Novel motor stator

Abstract

The utility model relates to a motor stator, a motor and a using method thereof, the motor stator comprises a stator body and flat wire conductors, the circumference of the stator body is provided with through grooves which are arranged at intervals in the vertical direction, each through groove is internally provided with four layers of flat wire conductors, plug hairpins are inserted into the through grooves to form a three-phase winding, and the plug hairpins are inserted into the flat wire conductors to form a three-phase winding. Each phase winding outputs four connectors, the connectors are led out through plugging wire cards, the number of the plugging wire cards is twelve, the twelve plugging wire cards are respectively plugged in the corresponding through grooves, and the plugging wire cards correspondingly connected with the copper bars achieve corresponding connection. According to the motor stator adopting the technical scheme, the original advantages are reserved, the stator is a three-phase winding, each phase outputs four joints, totally twelve joints, four winding schemes of a single Y shape, a single triangle, a double Y shape and a double triangle can be realized through different connection modes of the twelve joints by using a standard copper bar, and the stator is simple in structure and convenient to operate. The problem that the tool clamp is frequently replaced when the flat wire motor is produced is solved, the production line investment is reduced, and the production efficiency is improved.

Description

Technical Field

[0001] This utility model relates to an electric motor, specifically a novel electric motor stator. Background Technology

[0002] An electric motor (including electric motors and generators) is a device that converts electrical energy into mechanical energy (or mechanical energy into electrical energy) based on the principle of electromagnetic induction. It serves as a power source or generator for various electrical appliances such as household appliances, and various machines such as electric motorcycles and electric vehicles. Electric motors can be classified into DC motors and AC motors based on the type of electricity they operate on. AC motors can be further divided into single-phase motors and multi-phase motors (such as three-phase motors). An electric motor consists of a stator and a rotor, with windings arranged in the stator core slots. Existing motor winding forms include wave windings and lap windings. For segmented hairpin winding motors using pre-formed flat wire conductors, lap windings are used. The hairpins of this type of pre-formed flat wire conductor include an upper non-welded portion, straight portions on both sides, and a lower welded portion.

[0003] Different vehicle models and application scenarios have different performance requirements for motors, and therefore different motors are used. Currently, although each three-phase motor has three-phase windings, each phase winding outputs one connector, for a total of three connectors. These are connected using standard copper busbars, which can only achieve a single connection method. When motor manufacturers produce different motors according to orders, they need to frequently change tooling fixtures, resulting in high production line investment and low production efficiency. Utility Model Content

[0004] The technical problem to be solved by this utility model is to provide a motor stator that can meet the various performance requirements of motors for different vehicle models and application scenarios. At the same time, it solves the problem of frequently changing tooling fixtures when producing flat wire motors with different winding schemes, thereby reducing production line investment and improving production efficiency.

[0005] The above-mentioned technical objective of this utility model is achieved through the following technical solution:

[0006] An electric motor stator includes a stator body and flat wire conductors. The stator body has vertically spaced through slots around its periphery. Each through slot contains four layers of the flat wire conductors. The stator also includes a copper busbar. Each flat wire conductor includes a plug-in hairpin and a plug-in terminal block. The plug-in hairpin is inserted into the through slot to form a three-phase winding. Each phase winding outputs four connectors. There are twelve plug-in terminal blocks, each plugged into a corresponding through slot. The copper busbar is connected to the plug-in terminal blocks to achieve the corresponding connection method.

[0007] The motor stator using the above technical solution retains the advantages of the original hairpin motor stator, such as high slot fill factor, good heat dissipation, small size, and low AC loss. Since this stator has three-phase windings with four output terminals per phase, for a total of twelve terminals, four winding schemes can be achieved by using standard copper busbars to connect the twelve terminals in different ways: single Y-shaped, single delta, double Y-shaped, and double delta. This can solve the various performance requirements of motors for different vehicle models and application scenarios. At the same time, it solves the problem of frequently changing tooling fixtures when producing flat wire motors with the above different winding schemes, reducing production line investment and improving production efficiency.

[0008] Further specified, the number of through slots is forty-eight, and the plug-in hair clips are six first hair clips, thirty-six second hair clips, twelve third hair clips, and thirty-six fourth hair clips, wherein each plug-in hair clip includes an upper connecting part, a left straight insertion part, a right straight insertion part, and a lower welding part, and each wire clip includes a lower insertion end and an upper wiring end.

[0009] Furthermore, the bottom of the welding part of the first layer of the plug-in hairpin or the insertion end of the lower part of the wire card in the same through slot is fixedly connected to the welding part of the second layer of the plug-in hairpin; the bottom of the welding part of the fourth layer of the plug-in hairpin or the insertion end of the lower part of the wire card in the same through slot is fixedly connected to the welding part of the third layer of the plug-in hairpin.

[0010] Furthermore, in the above technical solution, the fixed connection is defined as welding.

[0011] In addition, this utility model provides an electric motor, including the motor stator described in the above technical solution.

[0012] Furthermore, this utility model provides methods for using this motor stator, namely, different wiring methods; there are four different wiring methods in total.

[0013] The first wiring method uses four copper busbars. The first busbar connects to connectors 9, 11, and 12; the second busbar connects to connectors 2 and 5; the third busbar connects to connectors 1 and 3; and the fourth busbar connects to connectors 4 and 6. Connectors 7, 8, and 10 provide three-phase outputs (U, V, W), forming a single Y-connection. This connection method offers higher torque and lower line current, and can be used with a low-cost controller. It is achieved by soldering standard copper busbars to different connectors.

[0014] The second wiring method uses six copper busbars. The first busbar connects to the eighth and twelfth connectors for the V phase output; the second busbar connects to the ninth and tenth connectors for the W phase output; the third busbar connects to the seventh and eleventh connectors for the U phase output; the fourth busbar connects to the first and third connectors; the fifth busbar connects to the second and fifth connectors; and the sixth busbar connects to the fourth and sixth connectors, forming a single delta connection. This connection method offers moderate phase current and higher speed than the Y-connection, making it suitable for high-speed tricycles. It is achieved by welding standard copper busbars to different connectors.

[0015] The third wiring method uses four copper busbars. The first busbar connects to the fifth and eighth connectors for the V phase output; the second busbar connects to the sixth and tenth connectors for the W phase output; the third busbar connects to the third and seventh connectors for the U phase output; and the fourth busbar connects to the first, second, fourth, ninth, eleventh, and twelfth connectors, forming a double Y-shaped connection. This connection method allows for high-speed operation and is suitable for electric motorcycle power. It is achieved by welding standard copper busbars to different connectors.

[0016] The fourth wiring method involves four copper busbars. The first busbar connects to the second, sixth, tenth, and eleventh connectors, outputting the V phase; the second busbar connects to the first, fifth, eighth, and ninth connectors, outputting the W phase; and the third busbar connects to the third, fourth, seventh, and twelfth connectors, outputting the U phase, forming a double-delta connection. This connection method is suitable for high-power, high-speed motors and is achieved by welding standard copper busbars to different connectors. Attached Figure Description

[0017] Figure 1a This is a front view of the first hairpin of this utility model;

[0018] Figure 1b This is the right view of the first card-spinning device of this utility model;

[0019] Figure 1c This is the first bottom view of the hairpin of this utility model;

[0020] Figure 2a This is a front view of the second hairpin of this utility model;

[0021] Figure 2b This is the right view of the second hairpin of this utility model;

[0022] Figure 2c This is a bottom view of the second hairpin of this utility model;

[0023] Figure 3a This is a front view of the third hairpin of this utility model;

[0024] Figure 3b This is the right view of the third hairpin of this utility model;

[0025] Figure 3cThis is a bottom view of the third hairpin of this utility model;

[0026] Figure 4a This is the front view of the fourth type of hairpin in this utility model;

[0027] Figure 4b This is the right view of the fourth card of this utility model;

[0028] Figure 4c This is the fourth bottom view of the hairpin of this utility model;

[0029] Figure 5a This is a front view of the plug-in connector of this utility model;

[0030] Figure 5b This is a right view of the plug-in connector of this utility model;

[0031] Figure 5c This is a bottom view of the plug-in connector of this utility model;

[0032] Figure 6 This is a schematic diagram of a single Y-shaped connection of this utility model;

[0033] Figure 7 This is a schematic diagram of a single triangle connection according to this utility model;

[0034] Figure 8 This is a schematic diagram of the double Y-shaped connection of this utility model;

[0035] Figure 9 This is a schematic diagram of the double-triangle connection of this utility model;

[0036] Figure 10 This is a three-dimensional schematic diagram of a motor stator according to the present invention. Detailed Implementation

[0037] The present invention will be further described in detail below with reference to the accompanying drawings.

[0038] like Figure 1a , Figure 1b , Figure 1c , Figure 2a , Figure 2b , Figure 2c , Figure 3a , Figure 3b , Figure 3c , Figure 4a , Figure 4b , Figure 4c , Figure 5a , Figure 5b , Figure 5c and Figure 10As shown, a novel motor stator includes a stator body 10, six first hairpins 1, thirty-six second hairpins 2, twelve third hairpins 3, thirty-six fourth hairpins 4, and twelve plug-in connectors 5. Each of the first hairpins 1, second hairpins 2, third hairpins 3, and fourth hairpins 4 includes an upper connecting part 41, a left straight insertion part 42, a right straight insertion part 43, and a lower welding part 44. The stator body 10 has forty-eight vertically spaced through slots 11 around its circumference; each through slot 11 contains a hairpin or a plug-in connector, and each through slot 11 contains four layers.

[0039] The specific hair clips or connectors inserted into the forty-eight slots are listed in the table below:

[0040]

[0041]

[0042]

[0043] In the table above, "first hairpin 1 left" refers to the left straight insertion part of the first hairpin, "first hairpin 1 right" refers to the right straight insertion part of the first hairpin, "first hairpin 2 left" refers to the left straight insertion part of the second hairpin, "first hairpin 2 right" refers to the right straight insertion part of the second hairpin, "plug-in connector 1" refers to the first plug-in connector, and so on; "plug-in connector 1" refers to the first plug-in connector, "plug-in connector 2" refers to the second plug-in connector; "last layer" refers to the outermost layer of the through groove 10, and similarly, the second, third, and fourth layers refer to the innermost layer of the through groove 10.

[0044] Both the plug-in hairpins and plug-in wire clips are flat wire conductors. The plug-in hairpins are inserted into the through slots 10 to form a three-phase winding. Each phase winding outputs four connectors, which are led out through the plug-in wire clips 5. There are twelve plug-in wire clips 5, which are respectively inserted into the corresponding through slots 10. The copper busbars 6 are connected to the plug-in wire clips 5 to achieve the corresponding connection method. The welding part of the first layer of plug-in hairpins or the bottom of the insertion end of the wire clip in the same through slot 10 is fixedly connected to the welding part of the second layer of plug-in hairpins. The welding part of the fourth layer of plug-in hairpins or the bottom of the insertion end of the wire clip in the same through slot is fixedly connected to the welding part of the third layer of plug-in hairpins. The fixed connection is by welding.

[0045] It also includes copper busbars, which are standard and commonly used accessories used to connect connectors in parallel.

[0046] There are four different wiring methods for using this type of motor stator:

[0047] like Figure 6 As shown, in the first wiring method, there are four copper busbars. The first copper busbar 601 connects to the ninth connector 509, the eleventh connector 511, and the twelfth connector 512; the second copper busbar 602 connects to the second connector 502 and the fifth connector 505; the third copper busbar 603 connects to the first connector 501 and the third connector 503; the fourth copper busbar 604 connects to the fourth connector 504 and the sixth connector 506; the seventh, eighth, and tenth connectors are U, V, and W three-phase outputs, forming a single Y-connection. This connection method has a large torque and a small line current, and can be used with a low-cost controller, achieved by welding different connectors to standard copper busbars.

[0048] like Figure 7 As shown, in the second wiring method, there are six copper busbars. The first copper busbar 605 connects to the eighth and twelfth connectors, outputting the V phase; the second copper busbar 606 connects to the ninth connector 509 and the tenth connector 510, outputting the W phase; the third copper busbar 607 connects to the seventh connector 507 and the eleventh connector 511, outputting the U phase; the fourth copper busbar 608 connects to the first connector 501 and the third connector 503; the fifth copper busbar 609 connects to the second connector 502 and the fifth connector 505; and the sixth copper busbar 610 connects to the fourth connector 504 and the sixth connector 506, forming a single delta connection. This connection method has moderate phase current and a higher rotational speed than the Y-connection, making it suitable for high-speed tricycles. It is achieved by welding standard copper busbars to different connectors.

[0049] like Figure 8 As shown, in the third wiring method, there are four copper busbars. The first copper busbar 611 connects to the fifth connector 505 and the eighth connector 508, outputting the V phase; the second copper busbar 612 connects to the sixth connector 506 and the tenth connector 510, outputting the W phase; the third copper busbar 613 connects to the third connector 503 and the seventh connector 507, outputting the U phase; and the fourth copper busbar 614 connects to the first connector 501, the second connector 502, the fourth connector 504, the ninth connector 509, the eleventh connector 511, and the twelfth connector 512, forming a double Y-shaped connection. This connection method allows for high-speed operation and is suitable for electric motorcycle power. It is achieved by welding standard copper busbars to different connectors.

[0050] like Figure 9As shown, in the fourth wiring method, there are four copper busbars. The first copper busbar 615 connects to the second connector 502, the sixth connector 506, the tenth connector 510, and the eleventh connector 511, outputting the V phase. The second copper busbar 616 connects to the first connector 501, the fifth connector 505, the eighth connector 508, and the ninth connector 509, outputting the W phase. The third copper busbar 617 connects to the third connector 503, the fourth connector 504, the seventh connector 507, and the twelfth connector 512, outputting the U phase, forming a double delta connection. This connection method is suitable for high-power, high-speed motors and is achieved by welding standard copper busbars to different connectors.

[0051] The motor stator using the above technical solution retains the advantages of the original hairpin motor stator, such as high slot fill factor, good heat dissipation, small size, and low AC loss. Since this stator has three-phase windings with four output terminals per phase, for a total of twelve terminals, four winding schemes can be achieved by using standard copper busbars to connect the twelve terminals in different ways: single Y-shaped, single delta, double Y-shaped, and double delta. This can solve the various performance requirements of motors for different vehicle models and application scenarios. At the same time, it solves the problem of frequently changing tooling fixtures when producing flat wire motors with the above different winding schemes, reducing production line investment and improving production efficiency.

[0052] In addition, this utility model also protects the motor stator that includes the above-described technical solution.

[0053] This specific embodiment is merely an explanation of the present utility model and is not intended to limit the present utility model. After reading this specification, those skilled in the art can make modifications to this embodiment without contributing any inventive step, but as long as they are within the scope of the claims of the present utility model, they are protected by patent law.

Claims

1. A novel motor stator, comprising a stator body and flat wire conductors, wherein the stator body has vertically spaced through slots arranged at intervals, and each through slot contains four layers of the flat wire conductors, characterized in that: It also includes a copper busbar. The flat wire conductor includes a plug-in hairpin and a plug-in wire clip. The plug-in hairpin is inserted into the through slot to form a three-phase winding. Each phase winding outputs four connectors. The connectors are led out through the plug-in wire clips. There are twelve plug-in wire clips. The twelve plug-in wire clips are respectively inserted into the corresponding through slots. The copper busbar is connected to the plug-in wire clips to realize the corresponding connection method.

2. The novel motor stator according to claim 1, characterized in that: The number of through slots is forty-eight, and the number of plug-in hair clips are six first hair clips, thirty-six second hair clips, twelve third hair clips, and thirty-six fourth hair clips. Each plug-in hair clip includes an upper connecting part, a left straight insertion part, a right straight insertion part, and a lower welding part. Each wire clip includes a lower insertion end and an upper wiring end.

3. The novel motor stator according to claim 2, characterized in that: The bottom of the welding part of the first layer of the plug-in hairpin or the insertion end of the lower part of the wire card in the same through slot is fixedly connected to the welding part of the second layer of the plug-in hairpin; the bottom of the welding part of the fourth layer of the plug-in hairpin or the insertion end of the lower part of the wire card in the same through slot is fixedly connected to the welding part of the third layer of the plug-in hairpin.

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