Stator assembly, motor and vehicle power assembly
By using the midpoint of the span between the L/2 and L/2+1 layers in the stator winding as the welding point, the problem of excessively large gap in the outermost layer wire span in the AAABBBB architecture winding motor is solved, which simplifies the coil insertion and saves copper, thereby improving motor production efficiency.
Patent Information
- Application Number
- CN202422694038.5
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-11-05
- Publication Date
- 2025-10-28
- Estimated Expiration
- 2034-11-05
AI Technical Summary
In the prior art, the span difference between the two outermost layers of wire on the welding side of the AAABBB structure winding motor is too large, which makes it difficult to twist the coil into the barrel, increasing the complexity of motor manufacturing and the amount of copper material used.
In the stator winding, the midpoint of the span between the L/2 layer and the L/2+1 layer is used as the welding point to optimize the span distribution of the coil, shorten the span difference of the outermost layer, reduce the difficulty of inserting the coil into the barrel and save copper.
This effectively shortens the span difference between adjacent layers of enameled wire, reduces the complexity of motor manufacturing and the amount of copper used, and improves production efficiency.
Smart Images
Figure CN223487964U_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of stator assembly design technology, and in particular to a stator assembly, motor and vehicle powertrain. Background Technology
[0002] For wound motors, such as those with an AAABBB winding structure and no cross-layer wires on the crown side, the welding point is typically set at the midpoint of the innermost span on the welding side. However, this results in a significant difference in the span between the two outermost layers of wires on the corresponding welding side. Consequently, during the motor manufacturing process of inserting the motor into the torsion cylinder, the wire length corresponding to the aforementioned short outermost span is insufficient. This necessitates lengthening the short wire to achieve successful insertion into the cylinder, greatly increasing the complexity of motor manufacturing and impacting production efficiency. Utility Model Content
[0003] To achieve the above objectives, this application proposes a stator assembly comprising:
[0004] A stator core having a plurality of stator slots spaced circumferentially along the stator core;
[0005] The stator winding includes a multiphase winding mounted on the stator core, and an L-layer is formed on each stator slot, where L is an even number greater than or equal to 6;
[0006] Each phase winding includes multiple coils, each coil having a crown side and a solder side; in any stator slot, the coils from the first layer to the second layer belong to the same phase winding, and the coils from the second layer to the first layer belong to the same phase winding; in at least one stator slot, the coils from the second layer and the second layer belong to different phase windings;
[0007] Furthermore, on the welding side, the midpoint of the span between the L / 2 and L / 2+1 layers is the welding point.
[0008] Optionally, L is 6.
[0009] Optionally, the number of slots per pole per phase of the stator assembly is not equal to the number of branches per phase.
[0010] Optionally, on the crown side, the coil span includes a first short pitch, a full pitch, a first long pitch, and a second short pitch; on the welding side, the coil span includes a first long pitch and a full pitch.
[0011] Wherein, the first short pitch is smaller than the second short pitch.
[0012] Optionally, the number of slots per pole per phase is 3, and the number of branches per phase is 2.
[0013] Optionally, the number of stator slots Z is 54 and the number of pole pairs P is 3;
[0014] The span of the full pitch is 9, the span of the first short pitch is 6, the span of the second short pitch is 7, and the span of the first long pitch is 10.
[0015] Optionally, the number of slots per pole per phase of the stator assembly is equal to the number of branches per phase.
[0016] This application also proposes an electric motor including a stator assembly as described in any of the preceding claims.
[0017] This application also proposes a vehicle powertrain including the electric motor as described above.
[0018] This application proposes a stator assembly including a stator core and stator windings. The stator core has a plurality of stator slots spaced circumferentially along the stator core. The stator windings include multi-phase windings mounted on the stator core, forming L layers in each stator slot, where L is an even number greater than or equal to 6. Each phase winding includes multiple coils, each coil having a crown side and a solder side. In any stator slot, the coils from the first layer to the second layer belong to the same phase winding, and the coils from the second layer to the first layer belong to the same phase winding. In at least one stator slot, the coils from the second layer and the second layer belong to different phase windings. Furthermore, on the solder side, the midpoint of the span between the second and second layers is the solder point. Thus, by using the midpoint of the span between the two middle layers with the longest span as the solder point, the problem of excessively long enameled wires in subsequent adjacent layers due to excessively large spans between the middle two layers can be effectively mitigated. Compared with existing technologies, this effectively shortens the span difference between adjacent layers of enameled wire, especially the span difference between the two outermost welding sides of the enameled wire, thereby reducing the difficulty of coil winding, saving copper usage, and further reducing the complexity of motor manufacturing. Attached Figure Description
[0019] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.
[0020] Figure 1 This is a schematic diagram of the connection of the welding side portion in one embodiment of the stator assembly of this application;
[0021] Figure 2 This is a schematic diagram of the stator assembly in one embodiment of the present application before it is twisted inside the barrel;
[0022] Figure 3 This is a schematic diagram of the welded side connection of an exemplary technology in the prior art;
[0023] Figure 4 This is a schematic diagram of the structure before the barrel is twisted, as exemplary in the prior art.
[0024] Figure 5 This is a schematic diagram of the winding connection of one phase winding of the stator winding in one embodiment of the stator assembly of this application.
[0025] Figure reference numerals: 10, welding point; 20, coil; 30, stator slot.
[0026] The realization of the purpose, functional features and advantages of this application will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation
[0027] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. Based on the embodiments of this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this application.
[0028] It should be noted that if the embodiments of this application involve directional indicators (such as up, down, left, right, front, back, etc.), the directional indicators are only used to explain the relative positional relationship and movement of the components in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indicators will also change accordingly.
[0029] Furthermore, if the embodiments of this application involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, features defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the technical solutions of various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. If the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed in this application.
[0030] For wound motors, such as those with an AAABBB winding structure and no cross-layer wires on the crown side, the welding point is typically set at the midpoint of the innermost span on the welding side. However, this results in a significant difference in the span between the two outermost layers of wires on the corresponding welding side. Consequently, during the motor manufacturing process of inserting the motor into the torsion cylinder, the wire length corresponding to the aforementioned short outermost span is insufficient. This necessitates lengthening the short wire to achieve successful insertion into the cylinder, greatly increasing the complexity of motor manufacturing and impacting production efficiency.
[0031] It's important to understand that the manufacturing process of a flat wire motor requires a hairpin coil. The hairpin coil consists of a crown-side section on the crown side, a middle section within the stator slot, and an enameled wire section on the welding side. After inserting the hairpin coil into the cylinder, the enameled wire section on the welding side needs to be twisted and welded. For each layer of enameled wire on the welding side of the stator slot, to ensure stable motor operation, the gap between each wire after twisting must be almost consistent. This requires that each wire in the same layer on the welding side twists in the same direction and has a consistent span on the welding side. For example, refer to... Figure 3 and Figure 4 , Figure 3 and Figure 4 This is an exemplary technique in the prior art. Figure 3 The diagram shows the weld side structure of a six-layer stator assembly with an AAABBB architecture. The windings form six layers in each stator slot, with one outermost layer and six innermost layers. It is evident that the span of the enameled wire in the second layer on the weld side is 3.5, and both are torqued to the right. Similarly, the span of the enameled wire in the third layer on the weld side is 5.5, and both are torqued to the left. The two enameled wires are then twisted and welded together; the weld joint is the welding point. The spans of the two welded enameled wires together form the span of the weld side between their corresponding intermediate sections.
[0032] Based on the above conditions, in existing technologies, the midpoint of the innermost span on the welding side is generally taken as the welding point, for example... Figure 3 In the diagram, the innermost layer has a span of 9. The two enameled wires (one in the fifth layer and one in the sixth layer) have spans of 4.5 and 4.5 respectively. Therefore, regarding the span between the fourth and fifth layers on the welding side, as shown in the diagram, the sum of the spans is 9. Since the span of the enameled wire in the fifth layer is 4.5, the span of the enameled wire on the welding side of the fourth layer is also 4.5. However, due to... Figure 3The stator windings shown are of an AAABBB structure, meaning that the windings of the phases belonging to the coils in layers 1 to 3 within any stator slot are necessarily identical, and the windings of the phases belonging to the coils in layers 4 to 6 within any stator slot are necessarily identical. However, there may be instances where the windings of the phases belonging to the coils in layers 3 and 4 within at least one stator slot are inconsistent. For example, refer to... Figure 5 In stator slot 30, the coils of the first three layers are wound with the same phase, while the coils of the last three layers are wound with a different phase. This structural design means that the span between the welded sides of the middle two layers is necessarily greater than the span between the welded sides of other adjacent layers. For example… Figure 3 As shown in the diagram, the span between the third and fourth layers is 10. From the above, we know that the span of the enameled wire on the welding side of the fourth layer is already 4.5. Therefore, the span of the enameled wire on the welding side of the third layer must be 5.5. Since the span between the second and third layers on the welding side is 9, the span of the enameled wire on the welding side of the second layer can only be 3.5. Similarly, as shown in the diagram, if the span between the first and second layers on the welding side is 9, the span of the enameled wire on the welding side of the first layer can only be 5.5.
[0033] As can be seen from the above, when the midpoint of the innermost span on the welding side is used as the welding point, in windings with a structure such as AAABBBB, the span difference between the two enameled wires on the outermost welding side will be too large. Figure 4 As shown in H1. This results in the short side being difficult to twist during the coil winding process, requiring the short enameled wire to be lengthened before being wound into the coil. This is equivalent to requiring a specially made hairpin coil, which greatly increases the complexity of the entire motor production and the amount of copper material used.
[0034] To address the aforementioned technical problems, this application proposes a stator assembly. (Reference) Figure 1 and Figure 2 In one embodiment of this application, the stator assembly includes:
[0035] The stator core has a plurality of stator slots 30 spaced apart along the circumference of the stator core;
[0036] The stator winding includes a multiphase winding mounted on the stator core, and an L-layer is formed on each of the stator slots 30, where L is an even number greater than or equal to 6;
[0037] Each phase winding includes a plurality of coils 20, each coil 20 having a crown side and a solder side; in any stator slot 30, coils 20 of the first layer to coils 20 of the L / 2 layer belong to the same phase winding, and coils 20 of the L / 2+1 layer to coils 20 of the L layer belong to the same phase winding; in at least one stator slot 30, coils 20 of the L / 2 layer and coils 20 of the L / 2+1 layer belong to different phase windings;
[0038] Furthermore, on the welding side, the midpoint of the span between the L / 2 and L / 2+1 layers is welding point 10.
[0039] In this embodiment, optionally, the first to Lth layers in the stator slot 30 can be arranged from the inside out, that is, the first layer is closest to the inner side of the iron core and the Lth layer is the outermost layer; or, the first to Lth layers in the stator slot 30 can be arranged from the outside in, with the Lth layer being closest to the inner side of the iron core and the first layer being the outermost layer.
[0040] Optionally, the stator windings are formed in an even number of L layers in each stator slot 30, for example, six layers. For each layer, there are q consecutive middle sections of coils 20 belonging to the same phase, then q adjacent middle sections of coils 20 belonging to another phase, and so on until the upper limit of the number of phases of the stator windings. Here, q is the number of slots per pole per phase of the motor, for example, equal to 1, 2, or 3, etc. In the embodiments of this application, the coils 20 of the first layer to the coils 20 of the L / 2 layer belong to the same phase winding, and the coils 20 of the L / 2+1 layer to the coils 20 of the L layer belong to the same phase winding, for example, referring to Figure 5 , Figure 5 In this configuration, the middle sections of any coil 20 in the first to third layers of any stator slot 30 belong to the same phase winding, and similarly, the middle sections of any coil 20 in the fourth to sixth layers of any stator slot 30 belong to the same phase winding. However, in at least one stator slot 30, the coil 20 in the L / 2 layer and the coil 20 in the L / 2+1 layer belong to different phase windings. For example, refer to... Figure 5 As shown, the phases of the middle sections of the third and fourth layers are staggered by one stator slot 30, forming an AAABBBB structure. Optionally, the staggered phases of the middle sections of the third and fourth layers can also be other numbers of stator slots 30, such as two or three. This configuration allows the stator windings to form a winding, which can effectively optimize and improve the NVH of the motor, reducing the vibration and noise amplitude generated during motor operation. Optionally, the stator windings form L layers on each stator slot, where L can be an even number greater than or equal to 6, for example... Figure 5 As shown, the winding has 6 layers in each stator slot, and the entire stator winding is a six-layer stator winding with an AAABBBB structure. Alternatively, L can also be 8 layers to form an eight-layer stator winding with an AAAABBBB structure. Alternatively, L can also be 10 layers to form a ten-layer stator winding with an AAAAABBBBB structure.
[0041] As can be seen from the above, the stator winding in this application has a phase misalignment only between the middle section of the L / 2 layer and the middle section of the L / 2+1 layer. Therefore, the span between the L / 2 layer and the L / 2+1 layer on the welding side is the largest span on the welding side. When the midpoint of the span between the L / 2 layer and the L / 2+1 layer is welding point 10, compared with the prior art where the midpoint of the span of the innermost layer is the welding point, the span difference between the two enameled wires of the outermost layer can be effectively shortened. The reason is as follows: due to the phase distribution structure mentioned above, the span distance between the two middle layers is the largest, and the spans between the other two layers are all smaller than the spans between the two middle layers. Therefore, in the prior art, if the midpoint of the innermost span is set as the welding point, the spans of the enameled wires corresponding to the spans of the two innermost layers are equal. Based on the characteristic that the spans of the enameled wires on the welding side of the same layer are consistent, in the middle layers, since the span between the two middle layers is the largest, the span of one of the corresponding two enameled wires will be increased. However, the span distance between the two adjacent layers further out will be smaller than that of the two middle layers. For the enameled wires in these two adjacent layers, one has an increased span, so the other needs to be shortened, which leads to a larger distance difference between the two enameled wires in the outermost layer. In this application, by using the midpoint of the span of the two middle layers with the longest span as the welding point, the problem of one of the enameled wires in subsequent adjacent layers being too long due to the excessively large span of the two middle layers can be effectively improved. For example, refer to... Figure 1 , Figure 1 The stator winding shown is Figure 3 The stator windings shown have the same span on the weld side and are all six-layer structures. Figure 1 It is evident that for the middle layer (layers three and four), the welding side span is 10, and taking the midpoint of this span as the welding midpoint, then the corresponding welding side enameled wire span for the third layer is 5, and the welding side enameled wire span for the fourth layer is also 5. When the span for layers two and three is 9, and the span for layers one and two is also 9, the welding side enameled wire span for the outermost first layer is 5, and the welding side enameled wire span for the second layer is 4, with a span difference of 1. Figure 1 and Figure 2 The embodiment shown is compared to Figure 3 and Figure 4 The difference in the outermost span in the prior art shown is 2 (5.5-3.5), which is reduced by 1 (i.e. Figure 4 H1 is greater than Figure 2 The H2 in the middle effectively shortens the span difference between adjacent layers of enameled wire, especially shortening the span difference between the two outermost welding side enameled wires, thereby reducing the difficulty of coil 20 entering the cylinder for twisting, saving copper usage, and further reducing the complexity of motor manufacturing.
[0042] Optionally, in one embodiment, the number of slots per pole and per phase of the stator assembly can be equal to the number of branches per phase. For example, the number of slots and branches per pole and per phase are both 3, or the number of slots and branches per pole and per phase are both 2, etc. This configuration can effectively reduce the noise of the motor during operation and improve the power density of the motor.
[0043] Alternatively, in another embodiment, the number of slots per pole per phase of the stator assembly may not be equal to the number of branches per phase. For example, the number of slots per pole per phase is 3, and the number of branches per phase is 2, etc. This configuration can effectively reduce harmonics in the motor, especially the 5th and 7th harmonics, which helps to reduce motor noise and vibration. Furthermore, due to the reduction of harmonics and the improvement of the power factor, the overall efficiency of the motor can be improved.
[0044] Optionally, in one embodiment, on the crown side, the span of the coil includes a first short pitch, a full pitch, a first long pitch, and a second short pitch; on the welding side, the span of the coil includes a first long pitch and a full pitch; wherein the first short pitch is smaller than the second short pitch.
[0045] In one example, reference Figure 5 , Figure 5 In the example shown, the dashed lines represent welded side connections, and the solid lines represent crown side connections. The number of stator slots Z is 54, the number of pole pairs P is 3, the number of rotor poles 2p = 6, L = 6, the number of slots per pole per phase is 3, and the number of branches per phase is 2. The span of the full pitch is Z / 2p = 9, the span of the first short pitch is Z / 2p - 3 = 6, the span of the second short pitch is Z / 2p - 2 = 7, and the span of the first long pitch is Z / 2p + 1 = 10. On the welded side, the span includes the full pitch and the first long pitch. For example, the span between the middle section of stator slot 31 (middle section 23) in the third layer and the middle section of slot 21 (middle section 22) in the fourth layer is 10; the span between the middle section of stator slot 31 (middle section 5) in the first layer and the middle section of stator slot 22 (middle section 4) in the second layer is 9. On the crown side, the span includes the first short pitch, the full pitch, the first long pitch, and the second short pitch. For example, the span between the middle section of slot 51 (middle section 19) in the third layer and the middle section of slot 3 (middle section 20) in the fourth layer is 6; the span between the middle section of slot 51 (middle section 1) in the first layer and the middle section of slot 4 (middle section 2) in the second layer is 7; the span between the middle section of slot 50 (middle section 13) in the first layer and the middle section of slot 6 (middle section 14) in the second layer is 10; and the span between the middle section of slot 50 (middle section 31) in the third layer and the middle section of slot 5 (middle section 32) in the fourth layer is 9. Figure 1The diagram illustrates a single-phase winding, with each phase having 2 branches. The electrical input line 1+ of the first branch enters from the middle section of slot 51 in the first layer, then passes through the middle section of slot 4 in the second layer, the middle section of slot 13 in the first layer, and so on, until it exits from the middle section of slot 41 in the sixth layer, where the electrical output line 1- of the first branch exits. The electrical input line 2+ of the second branch enters from the middle section of slot 48 in the sixth layer, passes through the middle section of slot 41 in the fifth layer, the middle section of slot 22 in the sixth layer, and so on, until it exits from the middle section of slot 4 in the first layer, where the electrical output line 2- of the second branch exits.
[0046] This application also proposes an electric motor comprising a stator assembly as described in any of the preceding claims.
[0047] It is worth noting that, since the motor of this application includes the aforementioned stator assembly, all technical solutions of the motor of this application that include the stator assembly also possess at least all the beneficial effects brought about by the technical solutions of the above embodiments, which will not be elaborated upon here.
[0048] This application also proposes a vehicle powertrain, which includes an electric motor as described in any of the preceding claims.
[0049] It is worth noting that, since the vehicle powertrain of this application includes the aforementioned motor, all technical solutions of the vehicle powertrain of this application that include a motor also possess at least all the beneficial effects brought about by the technical solutions of the above embodiments, which will not be elaborated upon here.
[0050] The above content is only an optional embodiment of this application and does not limit the patent scope of this application. All equivalent structural transformations made based on the content of this application's specification and drawings under the application concept of this application, or direct / indirect applications in other related technical fields, are included within the patent protection scope of this application.
Claims
1. A stator assembly, characterized in that, The stator assembly includes: A stator core having a plurality of stator slots spaced circumferentially along the stator core; The stator winding includes a multiphase winding mounted on the stator core, and an L-layer is formed on each stator slot, where L is an even number greater than or equal to 6; Each phase winding includes multiple coils, each coil having a crown side and a solder side; in any stator slot, the coils from the first layer to the second layer belong to the same phase winding, and the coils from the second layer to the first layer belong to the same phase winding; in at least one stator slot, the coils from the second layer and the second layer belong to different phase windings; Furthermore, on the welding side, the midpoint of the span between the L / 2 and L / 2+1 layers is the welding point.
2. The stator assembly as claimed in claim 1, characterized in that, The value of L is 6.
3. The stator assembly as claimed in claim 1, characterized in that, The number of slots per pole per phase of the stator assembly is not equal to the number of branches per phase.
4. The stator assembly as claimed in claim 3, characterized in that, On the crown side, the coil span includes a first short pitch, a full pitch, a first long pitch, and a second short pitch; on the welding side, the coil span includes a first long pitch and a full pitch. Wherein, the first short pitch is smaller than the second short pitch.
5. The stator assembly as claimed in claim 4, characterized in that, The number of slots per pole per phase is 3, and the number of branches per phase is 2.
6. The stator assembly as claimed in claim 5, characterized in that, The number of stator slots Z is 54, and the number of pole pairs P is 3; The span of the full pitch is 9, the span of the first short pitch is 6, the span of the second short pitch is 7, and the span of the first long pitch is 10.
7. The stator assembly as claimed in claim 1, characterized in that, The number of slots per pole and per phase of the stator assembly is equal to the number of branches per phase.
8. An electric motor, characterized in that, Includes the stator assembly as described in any one of claims 1-7.
9. A vehicle powertrain, characterized in that, Includes the motor as described in claim 8.