Conductor, motor and electric drive system

Abstract

The utility model relates to electric drive system technical field provides a kind of conductor, motor and electric drive system, including plug-in end, connecting portion and welding end. Among them, plug-in end includes first conducting section, second conducting section and transition section, first conducting section and second conducting section are included obtuse angle, transition section connects the one end of first conducting section with the one end of second conducting section located in first direction same side, transition section is circular arc and central angle is less than or equal to 180 °;Connecting portion and welding end are both provided with two, the other end of first conducting section is sequentially connected with one connecting portion and one welding end, the other end of second conducting section is sequentially connected with another connecting portion and another welding end, two connecting portions are all parallel with first direction, and welding end is included obtuse angle with corresponding connecting portion. Such can reduce the size of motor axial, reduce motor weight, so that overall structure is more compact.

Description

Technical Field

[0001] This utility model relates to the field of electric drive system technology, and in particular to a conductor, a motor and an electric drive system. Background Technology

[0002] In the manufacturing of electric motors, especially permanent magnet motors or induction motors, stator windings often employ an insert-type conductor design. In traditional processes, to facilitate coil embedding into the core slots and ensure sufficient electrical insulation distance, the conductor's insertion ends (i.e., the winding ends) on both sides of the core typically require a relatively long axial extension. This design inevitably leads to an increase in the overall axial dimension of the motor.

[0003] Excessive axial length directly restricts the application of motors in space-constrained environments (such as aerospace, electric vehicles, and precision servo drives). Furthermore, as one of the main heat sources of a motor, excessively long winding ends lead to increased end winding resistance and copper losses, a longer heat dissipation path, worsened motor temperature rise, and impacted power density and efficiency. Moreover, longer conductors mean greater copper consumption, significantly increasing manufacturing costs.

[0004] Therefore, there is an urgent need for a conductor, motor, and electric drive system to solve the above-mentioned technical problems. Utility Model Content

[0005] The purpose of this invention is to provide a conductor, motor and electric drive system that can reduce the axial dimension of the motor, reduce the weight of the motor, and make the overall structure more compact.

[0006] To achieve this objective, the present invention adopts the following technical solution:

[0007] A conductor, comprising:

[0008] The plug end includes a first conductive segment, a second conductive segment, and a transition segment. The first conductive segment and the second conductive segment are formed at an obtuse angle. The transition segment connects one end of the first conductive segment and one end of the second conductive segment located on the same side of the first direction. The transition segment is arc-shaped and the central angle is less than or equal to 180°.

[0009] Both the connecting part and the welding end are provided with two. The other end of the first conductive segment is sequentially connected to one of the connecting parts and one of the welding ends. The other end of the second conductive segment is sequentially connected to another of the connecting parts and another of the welding ends. Both of the connecting parts are parallel to the first direction. The welding end and the corresponding connecting part are at an obtuse angle.

[0010] As a preferred technical solution for the aforementioned conductor, the two aforementioned welding ends are arranged in parallel.

[0011] As a preferred technical solution for the aforementioned conductor, the two aforementioned welding ends are arranged at an angle, and the ends of the two welding ends away from the aforementioned connection portion extend and deflect in a direction away from the first straight line, wherein the aforementioned first straight line is the angle bisector of the aforementioned insertion end.

[0012] An electric motor is also provided, including a rotor and the aforementioned conductors, wherein multiple conductors are provided, and the multiple conductors form a stator winding, wherein the rotor is concentrically arranged with the stator winding and is capable of rotating relative to it.

[0013] As a preferred technical solution for the aforementioned motor, the stator winding is an X-pin winding.

[0014] As a preferred technical solution for the aforementioned motor, the stator winding is provided in two sets, and the two sets of stator windings are connected in parallel.

[0015] As a preferred technical solution for the above-mentioned motor, the rotor includes a magnet and a rotor core, the magnet has a skewed pole structure, and the magnet is attached to the outer surface of the rotor core.

[0016] As a preferred technical solution for the above-mentioned motor, the rotor further includes carbon fiber bundles and a magnetic yoke. The carbon fiber bundles are wound around the axis of the rotor core on the side of the magnet facing away from the rotor core, and the magnetic yoke is made of industrial pure iron.

[0017] As a preferred technical solution for the aforementioned motor, the rotor further includes multiple magnets, each of which has a different magnetization direction angle.

[0018] An electric drive system is also provided, including the conductor described above, or the motor described above.

[0019] The beneficial effects of this utility model are:

[0020] This application provides a conductor, a motor, and an electric drive system. The conductor includes a plug terminal, a connecting portion, and a soldering end. The plug terminal includes a first conductive segment, a second conductive segment, and a transition segment. The first and second conductive segments form an obtuse angle. The transition segment connects one end of the first conductive segment to the other end of the second conductive segment located on the same side of a first direction. The transition segment is arc-shaped with a central angle less than or equal to 180°. Two connecting portions and two soldering ends are provided. The other end of the first conductive segment is sequentially connected to one connecting portion and one soldering end. The other end of the second conductive segment is sequentially connected to another connecting portion and another soldering end. Both connecting portions are parallel to the first direction, and the soldering end forms an obtuse angle with the corresponding connecting portion.

[0021] Thus, the conductor forms a hairpin structure. The obtuse angle design of the first and second conductive sections of the plug-in end shortens the extension of the plug-in end in the first direction. Furthermore, the inferior arc design of the transition section makes the top of the plug-in section rounded, reducing the protruding dimension. This reduces the size of one end of the motor's axial direction. Further, the obtuse angle connection between the welded end and the connecting part reduces the size of the other end of the motor's axial direction, thereby reducing the motor's weight and making the overall structure more compact. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the conductor structure provided in this embodiment of the utility model. Figure 1 ;

[0023] Figure 2 yes Figure 1 A magnified view of a section at point A in the middle;

[0024] Figure 3 This is a schematic diagram of the conductor structure provided in this embodiment of the utility model. Figure 2 ;

[0025] Figure 4 This is a schematic diagram of the stator structure provided in an embodiment of the present invention;

[0026] Figure 5 This is a schematic diagram of the rotor structure provided in an embodiment of the present invention;

[0027] Figure 6 yes Figure 5 A magnified view of a section at point B in the middle;

[0028] Figure 7 This is a schematic diagram of the arrangement of magnets provided in an embodiment of this utility model.

[0029] In the picture:

[0030] X, first direction; Y, second direction;

[0031] 100. Stator;

[0032] 110. Conductor;

[0033] 1. Plug-in end; 11. First conductive section; 12. Second conductive section; 13. Transition section;

[0034] 2. Connecting part; 21. First connecting part; 22. Second connecting part;

[0035] 3. Welding end; 31. First welding end; 32. Second welding end;

[0036] 141. First U-phase copper busbar; 142. First V-phase copper busbar; 143. First W-phase copper busbar; 144. Second U-phase copper busbar; 145. Second V-phase copper busbar; 146. Second W-phase copper busbar;

[0037] 120. Stator winding; 121. First stator winding; 122. Second stator winding;

[0038] 130. Stator core;

[0039] 200. Rotor;

[0040] 210. Magnet; 211. Tangential magnet; 21. Radial magnet;

[0041] 220. Carbon fiber bundle; 230. Rotor support; 240. Rotor core. Detailed Implementation

[0042] The technical solution of this utility model will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this utility model. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this utility model.

[0043] In the description of this utility model, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this utility model and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance. The terms "first position" and "second position" refer to two different positions. Moreover, "above," "on top of," and "over" the first feature in relation to the second feature includes the first feature directly above and diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "under," and "below" the first feature in relation to the second feature includes the first feature directly below and diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0044] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0045] The embodiments of this utility model are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain this utility model, and should not be construed as limiting this utility model.

[0046] like Figures 1 to 3 As shown, this application provides a conductor 110, including a plug-in terminal 1, a connecting portion 2, and a soldering terminal 3. The plug-in terminal 1 includes a first conductive segment 11, a second conductive segment 12, and a transition segment 13. The first conductive segment 11 and the second conductive segment 12 form an obtuse angle. The transition segment 13 connects one end of the first conductive segment 11 to the end of the second conductive segment 12 located on the same side of the first direction X. The transition segment 13 is arc-shaped with a central angle less than or equal to 180°. Two connecting portions 2 and two soldering terminals 3 are provided. The other end of the first conductive segment 11 is sequentially connected to one connecting portion 2 and one soldering terminal 3. The other end of the second conductive segment 12 is sequentially connected to another connecting portion 2 and another soldering terminal 3. Both connecting portions 2 are parallel to the first direction X, and the soldering terminal 3 forms an obtuse angle with the corresponding connecting portion 2.

[0047] For example, the second direction Y is perpendicular to the first direction X. Within the plane defined by the first direction X and the second direction Y, the insertion end 1 is V-shaped. That is, the first conductive segment 11 and the second conductive segment 12 are symmetrically arranged with a first straight line as the line of symmetry. The first straight line is parallel to the first direction X, and the first conductive segment 11 and the second conductive segment 12 form an obtuse angle. That is, the projected length of the first conductive segment 11 in the first direction X is greater than its projected length in the second direction Y, and the projected length of the second conductive segment 12 in the first direction X is greater than its projected length in the second direction Y. The transition segment 13 is a minor arc, that is, the transition segment 13 is an arc shape, and its central angle is less than or equal to 180°. The first and last ends of the transition segment 13 are respectively connected to one end of the first conductive segment 11 and one end of the second conductive segment 12 located on the same side of the first direction X. The connecting part 2 includes two parts, referred to as the first connecting part 21 and the second connecting part 22 respectively. Both the first connecting part 21 and the second connecting part 22 are parallel to the first direction X. The welding end 3 includes two parts, referred to as the first welding end 31 and the second welding end 32 respectively. The end of the first conductive segment 11 away from the transition segment 13 is connected to the first welding end 31 through the first connecting part 21. The end of the second conductive segment 12 away from the transition segment 13 is connected to the second welding end 32 through the second connecting part 22. The first welding end 31 and the first connecting part 21 form an obtuse angle, and the second welding end 32 and the first connecting part 21 form an obtuse angle.

[0048] Thus, conductor 110 forms a hairpin structure. The obtuse angle design of the first conductive segment 11 and the second conductive segment 12 of the plug end 1 shortens the extension of the plug end 1 in the first direction X. Furthermore, the inferior arc setting of the transition segment 13 makes the top of the plug segment rounded, reducing the protruding size. This reduces the size of one end of the motor axially. Further, the obtuse angle connection between the welding end 3 and the connecting part 2 reduces the size of the other end of the motor axially, thereby reducing the motor weight and making the overall structure more compact.

[0049] The further conductor 110 is a flat wire hairpin structure.

[0050] Optionally, the two welding ends 3 are arranged in parallel.

[0051] For example, such as Figure 3As shown, the two welding ends 3 are respectively designated as the first welding end 31 and the second welding end 32. One end of the first welding end 31 is connected to the end of the first connecting part 21 away from the first conductive segment 11, while the other end is deflected towards the side closer to the first straight line. One end of the second welding end 32 is connected to the end of the second connecting part 22 away from the second conductive segment 12, while the other end is deflected towards the side away from the first straight line. The first welding end 31 and the second welding end 32 are parallel to each other. With this configuration, by bending the welding ends 3 to the same side, the overall axial length of the coil end face can be greatly reduced, making the motor more compact in the axial direction, achieving higher power density. Furthermore, the shorter end can avoid interference with surrounding components, making the motor more compatible with installation space.

[0052] It should be noted that the first straight line is the angle bisector of the insertion end 1.

[0053] Optionally, the two welding ends 3 are set at an angle, and the ends of the two welding ends 3 away from the connecting part 2 extend and deflect in a direction away from the first straight line, which is the angle bisector of the insertion end 1.

[0054] For example, such as Figure 1 As shown, the two welding ends 3 are designated as the first welding end 31 and the second welding end 32. One end of the first welding end 31 is connected to the end of the first connecting part 21 away from the first conductive segment 11, while the other end is deflected away from the first straight line. One end of the second welding end 32 is connected to the end of the second connecting part 22 away from the second conductive segment 12, while the other end is deflected away from the first straight line. The first welding ends 31 and the second welding end 32 are arranged in a V-shape. This arrangement physically isolates the welding ends 3 of different phases in space, placing them on both sides of the stator 100 core. This greatly reduces the probability of accidental short circuits between high-potential conductors of different phases due to vibration, insulation varnish wear, condensation, or contamination, while meeting the required creepage distance and clearance between different phases. It also prevents all heat sources, i.e., the welding ends 3, from concentrating in a single area, thus avoiding localized overheating.

[0055] An electric motor is also provided, including a rotor 200 and the aforementioned conductors 110. Multiple conductors 110 are provided, and the multiple conductors 110 form a stator winding 120. The rotor 200 and the stator winding 120 are concentrically arranged and can rotate relative to each other.

[0056] For example, the motor includes a rotor 200 and a stator 100, wherein the stator 100 includes a stator core and a stator winding 120. The stator winding 120 is formed by a plurality of conductors 110 arranged and connected in a specific manner, and the stator winding 120 is installed in the stator slots of the stator core. The rotor 200 is concentric with the stator 100 and can rotate relative to it. When the stator 100 receives electrical energy, it can drive the rotor 200 to rotate around its own axis.

[0057] Optionally, stator winding 120 is an X-pin winding.

[0058] For example, conductor 110 is a flat wire. Before being inserted into the stator slot of stator 100, the welding ends 3 of conductor 110 are processed into a cross configuration. After conductor 110 is inserted into the stator slot, the welding ends 3 of adjacent conductors 110 can cross, eliminating the need for a twisting step, allowing welding of the welding ends 3 and shortening their axial length. This configuration significantly shortens the axial dimension of the motor, reduces weight, and achieves higher power density. Simultaneously, shorter welding ends 3 mean a reduction in the length of ineffective conductors 110, which can reduce ohmic losses. The cross structure helps optimize the magnetic field distribution at the welding point, thereby mitigating the proximity effect to some extent and further reducing AC losses at high frequencies.

[0059] Optionally, the stator winding 120 is provided in two sets, and the two sets of stator winding 120 are connected in parallel.

[0060] For example, such as Figure 4 As shown, the stator 100 includes two sets of stator windings 120, referred to as the first stator winding 121 and the second stator winding 122 respectively. The two sets of stator windings 120 are installed in the stator 100 slots of the same stator 100 core. The two sets of stator windings 120 are physically isolated from each other. The first stator winding 121 is equipped with a first U-phase copper busbar 141, a first V-phase copper busbar 142 and a first W-phase copper busbar 143. The second stator winding 122 is equipped with a second U-phase copper busbar 144, a second V-phase copper busbar 145 and a second W-phase copper busbar 146. The first stator winding 121 and the second stator winding 122 can operate independently. Two sets of 120mm stator windings are connected in parallel, with one set working as the main system and the other as a backup, which is a redundant design. When the main system fails due to short circuit, open circuit or other reasons, the backup system can switch immediately or automatically to replace the main system and ensure that the motor will not suddenly stop, thereby ensuring the continuous operation of the entire system.

[0061] Furthermore, the parallel connection of the two sets of stator windings 120 can reduce the current in a single branch, thereby extending the service life of the two sets of stator windings 120.

[0062] Furthermore, the two sets of stator windings 120 can be distributed in the same slot, that is, the conductors 110 of the two sets of stator windings 120 may be placed in the same stator 100 slot, but there must be reliable insulation between them.

[0063] Furthermore, the two sets of stator windings 120 can also be arranged in slots. For example, the stator 100 slots are divided into odd-numbered slots and even-numbered slots according to the arrangement order, with the odd-numbered slots alternating with the even-numbered slots. One set of stator windings 120 is installed in the odd-numbered slots, and the other set of stator windings 120 is installed in the even-numbered slots. This achieves physical and thermal isolation between the two sets of stator windings 120.

[0064] like Figures 5 to 7 As shown, optionally, the rotor 200 includes a magnet 210 and a rotor core 240. The magnet 210 has a skewed pole structure and is attached to the outer surface of the rotor core 240.

[0065] For example, the magnets 210 are arranged in a V-shape or double V-shape, causing the center line of the equivalent magnetic field they generate to be tilted. The magnetization direction or physical shape of the permanent magnets 210 on the rotor 200 is no longer kept parallel along the axial direction, but is tilted at an angle.

[0066] Thus, when the stator 100 interacts with the magnetic poles of the rotor 200, the magnitude and direction of the magnetic force felt at different positions along the axial direction change gradually, rather than suddenly reaching the maximum or minimum synchronously. This causes the magnetic forces on the entire circumference to cancel each other out, thereby significantly smoothing the cogging torque.

[0067] Furthermore, the skewed pole structure can effectively reduce higher harmonics in the back electromotive force (EMF). Since torque is generated by the interaction of magnetic field and current, a more sinusoidal back EMF means a smoother torque output. This improves the control accuracy and smoothness of the motor.

[0068] Furthermore, the skewed pole structure changes the axial distribution of the magnetic field, which can reduce the rate of change of magnetic flux in the stator 100 and the rotor core 240 to a certain extent, thereby reducing the loss of the rotor core 240.

[0069] Optionally, the rotor 200 also includes a carbon fiber bundle 220 and a magnetic yoke. The carbon fiber bundle 220 is wound around the axis of the rotor core 240 on the side of the magnet 210 facing away from the rotor core 240, and the magnetic yoke is made of industrial pure iron.

[0070] For example, such as Figure 6As shown, magnet 210 is glued to the surface of rotor core 240, rotor core 240 is mounted on rotor support 230, and carbon fiber bundle 220 is wound around the outer surface of rotor 200 with a certain tension. After curing, carbon fiber bundle 220 can be firmly bonded into a whole and tightly wrap around rotor 200.

[0071] Because carbon fiber materials have extremely high tensile strength and specific strength (strength / density), the carbon fiber bundle 220 can generate huge prestress to counteract the centrifugal force generated by the magnet 210 when the rotor 200 rotates at high speed, thereby preventing the magnet 210 from flying off from the rotor core 240.

[0072] Furthermore, this application also uses a magnetic yoke made of industrial pure iron to eliminate the risk of the carbon fiber bundle 220 crushing the rotor core 240.

[0073] Optionally, the rotor 200 may also include multiple magnets 210, each magnet 210 having a different magnetization direction angle.

[0074] For example, such as Figure 7 As shown, the magnet 210 includes a tangential magnet 211 and a radial magnet 212. The magnetization directions of the tangential magnet 211 and the radial magnet 212 are set at 90° and are alternately distributed. Multiple magnets 210 form a Heilbeck array. The N-pole permanent magnet 210 is composed of three permanent magnets 210 with different magnetization directions. By controlling the magnetization direction of the three magnets 210, a highly sinusoidal magnetic field can be formed, generating a highly sinusoidal back electromotive force, which reduces the loss and vibration of the motor.

[0075] Furthermore, the use of the Hellbeck array significantly enhances the magnetic field on one side of the array while significantly weakening it on the other side, achieving maximum magnetic field strength with minimal 210 magnet material. It can also concentrate magnetic flux where a strong magnetic field is needed (such as below the array) while reducing magnetic interference to the surrounding environment (such as above the array).

[0076] The Heilbeck array used in this invention can employ low-density non-magnetic yokes, such as low-density materials like titanium alloys and aluminum alloys, which reduces motor weight and improves motor performance.

[0077] An electric drive system is also provided, including the aforementioned conductor 110, or the aforementioned motor.

[0078] Obviously, the above embodiments of this utility model are merely examples for clearly illustrating the present utility model, and are not intended to limit the implementation of the present utility model. Those skilled in the art can make other variations or modifications based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this utility model should be included within the protection scope of the claims of this utility model.

Claims

1. A conductor, characterized in that, include: The plug terminal (1) includes a first conductive segment (11), a second conductive segment (12), and a transition segment (13). The first conductive segment (11) and the second conductive segment (12) are at an obtuse angle. The transition segment (13) connects one end of the first conductive segment (11) and one end of the second conductive segment (12) located on the same side of the first direction (X). The transition segment (13) is arc-shaped and the central angle is less than or equal to 180°. Two connecting parts (2) and two welding ends (3) are provided. The other end of the first conductive segment (11) is connected to one connecting part (2) and one welding end (3) in sequence. The other end of the second conductive segment (12) is connected to another connecting part (2) and another welding end (3) in sequence. Both connecting parts (2) are parallel to the first direction (X). The welding end (3) is at an obtuse angle to the corresponding connecting part (2).

2. The conductor according to claim 1, characterized in that, The two welding ends (3) are arranged in parallel.

3. The conductor according to claim 1, characterized in that, The two welding ends (3) are set at an angle, and the ends of the two welding ends (3) away from the connecting part (2) extend and deflect in a direction away from the first straight line, which is the angle bisector of the insertion end (1).

4. An electric motor, characterized in that, Includes a rotor (200) and a conductor (110) as described in any one of claims 1-3, wherein multiple conductors (110) are provided, and the multiple conductors (110) form a stator winding (120), wherein the rotor (200) is concentrically arranged with the stator winding (120) and is capable of rotating relative to it.

5. The motor according to claim 4, characterized in that, The stator winding (120) is an X-pin winding.

6. The motor according to claim 4, characterized in that, The stator winding (120) is provided in two sets, and the two sets of stator winding (120) are connected in parallel.

7. The motor according to claim 4, characterized in that, The rotor (200) includes a magnet (210) and a rotor core (240). The magnet (210) has a skewed pole structure and is attached to the outer surface of the rotor core (240).

8. The motor according to claim 7, characterized in that, The rotor (200) also includes a carbon fiber bundle (220) and a magnetic yoke. The carbon fiber bundle (220) is wound around the axis of the rotor core (240) on the side of the magnet (210) facing away from the rotor core (240). The magnetic yoke is made of industrial pure iron.

9. The motor according to claim 4, characterized in that, The rotor (200) also includes a plurality of magnets (210), each of which has a different magnetization direction angle.

10. An electric drive system, characterized in that, Includes the conductor (110) as described in any one of claims 1-3, or the motor as described in any one of claims 4-9.

Images