of the first layer and the second layer. The two ends of the middle layer wire are respectively inserted into the third layer and the fourth layer at an interval of 4 slots, filling the remaining positions of the third layer and the fourth layer. Both ends of the inner layer wires are inserted into the fifth and sixth layers respectively, with a spacing of 4 slots between them, and the remaining positions of the fifth and sixth layers are filled up.

6. The stator lead forming module according to claim 2, wherein: Slot 20 of the first layer is connected in parallel with slot 61 of the first layer; slot 25 of the first layer is connected in parallel with slot 34 of the sixth layer; slot 38 of the first layer is connected in parallel with slot 39 of the sixth layer; slot 43 of the first layer is connected in parallel with slot 52 of the sixth layer; slot 40 of the second layer is connected in parallel with slot 26 of the third layer; slot 57 of the first layer is connected in parallel with slot 57 of the sixth layer.

7. A stator lead forming module according to claim 1, characterized in that: The inner wall of the slot is covered with insulating paper.

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