Low-loss stator
By using a flat stator base made of insulating and non-magnetic material and optimizing the core wire layout, combined with a heat dissipation shell and connecting cooling pipes, the problems of high stator mass and high loss are solved, achieving lightweight and efficient heat dissipation, and improving the stability and service life of the equipment.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-04-28
- Publication Date
- 2026-04-03
AI Technical Summary
The existing stator has a large mass during the manufacturing process, which limits its use in certain installation situations, and the number of coils affects the overall mass and losses.
The stator base is made of a flat plate made of insulating and non-magnetic material, combined with a ring or strip coil group, and connected to a cooling pipe through a heat dissipation shell. This optimizes the core wire layout and heat dissipation path, reducing iron loss and eddy current loss.
It achieves lightweight stator and efficient heat dissipation, improves equipment stability and service life, prevents overheating, and ensures stable operation under high load or long-term operation.
Smart Images
Figure CN224083273U_ABST
Abstract
Description
Technical Field
[0001] This utility model belongs to the field of stator technology, and in particular relates to a low-loss stator. Background Technology
[0002] The stator is the stationary part of an electric motor or generator. It consists of three parts: the stator core, the stator windings, and the frame. The stator is used to generate a rotating magnetic field.
[0003] Existing stators are generally manufactured using a pure metal shell, which results in a large overall stator mass. This can easily limit their use in some installation scenarios. Furthermore, the overall mass of the stator is also affected by the number of coils. Therefore, we have specially designed a low-loss stator. Utility Model Content
[0004] The purpose of this invention is to address the aforementioned technical problems by providing a low-loss stator that achieves the effect of being lightweight and easy to use.
[0005] In view of this, the present invention provides a low-loss stator, comprising:
[0006] The stator base is flat and made of insulating, non-magnetic material. Wire holes are provided on the stator base.
[0007] A coil unit comprises several coil groups, which are arranged on both sides of the stator base. The coil groups are distributed in a ring or strip shape on the stator base.
[0008] The heat sink is located on the outside of the stator frame. Multiple slots are provided on the outer wall of the heat sink for connecting cooling pipes.
[0009] The coil unit is composed of several adjacent coil groups connected in series by coil wires;
[0010] The coil assembly consists of a single coil layer or multiple single coil layers stacked together in a direction perpendicular to the stator base;
[0011] In this coil unit, the diameter and number of turns of each single coil layer in the same layer are the same, and the number of layers of each coil group is the same.
[0012] In this single coil layer, two or more core wires with insulation layers are combined into a single non-twisted strand, and the core wires in the same single coil layer are wound in the same direction of rotation in the same layer plane and are always parallel to each other.
[0013] In the above technical solution, further, a single coil layer is composed of an even number of core wires of the same number of layers, the axial number of wires in a single coil layer is a single wire, and the axial dimension of a single coil layer is the width of the core wire.
[0014] In this system, the core wires within a single coil layer are connected in series, and the core wires in a single coil layer are wound in only one direction of rotation.
[0015] In the above technical solution, furthermore, the winding-in end and winding-out end of each coil group are located on the outer ring of the single coil layer.
[0016] In the above technical solution, further, in the ring-shaped coil group, the radial positions of the core wires in the single coil layer are arranged sequentially with respect to the center of the circle, and the core wires in each single coil layer are connected to the core wires in the adjacent single coil layer in a sequential manner on different circumferences, so that the average distance of each core wire from the center of the rotor is consistent or close.
[0017] In the above technical solution, the core wire includes two cross-sections: flat and rectangular, and the core wire shape is the same as that in the single coil layer on the same stator.
[0018] Furthermore, the above technical solution also includes:
[0019] The terminal block is located on the outermost single coil layer of the coil group on both sides.
[0020] In the above technical solution, furthermore, a number of coil units are provided, each individual coil unit includes a single layer or multiple layers of single coil layers, and the core wires in the coil unit are electrically connected at the input terminal and the output terminal respectively.
[0021] In the above technical solution, furthermore, the single coil layers in the individual coil unit on the stator base are connected by the same plane parallel to the stator base.
[0022] In the above technical solution, furthermore, the single coil layers in each set of coil units on the stator base are arranged and connected in an alternating manner in different planes.
[0023] The beneficial effects of this utility model are as follows:
[0024] 1. A flat stator base made of insulating and non-magnetic material. One or more hollow coil groups are fixed on both sides of the stator base. They do not have iron cores, thus reducing the volume and weight, eliminating iron loss, and the core wire layout is reasonable. The coil groups formed by stacking the core wires are hollow inside the wire holes.
[0025] 2. By setting up a heat dissipation shell, the heat dissipation surface area is increased and an effective cooling pipe connection path is provided, which enables the stator to maintain a suitable operating temperature range, improves its overall stability and service life, enhances the heat dissipation efficiency of the equipment, prevents overheating, and ensures stable operation of the equipment under high load or long-term operation. Attached Figure Description
[0026] Figure 1 This is a schematic diagram of the structure of this utility model;
[0027] Figure 2 This is a schematic diagram of the base structure of this utility model;
[0028] Figure 3 This is a top view of the present invention;
[0029] Figure 4 This is a schematic diagram of the heat dissipation shell of this utility model;
[0030] Figure 5 yes Figure 3 AA section view in the middle;
[0031] The markings in the diagram are as follows: 1. Stator base; 11. Wire hole; 21. Coil group; 211. Single coil layer; 2111. Core wire; 3. Heat sink; 31. Insertion slot; 4. Terminal; 5. Coil wire. Detailed Implementation
[0032] The technical solutions of the embodiments of this application will be clearly described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this application. All other embodiments obtained by those skilled in the art based on the embodiments of this application are within the scope of protection of this application.
[0033] Example 1:
[0034] This embodiment provides a low-loss stator, including:
[0035] Stator base 1 is flat and made of insulating and non-magnetic material. Wire holes 11 are provided on the stator base 1.
[0036] The coil unit includes several coil groups 21, which are arranged on both sides of the stator base 1. The coil groups 21 are distributed in a ring or strip shape on the stator base 1.
[0037] Heat sink 3 is located on the outside of the stator frame. Multiple slots 31 are provided on the outer wall of the heat sink 3. The slots 31 are used to connect cooling pipes.
[0038] The coil unit is composed of several adjacent coil groups 21 connected in series by coil lines 5.
[0039] The coil group 21 is composed of a single coil layer 211 or multiple single coil layers 211 stacked together in a direction perpendicular to the stator base 1;
[0040] In this coil unit, the diameter and number of turns of each single coil layer 211 in the same layer are the same, and the number of layers of each coil group 21 is the same.
[0041] Among them, the single coil layer 211 is composed of two or more core wires 2111 with insulation layer combined into a single non-twisted strand, and the core wires 2111 in the same single coil layer 211 are always parallel and attached to each other in the same direction of rotation in the same layer plane.
[0042] As can be seen from this embodiment, a low-loss stator includes a stator base 1, a coil unit, and a heat sink 3;
[0043] Coil group 21 refers to a stack of coils that are individually overlapping when viewed from a direction perpendicular to the stator base 1, or a single layer of coils in total. Typically, the stator coils are symmetrically installed on both sides of the stator base 1.
[0044] The single or multiple coil groups 21 are arranged in a ring or in a long strip. When the stator base 1 is disc-shaped, it is a common disc motor stator, and the coil groups 21 are evenly arranged in a ring. When the stator base 1 is long strip, it is a linear motor, and the coil groups 21 are evenly arranged in a straight line.
[0045] Adjacent coil groups 21 are connected in series by coil lines 5 to form a coil unit. Multiple coil units can generate electromotive force output synchronously. To improve the output power, the input and output terminals of multiple coil units are connected separately. When the potential difference is low enough, parallel connection can improve the output power and reduce eddy current losses.
[0046] The coil group 21 is composed of a single coil layer 211 or multiple single coil layers 211 stacked in a direction perpendicular to the stator base 1. The diameter and number of turns of each single coil layer 211 in the same layer of the coil unit are the same, and the number of layers of each coil group 21 is the same. In a preferred embodiment, the coil group 21 is composed of only a single coil layer 211.
[0047] A single coil layer 211 is composed of two or more insulated core wires 2111 wound together as a single, non-twisted strand, with them wound parallel to each other in the same direction of rotation within the same layer plane. The core wires 2111 of the single coil layer 211 lie in one plane. This arrangement maximizes the utilization of the magnetic field space, increases the copper content, and places the stator within the strongest magnetic field range along the shortest possible magnetic flux path, thus increasing power density. The paralleling of single-layer core wires 2111 also improves load capacity, and multiple core wires 2111 reduce eddy currents, thereby reducing copper losses.
[0048] The heat sink 3 is positioned on the outside of the stator frame. By placing the heat sink 3 outside the stator frame, the surface area for heat dissipation can be maximized, improving heat conduction and dissipation. The outer surface is designed with multiple grooves 31. These grooves 31 connect to cooling pipes, allowing the coolant or airflow within the cooling pipes to carry away heat and reduce the stator temperature. The grooves 31 provide space and convenience for connecting the cooling pipes, enabling the coolant or cooling gas to directly contact the surface of the heat sink 3, forming an efficient heat exchange path. During the flow of the liquid or gas in the cooling pipes, heat is absorbed from the surface of the heat sink 3, quickly carrying away excess heat generated by the equipment and preventing overheating. Because the heat sink 3 covers the outside of the stator frame, its surface and the grooves 31 of the cooling pipes achieve uniform heat transfer. The distribution of multiple grooves 31 ensures even distribution of the cooling pipes, enhancing heat dissipation and ensuring that the equipment's heat is dissipated evenly and effectively, preventing localized overheating. This efficient heat dissipation system ensures that the equipment will not experience performance degradation or damage due to overheating during prolonged operation.
[0049] The stator base 1 is a flat plate made of insulating and non-magnetic material. One or more hollow coil groups 21 are fixed on both sides of the stator base 1. They are without iron cores, thus reducing the volume and weight, and eliminating iron loss. The core wires 2111 are arranged in a reasonable manner, and the coil groups 21 formed by stacking the core wires 2111 are hollow inside the wire holes 11.
[0050] By setting up the heat dissipation shell 3, the heat dissipation surface area is increased and an effective cooling pipe connection path is provided, which enables the stator to maintain a suitable operating temperature range, improves its overall stability and service life, enhances the heat dissipation efficiency of the equipment, prevents overheating, and ensures stable operation of the equipment under high load or long-term operation.
[0051] Example 2:
[0052] This embodiment provides a low-loss stator, which, in addition to the technical solutions of the above embodiments, also has the following technical features.
[0053] A single coil layer 211 is composed of an even number of core wires 2111 of the same number of layers. The axial number of wires in a single coil layer 211 is a single wire, and the axial dimension of a single coil layer 211 is the width of the core wire 2111.
[0054] In this single coil layer 211, the core wires 2111 are connected in series, and the core wires 2111 in the single coil layer 211 are wound in only one direction.
[0055] As can be seen from this embodiment, each single coil layer 211 is composed of an even number of single coil layers 21 of the same number of layers. A typical single coil layer 211 has two layers. The axial core wire 2111 of a single coil layer 211 has a single wire. The axial dimension of a single coil layer 211 is the width of the core wire 2111. The single core wires 2111 in a single coil layer 211 are connected in series. The single core wires 2111 in a single coil layer 211 are wound in only one direction of rotation.
[0056] Preferably, the core wire 2111 in the coil group 21 is wound in only one direction, which can improve production efficiency and reduce costs.
[0057] Example 3:
[0058] This embodiment provides a low-loss stator, which, in addition to the technical solutions of the above embodiments, also has the following technical features.
[0059] The winding-in end and winding-out end of each coil group 21 are located on the outer ring of the core wire 2111.
[0060] As can be seen in this embodiment, after the single coil layer 211 is wound from the outer circle to the center position, it turns into the next layer and is wound from the inside to the outside in the same direction until the outermost circle.
[0061] The winding-in end and winding-out end are both on the outermost layer, without the need for an extra layer of space to cross the lead wire. The winding-in end and winding-out end of each coil group 21 are located on the outer ring of the single coil layer 211 and are tangentially led out without radially crossing the metal wire.
[0062] Example 4:
[0063] This embodiment provides a low-loss stator, which, in addition to the technical solutions of the above embodiments, also has the following technical features.
[0064] The coil group 21 is arranged in a ring. The radial positions of the core wires 2111 in the single coil layer 211 are arranged in sequence with respect to the center of the circle. The core wires 2111 in each single coil layer 211 are connected to the core wires 2111 in the adjacent single coil layer 211 in sequence on different circumferences, so that the average distance of each core wire 2111 from the center of the rotor is consistent or close.
[0065] As can be seen in this embodiment, by setting up a ring-shaped coil group 21, the distances of each core wire 2111 in the multi-core wires 2111 in the single coil layer 211 relative to the center of the circle are arranged sequentially. The multi-core wires 2111 in each single coil layer 211 are sequentially interwoven with the multi-core wires 2111 in the horizontally adjacent single coil layer 211 on different circumferences, so that the average distance of each core wire 2111 from the center of the rotor is consistent or close. This can reduce the potential difference between the multi-core wires 2111 and reduce the wire load loss.
[0066] Furthermore, the ratio of the outer diameter of the stator coils arranged in a ring to the thickness of the stator coils is ~. High power density is achieved within this ratio range. This means that the distance between the rotor magnetic fields on both sides of the stator coils is sufficiently close, concentrating the magnetic lines of force in the space occupied by the stator coils, thereby increasing the magnetic flux density and resulting in high power output.
[0067] Similarly, as another embodiment, in a linear motor, the ratio of the width to the thickness of the stator coils arranged in a straight line is ~. The power density of the linear motor is high within this ratio range.
[0068] Example 5:
[0069] This embodiment provides a low-loss stator, which, in addition to the technical solutions of the above embodiments, also has the following technical features.
[0070] The core wire 2111 includes two types of cross-sections: flat and rectangular. The core wire 2111 in the single coil layer 211 on the same stator has the same shape.
[0071] As can be seen from this embodiment, by setting the core wire 2111 with a flat cross-section, the copper ratio can be effectively increased. Furthermore, the ideal cross-sectional shape is rectangular, which can further improve the space utilization rate.
[0072] Example 6:
[0073] This embodiment provides a low-loss stator, which, in addition to the technical solutions of the above embodiments, also has the following technical features.
[0074] Terminal 4 is located on the outermost single coil layer 211 of the coil group 21.
[0075] As can be seen from this embodiment, the wiring selection during installation is as follows: each single coil layer 211 has one terminal 4 on both the upper and lower single coil layers, and adjacent single coil layers 211 connected in series are arranged as follows:
[0076] The coil wires 5 between adjacent single coil layers 211 are arranged according to the winding direction of adjacent single coil layers 211 in the installation state. If the winding direction of adjacent single coil layers 211 is the same, the outgoing terminal 4 of the previous single coil layer 211 and the incoming terminal 4 of the next single coil layer 211 are connected between the upper single coil layer or between the lower single coil layer. If the winding direction of adjacent single coil layers 211 is opposite, the outgoing terminal 4 of the previous single coil layer 211 and the incoming terminal 4 of the next single coil layer 211 are connected between the upper single coil layer and the lower single coil layer.
[0077] Example 7:
[0078] This embodiment provides a low-loss stator, which, in addition to the technical solutions of the above embodiments, also has the following technical features.
[0079] There are several coil units. Each individual coil unit includes a single layer or multiple layers of single coil layers 211, and the core wires 2111 in the coil unit are electrically connected at the input terminal 4 and the output terminal 4 respectively.
[0080] As can be seen in this embodiment, multiple independent coil units are provided, each with a single or multiple single coil layers 211. Multiple independent outputs can be provided, which can then be connected in series for high-voltage output or have their input terminals interconnected and output terminals interconnected, increasing the output current while avoiding eddy current losses, or other connection methods to match the required power and voltage output.
[0081] One embodiment of the arrangement of multi-layer single coil layers 211 is that the single coil layers 211 in each set of coil units on the stator base 1 are connected through the same plane parallel to the stator base 1.
[0082] Another embodiment of the multi-layer single-coil layer 211 arrangement is shown in the figure. In each set of coil units on the stator base 1, the single-coil layers 211 are staggered and connected in different planes. This can reduce the asymmetry of the magnetic field distribution, achieve equipotential output, and reduce internal resistance voltage drop losses.
[0083] Example 8:
[0084] This embodiment provides a low-loss stator, which, in addition to the technical solutions of the above embodiments, also has the following technical features.
[0085] The single coil layer 211 in the individual coil unit on the stator base 1 is connected by the same plane arrangement parallel to the stator base 1.
[0086] As can be seen from this embodiment, in one embodiment of the arrangement of multi-layer single coil layers 211, the single coil layers 211 in each set of coil units on the stator base 1 are connected through the same plane parallel to the stator base 1.
[0087] Example 9:
[0088] This embodiment provides a low-loss stator, which, in addition to the technical solutions of the above embodiments, also has the following technical features.
[0089] The single coil layers 211 in each coil unit on the stator base 1 are staggered and connected in different planes.
[0090] As shown in this embodiment, a multi-layer single-coil layer 211 arrangement is as follows: in each coil unit on the stator base 1, the single-coil layers 211 are staggered and connected in different planes. This reduces magnetic field asymmetry, achieves equipotential output, and reduces internal resistance voltage drop losses.
[0091] The embodiments of this application have been described above with reference to the accompanying drawings. Unless otherwise specified, the embodiments and features in the embodiments of this application can be combined with each other. This application is not limited to the specific embodiments described above. The specific embodiments described above are merely illustrative and not restrictive. Those skilled in the art can make many other forms under the guidance of this application without departing from the spirit and scope of the claims, and all of these forms are within the protection scope of this application.
Claims
1. A low-loss stator characterized in that, It includes: The stator base (1) is flat and made of insulating non-magnetic material, and the wire hole (11) is arranged on the stator base (1); The coil unit includes a plurality of coil groups (21), and the coil groups (21) are arranged on both sides of the stator base (1), and the coil groups (21) are arranged in a ring or strip shape on the stator base (1); The heat dissipation shell (3) is arranged outside the stator frame, and a plurality of embedding grooves (31) are arranged on the outer wall surface of the heat dissipation shell (3), and the embedding grooves (31) are used to connect the cooling pipes; Wherein, the coil unit is composed of a plurality of adjacent coil groups (21) connected in series by coil wires (5); Wherein, the coil group (21) is composed of a single coil layer (211) or a plurality of single coil layers (211) stacked in the vertical direction of the stator base (1); Wherein, the diameter and the number of turns of each single coil layer (211) in the same layer of the coil unit are the same, and the number of layers of each coil group (21) is the same; Wherein, the single coil layer (211) is composed of two or more cores with an insulating layer, and the cores (2111) in the same single coil layer (211) are always parallel to each other in the same layer plane.
2. A low-loss stator according to claim 1, characterized in that Each single coil layer (211) is composed of an even number of core wires (2111) with the same number of layers, the axial wire number of the single coil layer (211) is single, and the axial dimension of the single coil layer (211) is the width of the core wire (2111); Wherein, the core wires (2111) in one single coil layer (211) are connected in series, and the core wires (2111) in the single coil layer (211) are wound in only one direction.
3. A low-loss stator according to claim 2, characterized in that The winding end and the winding end of each coil group (21) are located on the outer circle of the single coil layer (211).
4. A low-loss stator according to claim 3, characterized in that The coil groups (21) arranged in a ring are arranged in a ring, and the radial positions of the core wires (2111) in the single coil layer (211) are arranged in sequence relative to the center distance, and the core wires (2111) in each single coil layer (211) are sequentially connected with the core wires (2111) in the adjacent single coil layer (211) on different circumferences, so that the average distance of each core wire (2111) from the center of the rotor is consistent or close.
5. A low-loss stator according to claim 4, characterized in that The core wire (2111) includes two kinds of cross sections of flat shape and rectangular shape, and the shape of the core wire (2111) in the single coil layer (211) on the stator is the same.
6. A low-loss stator according to claim 5, further characterized by It includes: The wiring end (4) is arranged on the single coil layer (211) on the side where the coil group (21) is located on the outermost side.
7. A low-loss stator according to claim 6, characterized in that The coil unit is provided with a plurality of single coil layers (211), and the core wires (2111) in the coil unit are electrically connected at the wire inlet and outlet terminals (4), respectively.
8. A low-loss stator according to claim 7, characterized in that The single coil layers (211) in the single coil unit on the stator base (1) are arranged and connected through the same plane parallel to the stator base (1).
9. A low-loss stator according to claim 8, characterized in that The single coil layers (211) in each set of coil units on the stator base (1) are arranged in different planes and connected in an interleaved manner.