Stator assembly, motor and vehicle powertrain

Abstract

This application discloses a stator assembly, a motor, and a vehicle powertrain, relating to the field of stator assembly design technology. The stator assembly includes a stator core and stator windings. The stator core has multiple stator slots; the stator windings include multi-phase flat wire windings disposed in the multiple stator slots; in the multi-phase flat wire windings, the turn interval between the input wire of any phase winding and the output wire of any one of the other two phase windings is not less than three turns. This application employs a stator core with multiple stator slots, and further includes stator windings, with the stator windings comprising multi-phase flat wire windings disposed in multiple stator slots. Furthermore, the turn interval between the input wire of any phase winding and the output wire of any one of the other two phase windings is not less than three turns. Thus, when the motor starts and runs to the third turn, the phase-to-phase voltage tends to stabilize. This helps improve the insulation performance of the motor operating under high-voltage conditions and increases the PDIV value.

Description

Technical Field

[0001] This application relates to the field of stator assembly design technology, and more particularly to a stator assembly, motor and vehicle powertrain. Background Technology

[0002] In the existing winding design of flat wire motors, when the voltage fluctuates greatly during motor startup, the excessively high surge voltage may cause a decrease in the interphase insulation performance of the stator windings, thereby increasing the risk of insulation failure between windings. Utility Model Content

[0003] The main objective of this invention is to provide a stator assembly designed to reduce the insulation risk between out-of-phase windings of a motor.

[0004] To achieve the above objectives, this utility model provides a stator assembly, the stator assembly comprising: A stator core having multiple stator slots; The stator winding includes a multiphase flat wire winding disposed in a plurality of the stator slots; In a multiphase flat wire winding, the number of turns between the incoming line of any phase winding and the outgoing line of any one of the other two phase windings shall not be less than three turns.

[0005] Optionally, the interval between the incoming line of any phase winding and the outgoing line of another phase winding is three turns.

[0006] Optionally, when the stator assembly is 6 poles and 54 slots, the minimum interval between the incoming line of any phase winding and the outgoing line of another phase winding is 3 turns.

[0007] Optionally, when the stator assembly is 6 poles and 54 slots, the maximum interval between the incoming line of any phase winding and the outgoing line of another phase winding is 5 turns.

[0008] Optionally, when the stator assembly is an 8-pole, 48-slot structure, the minimum interval between the input line of any phase winding and the output line of another phase winding is 5 turns.

[0009] Optionally, when the stator assembly is an 8-pole, 48-slot structure, the maximum interval between the input line of any phase winding and the output line of another phase winding is 8 turns.

[0010] Optionally, the stator winding is wound onto the stator core by means of wave winding or lap winding.

[0011] Optionally, each stator slot extends radially along the stator core, and multiple flat lines are arranged radially side by side in each stator slot. Each flat line is arranged perpendicular to the axial end face of the stator core at the outlet end of the stator slot. The flat lines constituting the same phase flat wire winding are connected to each other in pairs at the end of the stator core by hairpins.

[0012] In addition, to achieve the above objectives, this utility model also provides a motor, comprising: case; The bearing housing is located inside the housing; The rotor assembly is rotatably mounted on the bearing housing; and The stator assembly described above is nested with the rotor assembly.

[0013] In addition, to achieve the above objectives, this utility model also provides a vehicle powertrain, including the motor described above, wherein the motor is the power motor of the vehicle powertrain.

[0014] This embodiment of the invention employs a stator core with multiple stator slots and stator windings, including multi-phase flat wire windings located in multiple stator slots. The number of turns between the input and output of any phase winding is at least three turns. This ensures that when the motor starts and reaches the third turn, the phase-to-phase voltage tends to stabilize, which helps improve the insulation performance of the motor under high-voltage conditions and increases the PDIV value. In contrast, existing technologies typically place the first turns of different phases in adjacent slots. When the motor starts and the voltage reaches the third turn, the voltage between the input and output of different phases reaches its peak, leading to voltage superposition and potentially excessively high voltage amplitudes, significantly increasing the risk of insulation failure between windings. By spacing the first turns of different phases by at least three turns, the voltage peak positions are staggered, thereby significantly reducing the risk of motor insulation failure. Attached Figure Description

[0015] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application.

[0016] To more clearly illustrate the technical solutions in the embodiments of this utility model 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 utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1This is a schematic diagram showing the positional distribution of the out-of-phase first-turn windings in the stator windings of the prior art. Figure 2 This is a schematic diagram of the stator assembly according to an embodiment of the present invention; Figure 3 for Figure 2 A schematic diagram showing the positional distribution of the non-phase first-turn windings of the stator windings in the circuit. Figure 4 This is a voltage distribution diagram of the phase-to-phase line voltage.

[0018] Explanation of icon numbers:

[0019] The realization of the purpose, functional features and advantages of this utility model will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0020] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Furthermore, the described features, architectures, or functions can be combined in any way in one or more embodiments. Those skilled in the art should understand that the various embodiments described below are only for illustrative purposes and are not intended to limit the scope of protection of the present invention.

[0021] In the process of constructing 6-pole 54-slot, 8-pole 48-slot, and 12-pole 72-slot flat wire motors, such as Figure 1 As shown, the first turns of the out-of-phase circuits are typically arranged in adjacent stator slots 11. For example... Figure 4 As shown, voltage fluctuations are clearly observed in the initial stage of motor startup. As the motor starts and enters operation, the voltage gradually rises to a peak and then slowly decreases. If adjacent non-phase windings, one as the input and the other as the output (e.g., the input of phase U and the output of phase V), have opposite voltage directions, the voltage difference between them will be the sum of the voltages of these two non-phase windings. If the phase voltage is 1300V, then when the input of phase U and the output of phase V meet at their highest voltage points, the resulting voltage superposition could reach a high voltage of 2600V. This excessively high surge voltage could damage the insulation performance between the stator windings 20, thereby increasing the potential risk of insulation failure between windings.

[0022] To address the aforementioned problems, this application proposes a stator assembly. (Refer to...) Figure 2 and Figure 3 In one embodiment of this utility model, the stator assembly includes a stator core 10 and a stator winding 20, wherein: The stator core 10 has multiple stator slots 11; the stator winding 20 includes multi-phase flat wire windings disposed in the multiple stator slots 11; the number of turns between the input wire of any phase winding and the output wire of any phase winding is not less than three turns.

[0023] Among them, the multi-phase flat wire winding can be a three-phase flat wire winding, a four-phase flat wire winding, or other number of phase flat wire windings, depending on the design requirements of the motor.

[0024] In this embodiment, the stator winding 20 is wound in multiple stator slots 11 on the stator core 10. Assuming it is a three-phase stator assembly with three phases (U, V, W), it can be a two-phase input and one-phase output configuration, or a one-phase input and two-phase output configuration. When winding the stator winding 20 into the stator slots 11, for example, if phase U is the input and phase V is the output, assuming phase U is installed in the first stator slot 11, phase V needs to be installed at least three stator slots 11 apart circumferentially along the stator core 10. That is, phase V needs to be installed in a position after the fourth slot. Figure 4 As shown, in the third turn, the voltages of phases U and V will be at their highest points. However, because phases U and V are staggered by three turns, their voltages will not both be at their highest points after the three turns are offset. Therefore, the voltage difference, after being superimposed, will be much smaller than if both were at their highest points. This avoids the impact of excessively high surge voltage on the 20-phase insulation performance of the stator winding. This design effectively reduces the voltage superposition effect between adjacent non-phase windings, reduces current surges during motor startup, extends motor lifespan, and thus reduces the risk of insulation problems between windings. Furthermore, by rationally arranging the turn spacing of the windings, the starting performance and operational stability of the motor can be optimized.

[0025] Optionally, the stator winding 20 is wound on the stator core 10 by wave winding; or the stator winding 20 is wound on the stator core 10 by lap winding.

[0026] Wave winding is a common winding method. It involves winding flat wire windings sequentially in a wave-like pattern in the stator slots 11, creating an angle between adjacent windings and thus generating a uniform magnetic field distribution during motor operation. Lap winding, on the other hand, involves cascading flat wire windings in the stator slots 11. This method can increase the motor's power density but places higher demands on the winding insulation. In this invention, the winding method of the stator winding 20 can be selected according to the specific requirements and performance objectives of the motor to achieve optimal motor performance.

[0027] Optionally, each stator slot 11 extends radially along the stator core 10, and multiple flat lines are arranged radially side by side in each stator slot 11. Each flat line is arranged perpendicular to the axial end face of the stator core 10 at the wire outlet end of the stator slot 11. The flat lines constituting the same phase flat wire winding are connected to each other in pairs at the ends of the stator core 10 by hairpins.

[0028] The stator slots 11 extend radially along the stator core 10, making the motor structure more compact and increasing the magnetic flux utilization of the stator core 10. Multiple flat lines arranged side-by-side within each stator slot 11 not only improve the winding fill rate but also help reduce heat loss during motor operation. The flat lines are connected at the ends of the stator core 10 by hairpins, ensuring good electrical connection between the windings and facilitating motor maintenance and repair.

[0029] Optionally, refer to Figure 3 Another embodiment of this utility model provides a stator assembly based on the above. Figure 2 and Figure 3 In the embodiment shown, the interval between the incoming line of one phase winding and the outgoing line of another phase winding is three turns.

[0030] By limiting the interval between the input wire of one phase winding and the output wire of another phase winding to three turns, it is ensured that the voltage difference between the windings will not be too large during motor startup and operation, thus avoiding insulation problems caused by voltage surges. Furthermore, the three-turn limitation prevents excessive stator assembly spacing, ensuring a compact motor structure and good thermal conductivity. In practical applications, if one phase winding is U-phase and the other phase winding is V-phase or W-phase, limiting the interval between U-phase and V-phase or U-phase and W-phase to three turns ensures that the voltage difference between U-phase and V-phase or U-phase and W-phase is not too large, while also preventing excessive winding spacing. This balances motor performance with structural compactness and heat dissipation efficiency. In motor manufacturing and assembly, this design simplifies the process, reduces manufacturing costs, and improves motor reliability and durability.

[0031] Furthermore, by optimizing the winding turn spacing, the efficiency and power density of the motor can be significantly improved, meeting the performance requirements of different application scenarios. For example, in applications requiring high efficiency and high power density, such as electric vehicles or wind power generation, the stator assembly design in this embodiment can provide better performance. By precisely controlling the winding turn spacing, the problem of excessive voltage difference caused by voltage fluctuations during motor startup can be effectively controlled, thereby improving the motor's operating efficiency and stability. In addition, since insulation problems caused by voltage surges are reduced, the motor's maintenance costs and failure rate are also correspondingly reduced, significantly improving the overall reliability of the motor.

[0032] Optionally, refer to Figure 3 Another embodiment of this utility model provides a stator assembly, based on the above... Figure 2 In the embodiment shown, when the stator assembly is 6 poles and 54 slots, the minimum interval between the incoming line of any phase winding and the outgoing line of another phase winding is 3 turns; the maximum interval between the incoming line of any phase winding and the outgoing line of another phase winding is 5 turns.

[0033] A 6-pole, 54-slot motor design is typical. 8 poles refer to the motor having 8 magnetic poles, while 48 slots refer to the number of stator slots 11 on the stator core 10. Each slot can hold a flat wire winding. In this design, to optimize the motor's starting performance and operational stability, the maximum and minimum values ​​of the turn interval of the stator windings 20 are limited. This aims to reduce the voltage superposition effect between adjacent windings while ensuring a compact motor structure and efficient heat dissipation. For example, for a 6-pole, 54-slot motor, assuming it is a three-phase motor with UVW phases, the minimum interval between the input of the U-phase winding and the output of the V-phase winding can be 3 turns, and the maximum interval can be 5 turns. For example, the U-phase winding's input is located in the first stator slot 11, and calculations are performed circumferentially. The V-phase winding's output is then installed at intervals of 3-5 turns, specifically in the fourth to sixth slots. This ensures that the voltage difference between adjacent windings is not excessive during motor startup, and also ensures that the span between windings is not too large, thus avoiding insulation risks between windings and current surges during motor startup. This design results in a smoother starting current, a more stable startup process, and improved motor operating efficiency and lifespan.

[0034] Furthermore, by limiting the minimum and maximum spacing between windings, the consistent performance of the motor under various operating conditions can be ensured, guaranteeing its long-term stable operation. In practical applications, this design can adapt to different loads and operating environments, meeting the motor performance requirements of industries such as industry, automotive, and wind power generation.

[0035] Optionally, refer to Figure 3 In another embodiment, this utility model provides a stator assembly based on the above. Figure 2 In the embodiment shown, when the stator assembly is 8 poles and 48 slots, the minimum interval between the incoming line of any phase winding and the outgoing line of another phase winding is 5 turns; the maximum interval between the incoming line of any phase winding and the outgoing line of another phase winding is 8 turns.

[0036] The 8-pole, 48-slot design is another typical motor design. 8 poles refers to the motor having 8 magnetic poles, while 48 slots refers to the number of stator slots 11 on the stator core 10. Each slot can hold at least one flat wire winding. In this design, to optimize the motor's starting performance and operational stability, the maximum and minimum values ​​of the turn interval of the stator windings 20 are limited. This aims to reduce the voltage superposition effect between adjacent windings while ensuring a compact motor structure and efficient heat dissipation. For example, for an 8-pole, 48-slot motor, assuming it is a three-phase motor with UVW phases, the minimum interval between the input of the U-phase winding and the output of the V-phase winding can be 5 turns, and the maximum interval can be 8 turns. When the motor starts and runs to the 5th turn, the voltages of phases UVW are at their highest point. Only by spacing the input of any phase to the output of another phase by 5 turns can the position of the highest voltage be avoided. Furthermore, to prevent excessive spacing between the input and output of phases UVW, which would lead to excessive stator assembly span, the maximum spacing between the input of any phase and the output of another phase is limited to 8 turns. This ensures that the stator assembly structure is compact while reducing insulation risks. In practical applications, for example, the input of the U-phase winding is set in the first stator slot 11, and calculated circumferentially, the output of the V-phase winding is installed at intervals of 5-8 turns, i.e., in slots 6 to 9. This ensures that the voltage difference between adjacent windings is not too large during motor startup, and also ensures that the span between windings is not too large, thus avoiding insulation risks between windings and current surges during motor startup. Through this design, the motor's starting current is smoother, the startup process is more stable, and the motor's operating efficiency and lifespan are also improved. Furthermore, by limiting the minimum and maximum spacing between windings, the consistent performance of the motor under various operating conditions can be ensured, guaranteeing its long-term stable operation. In practical applications, this design can adapt to different loads and operating environments, meeting the motor performance requirements of industries such as industry, automotive, and wind power generation.

[0037] This utility model also proposes an electric motor, which includes a housing, a bearing housing, a rotor assembly, and a stator assembly as described in the above embodiments, wherein: The bearing housing is located inside the housing; the rotor assembly is rotatably mounted on the bearing housing; the stator assembly and the rotor assembly are nested together.

[0038] It is worth noting that since the motor of this utility model is based on the stator assembly described above, the embodiments of the motor of this utility model include all the technical solutions of all the embodiments of the stator assembly described above, and the technical effects achieved are exactly the same, so they will not be repeated here.

[0039] The housing is made of metal and includes internal cooling channels to dissipate heat generated during motor operation, ensuring excellent heat dissipation. The bearing housing is made of high-strength material to ensure sufficient stability and durability under high-speed rotation. The rotor assembly is fixed to the shaft, and the stator assembly is nested within the rotor assembly to ensure the motor's electromagnetic performance during operation.

[0040] This utility model also proposes a vehicle powertrain, which includes a motor as described in the above embodiments, wherein the motor is the power motor of the vehicle powertrain.

[0041] It is worth noting that since the vehicle powertrain of this utility model is based on the above-mentioned motor, the embodiments of the vehicle powertrain of this utility model include all the technical solutions of all the embodiments of the above-mentioned motor, and the technical effects achieved are exactly the same, so they will not be repeated here.

[0042] The above are merely preferred embodiments of this utility model and do not limit the patent scope of this utility model. Any equivalent structural or procedural transformations made based on the description and drawings of this utility model, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of this utility model.

Claims

1. A stator assembly characterized by, The stator assembly includes: A stator core having multiple stator slots; The stator winding includes a multiphase flat wire winding disposed in a plurality of the stator slots; In a multiphase flat wire winding, the number of turns between the incoming line of any phase winding and the outgoing line of any one of the other two phase windings shall not be less than three turns.

2. The stator assembly of claim 1, wherein, The interval between the incoming line of any phase winding and the outgoing line of another phase winding is three turns.

3. The stator assembly of claim 1, wherein, When the stator assembly is 6 poles and 54 slots, the minimum interval between the incoming line of any phase winding and the outgoing line of another phase winding is 3 turns.

4. The stator assembly of claim 1, wherein, When the stator assembly is 6 poles and 54 slots, the maximum interval between the incoming line of any phase winding and the outgoing line of another phase winding is 5 turns.

5. The stator assembly of claim 1, wherein, When the stator assembly is 8 poles and 48 slots, the minimum interval between the incoming line of any phase winding and the outgoing line of another phase winding is 5 turns.

6. The stator assembly of claim 1, wherein, When the stator assembly is 8 poles and 48 slots, the maximum interval between the incoming line of any phase winding and the outgoing line of another phase winding is 8 turns.

7. The stator assembly of claim 1, wherein, The stator winding is wound onto the stator core by means of wave winding or lap winding.

8. The stator assembly of claim 1, wherein, Each stator slot extends radially along the stator core, and multiple flat wires are arranged radially side by side in each stator slot. Each flat wire is arranged perpendicular to the axial end face of the stator core at the wire outlet end of the stator slot. The flat wires forming the same phase flat wire winding are connected to each other in pairs at the end of the stator core by hairpins.

9. An electric machine characterized by include: case; The bearing housing is located inside the housing; The rotor assembly is rotatably mounted on the bearing housing; as well as The stator assembly as described in any one of claims 1 to 8, wherein the stator assembly and the rotor assembly are nested together.

10. A vehicle powertrain, characterized by, Includes the motor as described in claim 9, wherein the motor is the power motor of the vehicle powertrain.

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