Connection structure for flat wire motor and flat wire motor

Abstract

The utility model relates to a kind of connecting structure and flat wire motor for flat wire motor.The flat wire motor includes stator, and the stator includes stator body and the stator winding of being arranged in the stator body.The stator winding is formed by aluminium flat wire, and the aluminium flat wire has connecting end part.The connecting structure includes the connecting end part of aluminium flat wire and aluminium round wire.The one end of the aluminium round wire is connected to the connecting end part of the aluminium flat wire, and the other end of the aluminium round wire is used to be connected to terminal box to be connected to power supply.The utility model for flat wire motor connecting structure solves the connection between aluminium flat wire and power supply problem, so that aluminium flat wire can be applied to flat wire motor, reduce the manufacturing cost of flat wire motor, reduce the quality of flat wire motor.

Description

Technical Field

[0001] This utility model relates to the field of motor technology. In particular, this utility model relates to a connection structure for a flat wire motor and a flat wire motor. Background Technology

[0002] This section provides background information related to the present invention, which does not necessarily constitute prior art.

[0003] An electric motor typically consists of a stator and a rotor. The stator includes the stator body and the stator windings (i.e., stator coils) mounted on the stator body. Based on the type of wire used in the stator windings, electric motors can be classified as round wire motors and flat wire motors.

[0004] The stator windings of a circular wire motor are made of round wire, usually copper round wire. They are directly connected to a cluster block or connected to a cluster block via a copper flower wire made of multiple thin copper wires twisted into one strand. The cluster block is then connected to the power supply, thus connecting the stator windings to the power supply.

[0005] The stator windings of flat-wire motors use flat wires. In related technologies, copper flat wires are typically used. Due to their wider dimensions and non-circular cross-sectional shape, copper flat wires generally cannot be directly connected to existing junction boxes (i.e., junction boxes used for round-wire motors). Furthermore, when welding copper flat wires to copper braided wires, the small contact area between the exposed copper wires and the flat wire allows only a portion of the copper wire to be welded, failing to meet the requirement that the copper braided wire's current-carrying capacity must be greater than that of the flat wire. Therefore, when welding copper flat wires to copper braided wires, pliers are usually used to hold the braided wire in place, ensuring a proper bond between the copper wires and the flat wire. However, using pliers to hold the braided wire can cause it to unravel, which is also detrimental to welding flat wires to copper braided wires. Additionally, although crimping machines exist in related technologies, the width of copper flat wires exceeds the size range of existing crimping machines, making it impossible to use them to crimp copper braided wires to copper flat wires. Therefore, in related technologies, the problem of connecting the copper flat wire to the power supply is usually solved by soldering the copper flat wire to the copper busbar and then connecting the copper busbar to the power line.

[0006] The use of copper flat wire to form the stator windings in related technologies results in high manufacturing costs and a large motor weight. Therefore, it is desirable to use other materials, such as aluminum flat wire, to form the stator windings in order to reduce the manufacturing cost and weight of the motor.

[0007] However, when using aluminum flat wire to form stator windings, similar to copper flat wire, aluminum flat wire, due to its wider size and non-circular cross-sectional shape, cannot be directly connected to existing junction boxes. Furthermore, because aluminum is relatively soft, it is difficult to draw it into extremely thin (e.g., with a diameter less than 30# wire) aluminum wires with good dimensional consistency. Therefore, there is currently no suitable aluminum braided wire to connect aluminum flat wire to existing junction boxes. Even if suitable aluminum braided wire existed, similar problems to those encountered when welding aluminum flat wire to copper braided wire may occur when welding them together, such as only welding a small portion of the aluminum wire or the aluminum braided wire fraying. Similarly, due to the wider size of aluminum flat wire, existing crimping machines cannot be used to crimp aluminum braided wire to aluminum flat wire. Moreover, because aluminum flat wire has a low melting point, when welding aluminum flat wire to copper braided wire or copper busbar, there is a possibility that the aluminum flat wire may melt before the copper braided wire or copper busbar melts, resulting in a failure to bond the aluminum flat wire to the copper braided wire or copper busbar. Utility Model Content

[0008] The purpose of this invention is to solve one or more of the technical problems mentioned above.

[0009] Specifically, the purpose of this invention is to provide a flat wire motor that is low in manufacturing cost and lightweight.

[0010] In particular, the purpose of this utility model is to provide a connection structure that can connect the aluminum flat wire of a flat wire motor to a power source.

[0011] In one aspect of this utility model, a connection structure for a flat wire motor is provided. The flat wire motor includes a stator, the stator body comprising a stator body and a stator winding disposed on the stator body. The stator winding is formed of aluminum flat wire, the aluminum flat wire having a connecting end. The connection structure includes: the connecting end of the aluminum flat wire; and an aluminum round wire, one end of which is connected to the connecting end of the aluminum flat wire, and the other end of which is used to connect to a junction box for connection to a power source.

[0012] The connection structure for flat wire motors of this invention enables the aluminum flat wires of the stator windings forming the stator of the flat wire motor to be connected to an existing junction box via an aluminum round wire made of a single aluminum conductor, thereby connecting the aluminum flat wires to the power supply and solving the problem of connecting the aluminum flat wires to the power supply.

[0013] Optionally, there are multiple aluminum round wires, and the connecting end of a single aluminum flat wire is connected to one end of the multiple aluminum round wires. Therefore, a single aluminum flat wire can be connected to a junction box through multiple aluminum round wires, which can improve current conductivity.

[0014] Optionally, there are two aluminum round wires, with the connecting end of the single aluminum flat wire connected to one end of the two aluminum round wires.

[0015] Optionally, the connecting end of the aluminum flat wire is connected to the end of the aluminum round wire by laser welding. Laser welding is not limited by the width of the aluminum flat wire, overcoming the limitation of existing crimping machines that cannot crimp wide aluminum flat wires.

[0016] In another aspect of this invention, a flat wire motor is provided. The flat wire motor includes the connection structure described in any of the preceding claims.

[0017] Optionally, the flat wire motor is a variable frequency flat wire motor.

[0018] Optionally, the flat wire motor is an induction flat wire motor.

[0019] Optionally, the stator windings of the stator of the flat wire motor are entirely formed from the aluminum flat wire.

[0020] In summary, the connection structure for flat wire motors of this invention enables the aluminum flat wires of the stator windings forming the stator of the flat wire motor to be connected to an existing junction box via aluminum round wires made from single aluminum conductors, thereby connecting the aluminum flat wires to the power supply. This solves the problem of connecting the aluminum flat wires to the power supply, allowing aluminum flat wires to be used in flat wire motors, reducing the manufacturing cost and weight of the flat wire motors. Attached Figure Description

[0021] The foregoing and other features and characteristics of this utility model will become clearer from the following detailed description with reference to the accompanying drawings, which are by way of example only and are not necessarily drawn to scale. The same reference numerals are used in the drawings to indicate the same parts, in which:

[0022] Figure 1 This is a perspective view of the connection structure and junction box connection for a flat wire motor according to one embodiment of the present utility model.

[0023] Figure 2 This is a plan view of the connection structure for a flat wire motor and the junction box connection according to one embodiment of the present invention.

[0024] Figure 3 This is a three-dimensional schematic diagram of the aluminum flat wires used to form the stator windings of a flat-wire motor; and

[0025] Figure 4 This is a perspective view of an aluminum round wire used in the connection structure of a flat wire motor according to one embodiment of the present invention. Detailed Implementation

[0026] Preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings. The following description is exemplary in nature and is not intended to limit the present invention or its application or use.

[0027] This invention provides a connection structure for a flat wire motor and a flat wire motor having the connection structure. The flat wire motor can be an induction flat wire motor, a variable frequency flat wire motor, etc. For example, the flat wire motor can be an induction variable frequency flat wire motor. This induction variable frequency flat wire motor can be an induction variable frequency flat wire motor used in vehicles.

[0028] A flat wire motor may include a stator and a rotor. The stator is typically fixed to the motor housing, while the rotor can rotate relative to the stator about its central axis. The stator and rotor cooperate to convert electrical energy into mechanical energy through electromagnetic induction. The stator may include a stator body and stator windings. The stator body may be an iron core, which forms the main magnetic circuit of the stator and also serves as the mounting and fixing component for the stator windings. The stator windings, also known as stator coils, are disposed within the stator body. In this invention, the stator windings are formed from aluminum flat wire. Specifically, the stator windings are formed entirely from aluminum flat wire. Aluminum flat wire has a flat outer surface. Traditional round wire has a complete circular cross-section and an arc-shaped outer surface. When arranged, round wires with arc-shaped outer surfaces will have gaps between them, while flat wires with flat outer surfaces can be arranged more closely. Therefore, compared to round wire, flat wire is advantageous for increasing the slot fill factor of the stator winding, which is the proportion of space occupied by the stator winding or stator coil after it is placed in the slot, thereby increasing the magnetic field strength and power density. Furthermore, compared to copper flat wire, aluminum flat wire can reduce the mass of flat wire motors and lower their manufacturing costs.

[0029] Figure 1 This is a perspective view of the connection structure 100 for a flat wire motor and the junction box 200 according to one embodiment of the present invention. Figure 2 This is a plan view of the connection structure 100 for a flat wire motor and the junction box 200 according to one embodiment of the present invention. Figure 3 This is a three-dimensional schematic diagram of aluminum flat wire 110 used to form the stator winding of a flat wire motor. Figure 4 This is a perspective view of an aluminum round wire 120 for a connection structure 100 of a flat wire motor according to one embodiment of the present invention. The aluminum flat wire 110 may include a body portion and a connecting end portion. The body portion is used to form a stator winding disposed on the stator body, while the connecting end portion participates in the connection, thereby forming part of the connection structure 100 according to the present invention. The following will be combined with... Figures 1 to 4 This section describes in detail the connection between the aluminum flat wire 110 of the stator winding of the flat wire motor and the junction box 200.

[0030] like Figure 1 and Figure 2 As shown, the connection structure 100 includes a connecting end of an aluminum flat wire 110 and an aluminum round wire 120. For example... Figure 3 As shown, the aluminum flat wire 110 has a slender, flat shape with a smooth outer surface and a rectangular cross-section. Of course, the cross-section of the aluminum flat wire 110 can also be square or any other suitable shape, as long as it can be closely arranged when forming the stator winding. Figure 4 As shown, the aluminum round wire 120 has a circular cross-section and an arc-shaped outer surface. The aluminum round wire 120 is made from a single aluminum conductor. One end of the aluminum round wire 120 is connected to the connecting end of the aluminum flat wire 110. Preferably, one end of the aluminum round wire 120 can be laser-welded to the connecting end of the aluminum flat wire 110. During the laser welding process between the aluminum round wire 120 and the aluminum flat wire 110, pliers can be used to hold the aluminum round wire 120 to ensure a full bond between them. Laser welding is not limited by the width of the aluminum flat wire 110, overcoming the limitation of existing crimping machines that cannot crimp wider aluminum flat wires 110. The other end of the aluminum round wire 120 is connected to an existing junction box 200 to connect to a power source, thereby connecting the aluminum flat wire 110, which forms the stator winding of the flat wire motor, to the power source.

[0031] The aluminum round wire 120 is suitable for connection with existing junction boxes 200 used in round wire motors. Therefore, the junction box 120 can be any existing suitable junction box 200 without modification. Furthermore, unlike a multi-strand wire (e.g., copper wire) formed from multiple thin metal wires, the aluminum round wire 120 is formed from a single aluminum conductor, allowing for better connection with the aluminum flat wire 110. For example, because the aluminum round wire 120 is formed from a single aluminum conductor, it avoids the problem of only a portion of the metal wires in a multi-strand wire connecting to the aluminum flat wire 110. Moreover, even when using pliers to hold the aluminum round wire 120 during laser welding to ensure a full bond between the aluminum flat wire 110 and the aluminum round wire 120, the problem of the aluminum round wire 120 unraveling, similar to that of a multi-strand wire, is avoided because it is made from a single aluminum conductor. Additionally, since both the aluminum flat wire 110 and the aluminum round wire 120 are made of aluminum, the problem of one melting while the other does not, preventing a proper bond, is also avoided.

[0032] Preferably, especially when the cross-sectional area of ​​the aluminum flat wire 110 is large, the aluminum flat wire 110 can be connected to the junction box 200 by multiple aluminum round wires 120 (each of the multiple aluminum round wires 120 is formed by a single aluminum conductor) to improve current conductivity. That is, the connection end of a single aluminum flat wire 110 can be connected to one end of multiple aluminum round wires 120. The number of aluminum round wires 120 connected to the aluminum flat wire 110 can be determined according to the cross-sectional dimensions of the aluminum flat wire 110 and the aluminum round wires 120. For example, in... Figure 1 and Figure 2 The diagram schematically shows three flat aluminum wires 110 and six round aluminum wires 120, wherein the connecting end of a single flat aluminum wire 110 is connected to two round aluminum wires 120.

[0033] In summary, the connection structure for flat wire motors of this invention enables the aluminum flat wires of the stator windings forming the stator of the flat wire motor to be connected to an existing junction box via aluminum round wires made from single aluminum conductors, thereby connecting the aluminum flat wires to the power supply. This solves the connection problem between aluminum flat wires and the power supply in related technologies, allowing aluminum flat wires to be used in flat wire motors, reducing the manufacturing cost and weight of flat wire motors.

[0034] It should be understood that various different implementation methods can be designed by combining or modifying different implementation methods and various technical features in different ways.

[0035] The preferred embodiments of this utility model have been described above. It is understood that the above description is exemplary and not restrictive, and various modifications and variations can be conceived by those skilled in the art without departing from the scope of this utility model. These modifications and variations are also included within the protection scope of this utility model.

Claims

1. A connection structure for a flat wire motor, the flat wire motor comprising a stator, the stator comprising a stator body and a stator winding disposed on the stator body, the stator winding being formed of aluminum flat wire, the aluminum flat wire having a connecting end, characterized in that, The connection structure includes: The connecting end of the aluminum flat wire; and An aluminum round wire, one end of which is connected to the connecting end of the aluminum flat wire, and the other end of which is used to connect to a junction box for connection to a power source.

2. The connection structure according to claim 1, characterized in that, The aluminum round wire is composed of multiple wires, and the connecting end of a single aluminum flat wire is connected to one end of the multiple aluminum round wires.

3. The connection structure according to claim 2, characterized in that, The aluminum round wire consists of two wires, with the connecting end of the single aluminum flat wire connected to one end of the two aluminum round wires.

4. The connection structure according to any one of claims 1 to 3, characterized in that, The connecting end of the aluminum flat wire is connected to the end of the aluminum round wire by laser welding.

5. A flat wire motor, characterized in that, The flat wire motor includes the connection structure described in any one of claims 1 to 4.

6. The flat wire motor according to claim 5, characterized in that, The flat wire motor is a variable frequency flat wire motor.

7. The flat wire motor according to claim 5, characterized in that, The flat wire motor is an induction flat wire motor.

8. The flat wire motor according to any one of claims 5 to 7, characterized in that, The stator windings of the flat wire motor are entirely formed from the aluminum flat wires.

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