Stator assembly and electric machine
By stacking the lead-out ends radially along the core in the winding structure of the flat wire motor and using locking sleeves and welding, the problem of eliminating the star-shaped copper busbars in the flat wire motor is solved, achieving a stable electrical connection and reducing welding costs.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- CHONGQING SOKON POWER CO LTD
- Filing Date
- 2025-08-21
- Publication Date
- 2026-07-21
AI Technical Summary
In the existing technology, it is difficult to eliminate the design of star-shaped copper busbars in flat wire motors because the cross-section of the conductors in flat wire motors is flat, and it is difficult to fix and electrically connect the winding structure output position through hot rolling process.
By forming the lead-out ends of the winding lines of the three phases of the flat wire motor winding structure, and stacking them sequentially along the radial direction of the core, electrical connection is achieved using locking sleeves and welding methods, including resistance welding and laser welding, to ensure the stability of the connection.
The design eliminates the need for star-shaped copper busbars in flat wire motors, improving connection stability and welding reliability while reducing welding costs.
Smart Images
Figure CN224537894U_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of motor technology, and in particular to a stator assembly and a motor. Background Technology
[0002] The stator assembly of an electric motor typically includes a core and a winding structure wound around it, usually made of wire. For a three-phase motor, the winding structure consists of three phases of winding lines, and the outlet points of these three phases are typically connected as "star points," which can be connected using star-point copper busbars. While existing technologies exist that directly connect the outlet points of the three phases together, eliminating the need for star-point copper busbars, this design is generally only suitable for round-wire motors, i.e., motors with circular wire cross-sections. This existing design is difficult to apply to flat-wire motors. Utility Model Content
[0003] Based on this, this application provides a stator assembly and a motor to improve the problem that it is difficult to eliminate the star-point copper busbar in the prior art flat wire motor.
[0004] In a first aspect, this application provides a stator assembly, the stator assembly including a stator winding and an iron core, the stator winding being disposed on the iron core, the stator winding including three phase winding lines, each phase winding line being wound with a flat cross-section wire, and each phase winding line having an outlet end at its outlet position, the outlet ends of the three phase winding lines forming at least one star point, and several outlet ends constituting the same star point being stacked sequentially along the radial direction of the iron core and welded and fixed to achieve electrical connection.
[0005] In one embodiment, a locking sleeve is also fitted over several of the outgoing ends constituting the same star point.
[0006] In one embodiment, the locking sleeve is made of a conductive material, and several of the lead-out ends are welded and fixed to the locking sleeve by resistance welding.
[0007] In one embodiment, a connecting layer is further provided on the inner side of the locking sleeve.
[0008] In one embodiment, the locking sleeve is provided with an opening groove to allow the locking sleeve to be disengaged.
[0009] In one embodiment, the plurality of the outgoing terminals constituting the same star point are welded together by laser welding.
[0010] In one embodiment, the winding circuit of each phase includes only one winding branch, and the outgoing ends of the winding circuits of the three phases form a star point.
[0011] In one embodiment, the winding circuit of each phase includes several winding branches, and the outgoing ends of the same winding branch of the winding circuits of the three phases respectively form a star point.
[0012] In one embodiment, each phase winding circuit includes a lead-out hairpin, and each phase winding circuit uses the lead-out hairpin as the last coil at its lead-out position. The lead-out hairpin includes an effective side, a welding end, and a hairpin end. The hairpin end and the welding end are located at both ends of the effective side, and the lead-out end is formed by extending from the hairpin end.
[0013] Secondly, this application provides an electric motor, which includes any of the stator components provided in this application.
[0014] Based on the flat cross-section of the conductor, this application forms the lead-out ends by setting the lead-out positions of the winding lines of the three phases of the winding structure, and stacks several lead-out ends that constitute the same star point along the radial direction of the iron core. This allows the several lead-out ends to have a relatively large contact area when stacked, so as to facilitate welding and fixing the several lead-out ends to achieve electrical connection and ensure the stability of the connection. This enables the flat wire motor to eliminate the star point copper busbar design. Attached Figure Description
[0015] Figure 1 This is a schematic diagram of the structure of a stator assembly provided in an embodiment of this application;
[0016] Figure 2 for Figure 1 Enlarged view of section A;
[0017] Figure 3 An exploded view of the lead-out clips and locking sleeves of the three phases of a stator assembly provided in an embodiment of this application.
[0018] Reference numerals: 100, core component; 110, stator slot; 200, lead-out end; 300, hairpin coil; 400, locking sleeve; 410, opening slot; 500, connecting layer; 600, lead-out hairpin; 610, effective edge; 620, welding end; 630, hairpin end. Detailed Implementation
[0019] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.
[0020] It should be noted that the illustrations provided in this embodiment are only schematic representations of the basic concept of this utility model.
[0021] The structures, proportions, sizes, etc., shown in the accompanying drawings of this specification are only for the purpose of assisting those skilled in the art in understanding and reading the content disclosed in the specification, and are not intended to limit the conditions under which this utility model can be implemented. Any modifications to the structure, changes in the proportions, or adjustments to the size, without affecting the effects and purposes that this utility model can produce, should still fall within the scope of the technical content disclosed in this utility model.
[0022] As described in the background section, the winding structure of a three-phase motor stator assembly includes three phase windings, and the outgoing positions of the three phase windings are typically connected as "star points" so that the three phase windings constitute a three-phase circuit. During connection, star-point copper busbars can be used for this purpose.
[0023] While existing technologies include designs that directly connect the three phase outputs together, eliminating the need for a star-shaped copper busbar, this design is typically only applicable to round wire motors, i.e., motors with circular cross-section conductors. In practical connection, the stator assembly of a round wire motor has relatively low requirements for the routing and arrangement of its winding structure. The conductors are usually wound on the iron core, forming coils with a specific number of turns. Furthermore, the conductors at the output positions of the winding structure can usually extend in any direction. Therefore, when eliminating the star-shaped copper busbar design, a round wire motor typically only needs to fix and electrically connect several circular cross-section conductors of the three phases. The common practice is to wrap metal wire around several circular cross-section conductors, and then use a hot rolling process to connect the metal wire to the circular cross-section conductors. Since the conductors at the output positions can extend freely, the hot rolling process is also relatively convenient.
[0024] For flat-wire motors, the cross-section of the conductors is flat. This flatness necessitates that the winding structure be wound into a specific shape during the winding process, typically a hairpin-shaped coil. The lead-out positions of the winding structure, based on the aforementioned hairpin-shaped coil structure, can usually only extend in a specified direction and for a limited distance. Therefore, when the star-shaped copper busbar design is eliminated in flat-wire motors, it becomes difficult to achieve fixation and electrical connection of the several flat-section conductors through hot rolling. In other words, the existing design that eliminates the star-shaped copper busbar is difficult to apply to flat-wire motors.
[0025] Based on this, this application provides a stator assembly, which includes a stator winding and an iron core 100. The stator winding is disposed on the iron core 100 and includes three phase windings. Each phase winding is made of a flat-section wire, and each phase winding has an outlet end 200 at its outlet position. The outlet ends 200 of the three phase windings form at least one star point. Several outlet ends 200 constituting the same star point are stacked and welded together radially along the iron core 100 to achieve electrical connection.
[0026] like Figure 1 As shown in this embodiment, the stator assembly may include a core 100 and a winding structure wound on the core 100. The core 100 may be formed by stacking a number of laminations, and a number of stator slots 110 may be provided on its inner side. The winding structure may be partially wound in the stator slots 110, and both ends of the winding structure extend outside the stator slots 110.
[0027] like Figure 1 and Figure 2 As shown, the winding structure in this embodiment is applicable to a three-phase motor and can include winding lines for three phases, each of which can be wound with wire. The cross-section of the wire used for winding can be flat, and the wire can be used to wind a hairpin coil 300. The hairpin coil 300 can be arranged in the stator slot 110 using a slot method. During winding, a single wire can be continuously wound into several hairpin coils 300, or it can be wound into only one hairpin coil 300, with adjacent hairpin coils 300 welded together to achieve electrical connection.
[0028] like Figure 2 As shown, when the winding of each phase is completed, its exit position forms an exit end 200. The exit end 200 can extend beyond the two ends of the three-phase winding structure, that is, extend outward a short distance. The exit ends 200 of the three-phase winding branches form at least one star point. For example, when the winding of each phase includes two parallel winding branches, the exit ends 200 of the first winding branch of the three phases can be connected to form one star point, and the exit ends 200 of the second winding branch of the three phases can be connected to form another star point; or the exit ends 200 of the two winding branches of the three phases can be connected to form only one star point.
[0029] Of course, in some embodiments, the number of parallel branches included in the winding of each phase may also be different.
[0030] like Figure 2As shown, among the several outgoing terminals 200 constituting the same star point, the several outgoing terminals 200 are stacked sequentially along the radial direction of the iron core 100, that is, the several outgoing terminals 200 are stacked along its thickness direction. At this time, there can be a relatively large contact area between two adjacent outgoing terminals 200. The several outgoing terminals 200 are welded and fixed to achieve electrical connection.
[0031] It is understandable that, based on setting the cross-section of the conductor to be flat, this application forms the lead-out end 200 by forming the lead-out position of the winding circuit of the three phases of the winding structure, and stacks several lead-out ends 200 constituting the same star point along the radial direction of the iron core 100. This allows the several lead-out ends 200 to have a relatively large contact area when stacked, so as to weld and fix the several lead-out ends 200 to achieve electrical connection and ensure the stability of the connection. This achieves the design of eliminating the star point copper busbar in the flat wire motor.
[0032] Specifically, a locking sleeve 400 is also fitted around several outgoing terminals 200 that constitute the same star point.
[0033] like Figure 2 and Figure 3 As shown in this embodiment, by way of example, the winding structure may further include a locking sleeve 400, which can be sleeved on a plurality of outgoing terminals 200 constituting the same star point, and is used to lock and fix the plurality of terminals constituting the same star point.
[0034] It is understood that by fitting locking sleeves 400 onto several outgoing terminals 200 that constitute the same star point, this embodiment can further improve the stability of welding and fixing between the several outgoing terminals 200.
[0035] More specifically, the locking sleeve 400 is made of conductive material, and several lead-out ends 200 are welded and fixed to the locking sleeve 400 by resistance welding.
[0036] like Figure 3 As shown in this embodiment, the locking sleeve 400 can be made of copper, i.e., the locking sleeve 400 is a copper sleeve, to give it relatively good conductivity. After the locking sleeve 400 is fitted onto several lead-out terminals 200, the several lead-out terminals 200 can also be fixed to the locking sleeve 400 by resistance welding, i.e., all the lead-out terminals 200 are welded to the locking sleeve 400. The resistance welding method can save welding costs while ensuring the stability of the weld.
[0037] It is understood that by placing the locking sleeve 400 on a conductive material and welding several lead-out ends 200 to the locking sleeve 400 by resistance welding, the stability of the welding and fixing of several lead-out ends 200 can be further improved.
[0038] More specifically, a connecting layer 500 is also provided on the inner side of the locking sleeve 400.
[0039] like Figure 3 As shown in this embodiment, it is exemplarily illustrated that when several lead-out terminals 200 can also be fixed to the locking sleeve 400 by resistance welding, a brazing tab can be provided on the inner side of the locking sleeve 400. When several lead-out terminals 200 are all fixed to the locking sleeve 400 by resistance welding, the brazing tab melts due to heat absorption and forms a liquid metal film. This liquid metal film will be tightly bonded to both the inner surface of the locking sleeve 400 and the outer surface of the several lead-out terminals 200 to improve the connection effect between the several lead-out terminals 200 and the locking sleeve 400. After the liquid metal film cools, it can be formed into a connecting layer 500 arranged on the inner side of the locking sleeve 400.
[0040] It is understood that by providing a connecting layer 500 on the inner side of the locking sleeve 400, this embodiment can improve the stability of the connection between several outlet ends 200 and the locking sleeve 400, so as to further improve the stability of welding and fixing between several outlet ends 200.
[0041] Specifically, the locking sleeve 400 is provided with an opening groove 410 so that the locking sleeve 400 can be disconnected.
[0042] like Figure 3 As shown in this embodiment, the locking sleeve 400 can have a rectangular cross-section, meaning it can be a rectangular sleeve. The locking sleeve 400 can be broken on either its length or width direction, creating an opening groove 410. The opening groove 410 can be a rectangular strip, and its length direction can be the axial direction of the core member 100.
[0043] It is understood that by providing an opening groove 410 on the locking sleeve 400 in this embodiment, the locking sleeve 400 can have a certain tension at least at the position where the opening groove 410 is located, so as to facilitate operation when the locking sleeve 400 is fitted onto several outlet ends 200, and to have a better locking and fixing effect after being fitted.
[0044] In some embodiments, the multiple lead-out terminals 200 constituting the same star point can also be welded and fixed together by laser welding. Since laser welding is a non-contact heating method with a relatively small heat-affected zone, it can achieve higher precision welding. In this case, even without locking sleeves 400 on the multiple lead-out terminals 200, the connection between them can still be stable. Of course, when laser welding is used to weld the multiple lead-out terminals 200 together, locking sleeves 400 can also be fitted onto them. The locking sleeves 400 can be made of metal and welded and fixed simultaneously with the multiple lead-out terminals 200. Alternatively, the locking sleeves 400 can be made of non-metallic materials and are not welded and fixed simultaneously with the multiple lead-out terminals 200.
[0045] Specifically, each phase winding circuit includes only one winding branch, and the outgoing terminals 200 of the three phase winding circuits form a star point.
[0046] like Figure 1 and Figure 2 As shown in this embodiment, by way of example, the winding circuit of each phase may include only one winding branch. Since each winding branch corresponds to one exit position, the winding circuits of the three phases have a total of three exit positions, and correspondingly form three exit terminals 200. The three exit terminals 200 are welded and fixed, forming a star point.
[0047] It is understood that in this embodiment, when each phase winding circuit includes only one winding branch, the output terminals 200 of the three phase winding circuits are formed into a star point, which can realize the design of eliminating the star point copper busbar in the flat wire motor.
[0048] Of course, in some embodiments, the winding circuit of each phase may also include several winding branches, and the output terminals 200 of the same winding branch of the three phases respectively form a star point. For example, the winding circuit of each phase may include two parallel winding branches, and the output terminals 200 of the first winding branch of the three phases are connected to form a star point, and the output terminals 200 of the second winding branch of the three phases are connected to form another star point.
[0049] It is not difficult to see that, compared with the connection method of connecting the outgoing terminals 200 of several winding branches of the three phases into a single star point, the connection method of connecting the outgoing terminals 200 of several winding branches of the three phases into several star points can reduce the number of welding ends 620 that need to be stacked in each star point, thereby reducing the volume of the star point. This can avoid local overheating during the operation of the winding structure, facilitate the connection between the outgoing terminals 200 of the three phases, and ensure the stability of the connection.
[0050] Specifically, each phase winding circuit includes a lead-out hairpin 600, and each phase winding circuit uses the lead-out hairpin 600 as the last coil at its lead-out position. The lead-out hairpin 600 includes an effective side 610, a welding end 620, and a hairpin end 630. The hairpin end 630 and the welding end 620 are located at both ends of the effective side 610, and the lead-out end 200 is formed by extending from the hairpin end 630.
[0051] like Figure 1 and Figure 3 As shown in this embodiment, by way of example, the winding circuit of each phase can include a lead-out hairpin 600, and the winding circuit of each phase can use the lead-out hairpin 600 as the last coil at its lead-out position. The lead-out hairpin 600 is a type of hairpin coil. When the winding circuit of each phase includes several winding branches, each winding branch includes one lead-out hairpin 600. Before winding to the position of the lead-out hairpin 600, each winding branch can be formed by connecting several other hairpin coils 300, and the number of other hairpin coils 300 is not limited here. Of course, before winding to the position of the lead-out hairpin 600, each winding branch can also be wound by one or several wires, and at least one wire can be used to continuously wind two hairpin coils 300.
[0052] In this embodiment, the lead-out clip 600 may include an effective edge 610, a welding end 620, and a clip end 630. The effective edge 610, welding end 620, and clip end 630 may be integrally formed. The effective edge 610 may be disposed within the stator slot 110, while the clip end 630 and welding end 620 may be disposed at both ends of the effective edge 610. The lead-out end 200 may be formed by extending from the clip end 630, that is, the lead-out end 200 may also be integrally formed. The extension direction of the lead-out end 200 may be the axial direction of the core component 100.
[0053] like Figure 3 As shown, in this embodiment, among the three phases that form the same star point in the outgoing terminal 200, the extending directions of the outgoing terminals 630 of the three outgoing terminals 600 can be different.
[0054] For example, the three phases of the stator assembly can be phase U, phase V, and phase W. The markings "U", "V", and "W" are only for the convenience of describing the three phases of the stator assembly and are not used to limit the stator assembly in any way. The three phases "U", "V", and "W" of the stator assembly can be interchanged arbitrarily. Of course, the three phases of the stator assembly can also be represented by other markings.
[0055] The effective edges 610 of the U-phase, V-phase, and W-phase outgoing line clips 600 can be arranged sequentially in different stator slots 110 along the circumference of the core 100. The clip end 630 of the V-phase outgoing line clip 600 extends along the axial direction of the core 100, while the clip end 630 of the U-phase outgoing line clip 600 can extend in an inclined direction close to the clip end 630 of the V-phase outgoing line clip 600. The clip end 630 of the W-phase outgoing line clip 600 can also extend in an inclined direction close to the clip end 630 of the V-phase outgoing line clip 600. At this time, the clip ends 630 of the U-phase outgoing line clip 600 and the clip ends 630 of the W-phase outgoing line clip 600 are in a convergent state. When the outlet ends 630 of the outlet outlets 600 of the U-phase, V-phase and W-phase are close to each other, the outlet ends 200 formed by the outlet ends 630 of the outlet outlets 600 of the U-phase, V-phase and W-phase can be radially offset and stacked in sequence to facilitate welding and fixing.
[0056] The implementation principle of a stator assembly provided in this application embodiment is as follows:
[0057] The winding lines of all three phases of the winding structure are wound on the iron core 100. In this embodiment, the winding line of each phase includes only one winding branch. Each winding branch is made of wire, and each winding branch uses the lead-out hairpin 600 as the last coil at the lead-out position. At the same time, the hairpin end 630 of the lead-out hairpin 600 extends to form the lead-out end 200. The lead-out ends 200 of the three phases are stacked radially along the iron core 100 and welded to achieve electrical connection and form a star point. The lead-out ends 200 of the three phases can be welded by resistance welding after the locking sleeve 400 is fitted on.
[0058] Based on the flat cross-section of the conductor, this application forms the lead-out terminals 200 by creating the lead-out positions of the three phases of the winding structure. Several lead-out terminals 200 constituting the same star point are stacked radially along the core 100. This allows the several lead-out terminals 200 to have a relatively large contact area when stacked, so that they can be welded and fixed to achieve electrical connection while ensuring the stability of the connection. This enables the flat wire motor to eliminate the star point copper busbar design.
[0059] This application also provides an electric motor, which includes any of the stator assemblies provided in this application.
[0060] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.
[0061] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the utility model patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.
Claims
1. A stator assembly, characterized in that, The stator assembly includes a stator winding and an iron core (100). The stator winding is disposed on the iron core (100). The stator winding includes three phase windings. Each phase winding is made of a flat-section wire. Each phase winding has an outlet end (200) at its outlet position. The outlet ends (200) of the three phase windings form at least one star point. Several outlet ends (200) constituting the same star point are stacked sequentially along the radial direction of the iron core (100) and welded to achieve electrical connection.
2. The stator assembly according to claim 1, characterized in that, A locking sleeve (400) is also provided on the outside of several of the output terminals (200) that constitute the same star point.
3. The stator assembly according to claim 2, characterized in that, The locking sleeve (400) is made of conductive material, and several of the lead-out ends (200) are welded and fixed to the locking sleeve (400) by resistance welding.
4. The stator assembly according to claim 3, characterized in that, The inner side of the locking sleeve (400) is also provided with a connecting layer (500).
5. The stator assembly according to claim 2, characterized in that, The locking sleeve (400) is provided with an opening groove (410) so that the locking sleeve (400) can be disconnected.
6. The stator assembly according to claim 1 or 2, characterized in that, The several outgoing terminals (200) constituting the same star point are welded and fixed together by laser welding.
7. The stator assembly according to claim 1, characterized in that, Each phase winding consists of only one winding branch, and the outgoing ends (200) of the three phase windings form a star point.
8. The stator assembly according to claim 1, characterized in that, Each phase winding circuit includes several winding branches, and the outgoing terminals (200) of the same winding branch of the three phase winding circuits respectively form a star point.
9. The stator assembly according to claim 1, characterized in that, Each phase winding circuit includes a lead-out hairpin (600), and each phase winding circuit uses the lead-out hairpin (600) as the last coil at its lead-out position. The lead-out hairpin (600) includes an effective side (610), a welding end (620), and a hairpin end (630). The hairpin end (630) and the welding end (620) are located at both ends of the effective side (610), and the lead-out end (200) is formed by extending from the hairpin end (630).
10. An electric motor, characterized in that, The motor includes the stator assembly as described in any one of claims 1-9.