Stator of flat wire motor and motor

Abstract

The utility model provides a stator of a flat wire motor and the motor. In the stator of the flat wire motor provided by the embodiment of the invention, the manufacturing material of the connecting part of the first busbar assembly and the leading-out end of the flat wire winding in the busbar assembly is the same as the manufacturing material of the leading-out end, so that the welding strength of the first busbar assembly and the flat wire winding is ensured, and the reliability of the connecting part of the first busbar assembly and the flat wire winding can be ensured. Meanwhile, the insulation protection piece is arranged to wrap the copper-aluminum connecting part located in the first busbar assembly or the flat wire winding, the copper-aluminum connecting part can be prevented from making contact with water vapor in the environment, the problem of electrochemical corrosion of the copper-aluminum connecting part can be avoided, and the electrical performance and the structural strength of the first busbar assembly or the flat wire winding can be guaranteed.

Description

Technical Field

[0001] This application relates to the field of motor technology, and more specifically to a stator and motor of a flat wire motor. Background Technology

[0002] Currently, the flat wires used in flat wire motors applied in the field of new energy vehicles are all copper flat wires. However, copper flat wires have the problems of heavy weight and high manufacturing cost.

[0003] Currently, some manufacturers are using aluminum flat wire instead of copper flat wire to reduce weight and cost. However, most motor busbars are now made of copper. Due to the different melting points of copper and aluminum, welding copper busbars to aluminum flat wires is difficult. Moreover, the copper-aluminum joint is prone to electrochemical corrosion when exposed to the external environment. Utility Model Content

[0004] The purpose of this application is to overcome or at least mitigate the shortcomings of the prior art and to provide a stator and motor for a flat wire motor that can avoid copper-aluminum welding and avoid exposure of the connection between the two.

[0005] According to a first aspect of this application, a stator for a flat wire motor is provided, comprising: a stator core, a flat wire winding, and a busbar assembly, wherein the flat wire winding is made of aluminum.

[0006] The bus assembly includes a first bus component connected to the lead-out end of a flat wire winding. The first bus component and the lead-out end are made of the same material as the lead-out end. The first bus component or the flat wire winding includes a copper-aluminum connection portion, which is covered by an insulating protective element.

[0007] In at least one embodiment, all the flat wires of the flat wire winding are aluminum flat wires, and each phase bus of the first bus assembly includes an integrally formed copper segment and an aluminum segment, which are connected to form a copper-aluminum connection, and the aluminum segment is welded to the lead end of the aluminum flat wire.

[0008] In at least one embodiment, both the copper-aluminum connector and the insulating protective member are curved and extend circumferentially along the stator, and all the copper-aluminum connectors in the first busbar assembly are arranged at intervals circumferentially.

[0009] In at least one embodiment, the aluminum segment includes a body portion and a welded portion connected to the body portion, the welded portion extending axially and welded to a lead-out end, and the welded portion and the lead-out end overlapping radially.

[0010] In at least one embodiment, the radial peripheral wall of the insulating protective member is formed with a clearance groove for the welding part to pass through.

[0011] In at least one embodiment, the copper-aluminum connector includes stacked aluminum and copper layers.

[0012] In at least one embodiment, each phase flat wire winding includes multiple aluminum flat wires and one lead wire. The lead wire includes integrally formed copper flat wire segments and aluminum flat wire segments. The copper-aluminum connection portion formed by connecting the copper flat wire segments and aluminum flat wire segments is located in the winding slot of the stator core.

[0013] The lead-out end is formed at the end of the copper flat wire segment away from the aluminum flat wire segment, and the first bus assembly is made of copper.

[0014] In at least one embodiment, the bus assembly further includes a second bus connected to the neutral point output terminal of each branch in the flat wire winding, the second bus being made of the same material as the neutral point output terminal.

[0015] In at least one embodiment, the copper-aluminum connector and the second busbar are encased in an insulating protective component to form an integrated structure.

[0016] According to a second aspect of this application, an electric motor is provided, comprising: the stator of the flat wire motor provided in the first aspect above.

[0017] In the stator of the flat wire motor provided in this embodiment, the manufacturing material of the connection portion between the first busbar assembly and the lead-out end of the flat wire winding in the busbar assembly is the same as the manufacturing material of the lead-out end, thereby ensuring the welding strength of the first busbar assembly and the flat wire winding and ensuring the reliability of the connection between the two. Simultaneously, by providing an insulating protective component to wrap the copper-aluminum connection portion located in the first busbar assembly or the flat wire winding, the contact of the copper-aluminum connection with moisture in the environment can be prevented, thus avoiding electrochemical corrosion at the copper-aluminum connection and ensuring the electrical performance and structural strength of the first busbar assembly or the flat wire winding. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the stator provided according to the first embodiment of this application.

[0019] Figure 2 yes Figure 1 The diagram shows an integrated structure formed by the first busbar assembly and the insulating protective component in the stator.

[0020] Figure 3 yes Figure 2 The bottom view.

[0021] Figure 4 yes Figure 2 The diagram shows the structure of the first busbar assembly.

[0022] Figure 5 yes Figure 2 The diagram shows the structure of the first phase bus in the first bus assembly.

[0023] Figure 6 This is a schematic diagram of the structure of the first busbar assembly in the stator according to the second embodiment of this application.

[0024] Figure 7 yes Figure 6 The diagram shows the structure of the third phase bus in the first bus assembly.

[0025] Figure 8 This is a schematic diagram of a stator provided according to the third embodiment of this application.

[0026] Figure 9 yes Figure 8 A schematic diagram of the lead wire structure in the flat wire winding of the stator shown.

[0027] Figure 10 yes Figure 9 A partial sectional view of the leader line shown.

[0028] Explanation of reference numerals in the attached figures:

[0029] 100 - Stator core;

[0030] 200 - Flat wire winding; 201 - Lead-out terminal; 202 - Neutral point lead-out terminal; 21 - Lead-out wire; 211 - Copper flat wire segment; 212 - Aluminum flat wire segment;

[0031] 30-First busbar assembly; 31-First phase busbar; 311-Copper segment; 312-Aluminum segment; 313-Welding section; 32-Second phase busbar; 33-Third phase busbar;

[0032] 40 - Second busbar;

[0033] 300 - Copper-aluminum connection; 301 - Aluminum layer; 302 - Copper layer;

[0034] 400 - Insulating protective component; 401 - Clearance groove. Detailed Implementation

[0035] Exemplary embodiments of this application are described below with reference to the accompanying drawings. It should be understood that these specific descriptions are for teaching those skilled in the art how to implement this application only, and are not intended to exhaustively describe all possible methods of this application, nor to limit the scope of this application.

[0036] Unless otherwise specified, the terms radial, axial, and circumferential as used below refer to the radial, axial, and circumferential directions of the stator.

[0037] First Implementation Method

[0038] Reference Figures 1 to 5 First, the stator and motor of the flat wire motor according to the first embodiment of this application will be introduced.

[0039] In this embodiment, the stator of the flat wire motor includes a stator core 100, a flat wire winding 200, and a busbar assembly. The flat wire winding is made of aluminum flat wire, and the material of the aluminum flat wire is pure aluminum or aluminum alloy. Those skilled in the art can choose according to actual needs.

[0040] The bus assembly is electrically connected to the flat wire winding 200. In this embodiment, the bus assembly includes a first bus component 30 located at the crown end of the flat wire winding 200.

[0041] In this embodiment, the flat wire winding 200 includes a three-phase winding, correspondingly, as shown below. Figures 2-3 As shown, the first bus assembly 30 includes three buses: a first phase bus 31, a second phase bus 32, and a third phase bus 33. The first phase bus 31, the second phase bus 32, and the third phase bus 33 are respectively connected to the U-phase winding, the V-phase winding, and the W-phase winding of the flat wire winding 200.

[0042] like Figure 1 As shown, the crown end of the flat wire winding 200 has multiple (6 in this embodiment, i.e., 2 leads per phase winding) leads 201 that are welded to the first busbar assembly 30.

[0043] In this embodiment, the manufacturing materials of the connection portions of the first phase busbar 31, the second phase busbar 32, and the third phase busbar 33 with the lead-out terminal 201 are the same as those of the lead-out terminal 201, for example, pure aluminum. This avoids the difference in materials at the welding points between each phase busbar and the flat wire winding 200, reduces the welding difficulty between each phase busbar and the flat wire winding 200, ensures the welding strength between each phase busbar and the flat wire winding 200, and guarantees the reliability of the welding between each phase busbar and the flat wire winding 200.

[0044] Specifically, such as Figure 5 As shown, the first phase busbar 31 includes an integrally formed copper segment 311 and an aluminum segment 312. The copper segment 311 is used for electrical connection with the power supply, and the aluminum segment 312 is welded to the lead-out end 201 of the aluminum flat wire. To ensure the connection strength between each phase busbar and the lead-out end 201, the welded portion 313 in the aluminum segment 312, which is connected to the main body, extends axially. That is, the extension direction of the welded portion 313 is the same as the extension direction of the lead-out end 201. This ensures that the welded portion 313 and the lead-out end 201 connected to it overlap radially and are flush axially, thereby ensuring the contact area between the welded portion 313 and the lead-out end 201. This facilitates the welding process and ensures the connection strength between the welded portion 313 and the lead-out end 201 after welding, improving the reliability of the stator during operation.

[0045] like Figure 5As shown, the two welded parts 313 of each phase busbar are distributed radially and arranged circumferentially. This arrangement can ensure the radial dimension of the aluminum segment 312 body, help ensure the structural strength of the aluminum segment 312, and also avoid interference between the welded parts 313, which facilitates the subsequent welding process.

[0046] like Figure 4 and Figure 5 As shown, in each phase busbar, a copper-aluminum connection 300 is formed at the junction of the copper segment 311 and the aluminum segment 312. It should be noted that, for the reader's intuitive understanding of the phase busbar structure, Figure 4 and Figure 5 The copper-aluminum connection 300 is indicated by a dashed box in the diagram. In the actual product, the phase busbar also has the dashed line shown in the diagram.

[0047] In this embodiment, each phase busbar is integrally formed, that is, the copper segment 311, the aluminum segment 312 and the copper-aluminum connection 300 are integrally formed structures, which can ensure the structural strength of the phase busbar, avoid the problem of cracking or even breakage at the copper-aluminum connection during the operation of the stator, and ensure the reliability of stator operation.

[0048] In this embodiment, a portion of the structure of the first bus assembly 30 is covered by an insulating protective element 400. Specifically, in conjunction with... Figure 2 , Figure 3 and Figure 4 It can be seen that the copper-aluminum connection 300 in each phase busbar is covered by the insulating protective component 400, which can prevent the copper-aluminum connection from contacting moisture in the environment, prevent the electrochemical corrosion of the copper-aluminum connection, and ensure the electrical performance and structural strength of each phase busbar.

[0049] Meanwhile, the first phase bus 31, the second phase bus 32, and the third phase bus 33 are connected into a whole by the insulating protective component 400, thereby enhancing the structural strength of the first bus assembly 30. Optionally, the insulating protective component 400 is formed by injection molding, thereby ensuring its connection strength with each phase bus.

[0050] In this embodiment, such as Figure 2 and Figure 3 As shown, the insulating protective component 400 is curved, extending circumferentially along the stator, as... Figure 4As shown, the copper-aluminum connecting portions 300 in the first phase busbar 31, the second phase busbar 32, and the third phase busbar 33 are arranged circumferentially at intervals and located in the same plane. The curvature of the curve segment formed by the line connecting the three copper-aluminum connecting portions 300 is the same as the curvature of the insulating protective component 400, so as to ensure that the three copper-aluminum connecting portions 300 can be completely wrapped by the insulating protective component 400. This helps to reduce the radial and axial dimensions of the insulating protective component 400, which is beneficial to reducing the weight and manufacturing cost of the insulating protective component 400. It also reduces the volume of the insulating protective component 400, which is convenient for the arrangement of sensors such as NTC (Negative Temperature Coefficient).

[0051] like Figure 2 and Figure 3 As shown, the outer radial peripheral wall and the inner radial peripheral wall of the insulating protective component 400 are formed with clearance grooves 401 to provide space for the welding part 313 to pass through, which helps to ensure the welding process between the welding part 313 and the lead-out end 201.

[0052] In this embodiment, such as Figure 1 As shown, the bus assembly also includes a second bus 40, which is welded to the neutral point output terminal 202 of each branch in the flat wire winding 200. Since the neutral point output terminal 202 is made of aluminum, the second bus 40 can be made of aluminum, thereby reducing the welding difficulty between the second bus 40 and the flat wire winding 200, ensuring the welding strength between the second bus 40 and the flat wire winding 200, and ensuring the reliability of the welding between the second bus 40 and the flat wire winding 200.

[0053] Based on the same inventive concept, this embodiment also provides a flat wire motor including the stator described above. Compared with existing aluminum winding motors, this flat wire motor has the characteristics of long service life and high operational reliability. Other beneficial effects of the flat wire motor can be referred to the above description of the stator, and will not be repeated here.

[0054] Second Implementation Method

[0055] Reference Figure 6 and Figure 7 This application describes the stator and motor of a flat wire motor according to a second embodiment. The second embodiment is a variation of the first embodiment. Components with the same or similar structure or function as those in the first embodiment are marked with the same reference numerals, and specific descriptions of these components are omitted.

[0056] The main difference between this embodiment and the first embodiment is that the copper-aluminum connection portion 300 includes a stacked aluminum layer 301 and a copper layer 302. Specifically, the aluminum layer 301 is formed by extending the aluminum sub-segment 312 towards the copper sub-segment 311, and the copper layer 302 is formed by extending the copper sub-segment 311 towards the aluminum sub-segment 312. This method increases the contact area between the aluminum layer 301 and the copper layer 302 in the copper-aluminum connection portion 300, thereby increasing the structural strength of the copper-aluminum connection portion 300.

[0057] In this embodiment, the aluminum layer 301 and the copper layer 302 are stacked axially. In other embodiments, the aluminum layer 301 and the copper layer 302 may also be stacked radially.

[0058] In this embodiment, aluminum strips and copper strips can be formed into phase busbars through rolling and pressing processes, or through melting and casting processes. This makes the copper segment 311, aluminum segment 312, and copper-aluminum connection 300 an integrally formed structure, which avoids copper-aluminum welding, ensures the structural strength of the phase busbars, and prevents the stator from cracking or even breaking at the copper-aluminum connection during operation, thus ensuring the reliability of stator operation.

[0059] Third Implementation Method

[0060] Reference Figure 8 , Figure 9 and Figure 10 This paper describes the stator and motor of a flat wire motor according to a second embodiment of this application. The third embodiment is a variation of the first and second embodiments. Components with the same or similar structure or function as those in the first embodiment are marked with the same reference numerals, and specific descriptions of these components are omitted.

[0061] The main difference between this embodiment and the first and second embodiments is that, in this embodiment, the copper-aluminum connection portion 300 is not disposed in the first busbar assembly 30, but in the flat wire winding 200.

[0062] In this embodiment, each phase winding of the flat wire winding 200 includes multiple aluminum flat wires and a lead wire 21. The lead wire 21 is a copper-aluminum composite flat wire. Specifically, the lead wire 21 includes an integrally formed copper flat wire segment 211 and an aluminum flat wire segment 212. The connection between the copper flat wire segment 211 and the aluminum flat wire segment 212 forms a copper-aluminum connection part 300. The insulating protective component 400 constitutes an insulating film for the lead wire 21, thereby covering the copper-aluminum connection part 300. This prevents the copper-aluminum connection part from contacting moisture in the environment and avoids electrochemical corrosion at the copper-aluminum connection part.

[0063] Optionally, the insulating protective component 400 is made of PEEK (Polyetheretherketone), which ensures that the insulating protective component 400 has sufficient structural strength to prevent the copper-aluminum connection 300 of the low lead 21 from breaking.

[0064] In this embodiment, by placing the copper-aluminum connector 300 in the lead wire 21 and positioning it within the winding slot of the stator core 100, the structural strength of the lead wire 21 is ensured. Furthermore, this design allows the lead end 201 to be formed at the end of the copper flat wire segment 211 away from the aluminum flat wire segment 212; that is, the lead end 201 is made of copper. This enables the first busbar assembly 30, which is welded to the lead end 201, to be made of copper, thus reducing the heat generated by the first busbar assembly 30 during operation.

[0065] In this embodiment, since the copper-aluminum connection is located in the flat wire winding 200, the first busbar assembly 30 does not require injection molding, which can reduce the manufacturing cost and manufacturing difficulty of the first busbar assembly 30.

[0066] It should be understood that the above-described embodiments and some aspects or features thereof can be appropriately combined. For example, in the first and second embodiments, the copper-aluminum connection portion 300 and the second busbar 40 in the stator are both wrapped by the insulating protective component 400 to form an integrated structure, thereby making the busbar assembly a single structure and ensuring the structural strength of the busbar assembly.

[0067] This application has at least one of the following advantages:

[0068] (i) In this embodiment, the manufacturing materials of the connection parts of the first phase bus, the second phase bus and the third phase bus and the lead-out end are the same as the manufacturing materials of the lead-out end, so as to avoid the difference in materials at the welding points of each phase bus and the flat wire winding, reduce the welding difficulty of each phase bus and the flat wire winding, ensure the welding strength of each phase bus and the flat wire winding, and ensure the reliability of the welding of each phase bus and the flat wire winding 200.

[0069] (ii) The copper-aluminum connections in each phase busbar are covered by insulating protective components, thereby preventing the copper-aluminum connections from coming into contact with moisture in the environment, avoiding electrochemical corrosion at the copper-aluminum connections, and ensuring the electrical performance and structural strength of each phase busbar. Furthermore, the insulating protective components connect the first phase busbar, the second phase busbar, and the third phase busbar into a whole, thereby enhancing the structural strength of the first busbar assembly.

[0070] (iii) The copper segments, aluminum segments and copper-aluminum connections in each phase busbar are integrally formed, which can ensure the structural strength of the phase busbar, avoid the problem of cracking or even breakage at the copper-aluminum connection during the operation of the stator, and ensure the reliability of the stator operation.

[0071] (iv) By placing the copper-aluminum connection in the lead wire, the copper-aluminum connection can be located within the winding slot of the stator core, which helps to ensure the structural strength of the lead wire. Moreover, this allows the first busbar assembly welded to the lead end to be made of copper, which helps to reduce the heat generated by the first busbar assembly during operation.

[0072] Of course, this application is not limited to the above-described embodiments. Those skilled in the art can make various modifications to the above-described embodiments of this application under the guidance of this application, without departing from the scope of this application.

Claims

1. A stator for a flat wire motor, comprising: A stator core, flat wire windings and busbar assembly, characterized in that the flat wire windings are made of aluminum; The bus assembly includes a first bus component connected to the lead-out end of the flat wire winding. The first bus component and the lead-out end are made of the same material as the lead-out end. The first bus component or the flat wire winding includes a copper-aluminum connection portion, which is covered by an insulating protective component.

2. The stator according to claim 1, characterized in that, All flat wires in the flat wire winding are aluminum flat wires. Each phase busbar of the first busbar assembly includes an integrally formed copper segment and an aluminum segment. The copper segment and the aluminum segment are connected to form the copper-aluminum connection part. The aluminum segment is welded to the lead end of the aluminum flat wire.

3. The stator according to claim 2, characterized in that, Both the copper-aluminum connection and the insulating protective component are curved and extend circumferentially along the stator, and all the copper-aluminum connection portions in the first busbar assembly are arranged at intervals circumferentially.

4. The stator according to claim 2, characterized in that, The aluminum segment includes a body portion and a welded portion connected to the body portion. The welded portion extends axially and is welded to the lead-out end. The welded portion and the lead-out end overlap radially.

5. The stator according to claim 4, characterized in that, The radial peripheral wall of the insulating protective component has a clearance groove for the welded part to pass through.

6. The stator according to claim 2, characterized in that, The copper-aluminum connection includes stacked aluminum and copper layers.

7. The stator according to claim 1, characterized in that, Each phase of the flat wire winding includes multiple aluminum flat wires and one lead wire. The lead wire includes an integrally formed copper flat wire segment and an aluminum flat wire segment. The copper-aluminum connection portion formed by connecting the copper flat wire segment and the aluminum flat wire segment is located in the winding slot of the stator core. The lead-out end is formed at the end of the copper flat wire segment away from the aluminum flat wire segment, and the first busbar assembly is made of copper.

8. The stator according to claim 1, characterized in that, The bus assembly further includes a second bus connected to the neutral point output terminal of each branch in the flat wire winding, the second bus being made of the same material as the neutral point output terminal.

9. The stator according to claim 8, characterized in that, The copper-aluminum connector and the second busbar are encased by the insulating protective component to form an integrated structure.

10. An electric motor, characterized in that, include: The stator of the flat wire motor according to any one of claims 1-9.

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