Motor, stator, and method of manufacturing the stator

Abstract

The present application provides a motor, a stator, and a method for manufacturing a stator. The motor stator includes a stator core and a stator winding. The axial end surface of the stator core is provided with a plurality of winding slots extending radially through the inner and outer walls of the stator core, the plurality of winding slots being spaced apart along the circumferential direction of the stator core. The stator winding includes at least one coil unit, the coil unit including a plurality of first conductors to be assembled, each of the first conductors including at least one insertion portion to be inserted into the winding slot. Because the coil unit is assembled and connected to and molded by the plurality of first conductors, when the stator winding is attached to the stator core, the plurality of first conductors can be connected to each other to form the coil unit before the entire coil unit is attached to the stator core. This simplifies the wiring process, facilitates automated mass production, simplifies the motor structure and assembly steps, and improves motor assembly efficiency.

Description

[Technical Field]

[0001] FIELD OF THE INVENTION This application relates to the field of power plants, and more particularly to motors, stators and methods of manufacturing stators. [Background technology]

[0002] The motor has become an important step in promoting vehicle weight reduction, increasing the driving range of electric vehicles, improving vehicle space utilization, and reducing powertrain costs.

[0003] How to simplify the structure of a motor and improve the assembly efficiency of the motor is an important research direction in the motor field. Summary of the Invention

[0004] The present application provides a motor, a stator, and a method for manufacturing a stator, which can simplify the structure of the motor and improve the assembly efficiency of the motor.

[0005] According to a first aspect, an embodiment of the present application provides a motor stator including a stator core and a stator winding. An end surface of the stator core along its axial direction is provided with a plurality of winding slots that penetrate the inner and outer walls of the stator core along a radial direction, and the plurality of winding slots are spaced apart along a circumferential direction of the stator core. The stator winding includes at least one coil unit, and the coil unit includes a plurality of assembled first conductors, each of which includes at least one insertion portion that is inserted into the winding slot.

[0006] In the above technical solution, the stator includes a stator core and a stator winding, and the coil unit of the stator winding is embedded in the winding slot of the stator core. Because the coil unit is assembled and connected by a plurality of first conductors, when the stator winding is attached to the stator core, the plurality of first conductors are first connected to form the coil unit, and then the entire coil unit is installed on the stator core. This simplifies the wiring process, facilitates automated mass production, simplifies the motor structure and assembly steps, and improves motor assembly efficiency. The plurality of first conductors of the coil unit are connected to form a distributed winding, which achieves high electromagnetic efficiency, reduces spatial harmonics, and improves technical effects such as NVH (noise, vibration, and acoustic harshness).

[0007] In some embodiments, the multiple first conductors of the coil unit are circumferentially offset, each including a first insertion portion and a second insertion portion connected to each other, the first insertion portion and the second insertion portion being inserted into different winding slots, and the first insertion portion of one first conductor is stacked with the second insertion portion of another first conductor of the coil unit in the same winding slot.

[0008] In the above technical solution, the first and second insertion portions of the first conductor are inserted into different winding slots, thereby improving the stability of the relative positions between the first conductor and the stator core. The insertion portions of the two first conductors of the coil unit are stacked, so that the two first conductors are stacked and interlocked with each other, thereby improving the stability of the relative positions between the multiple first conductors in the coil unit. Therefore, the embodiments of the present application not only simplify the motor structure and improve the motor assembly efficiency, but also improve the stability of the relative positions between the components in the stator and extend the service life of the stator.

[0009] In some embodiments, the first and second insertion portions of the same first conductor are arranged along the circumferential direction, and in any one winding slot, the first insertion portion of one first conductor of the coil unit is located closer to the bottom wall of the winding slot than the second insertion portion of another first conductor of the coil unit.

[0010] In the above technical solution, in any one of the winding slots, the first insertion portions of the first conductors are all closer to the bottom wall of the winding slot, so that the multiple first conductors can be arranged in order, overlapped and fitted together to form a coil unit with two layers of windings, and the first insertion portion of the first conductor is located in one of the winding layers, and the second insertion portion is located in the other winding layer, so that the multiple first conductors are fitted and stopped with each other, thereby improving the stability of the relative positions of the multiple first conductors within the coil unit.

[0011] In some embodiments, the span between the first and second insertion portions of the same first conductor is equal to the pole distance, which can simplify the winding structure of the first conductor.

[0012] In some embodiments, the stator winding includes a plurality of coil units arranged in layers along the axial direction of the stator core.

[0013] In the above technical solution, the amount of magnetic flux of the stator can be increased by installing multiple coil units.

[0014] In some embodiments, the first and second insertion portions of the same first conductor are arranged along the circumferential direction, and the first conductor further includes a connecting portion connecting the first and second insertion portions.

[0015] In the above technical solution, the first inserting part and the second inserting part can be connected via the connecting part at the end of the curl clip.

[0016] In some embodiments, the connecting portion is located on the side of the first and second insert portions toward the center of the stator core. By locating the connecting portion inside the stator core, the number of conductors to be welded inside the stator core can be reduced, which reduces the process difficulty.

[0017] In some embodiments, the connection portion includes a first connection portion and a second connection portion, the first connection portion extending from an end of the first insertion portion close to the center of the stator core and the first connection portion being bent obliquely toward the second insertion portion, the second connection portion extending from an end of the second insertion portion close to the center of the stator core and the second connection portion being bent obliquely toward the first insertion portion, and the first connection portion being connected to the second connection portion.

[0018] In the above technical solution, the first connecting portion and the second connecting portion are formed to extend along directions close to each other, which reduces the overall size of the connecting portion and the space occupied by the connecting portion within the center of the stator core.

[0019] In some embodiments, the connecting portion further includes a bend connecting the first connecting portion and the second connecting portion.

[0020] In the above technical solution, by installing a bending portion, the axial distance between the first and second insertion portions can be changed, and the first and second insertion portions can be easily installed on different winding layers, which further improves the problem of the space in the center of the stator core being cramped, and reduces the risk of interference between different conductors and damage to the insulating coating of the conductors when the first and second insertion portions cross layers.

[0021] In some embodiments, the first conductor is a unitary structure.

[0022] In the above technical solution, the integrally formed first conductor has a relatively high structural strength, which can improve the service life of the first conductor.

[0023] In some embodiments, the first conductor further includes a first pin and a second pin, the first pin being connected to an end remote from the connection portion of the first insertion portion, and the second pin being connected to an end remote from the connection portion of the second insertion portion, the coil unit including a plurality of conductive branches including a plurality of first conductors connected in series, and among any two adjacent first conductors of the conductive branches, the first pin of one first conductor is connected to the second pin of another first conductor.

[0024] In the above technical solution, a first pin and a second pin are further extended from the first conductor, so that the first conductor can be connected to other first conductors through the first pin and the second pin, and at least two first conductors in the conductive branch are connected to each other by the first pin and the second pin, and are connected in series to form the conductive branch.

[0025] In some embodiments, the first pin of one of any two adjacent first conductors of the conductive branch is axially overlapped and connected to the second pin of the other first conductor, thereby increasing the contact area between the first pin and the second pin, ensuring the stability of the relative positions of the first pin and the second pin, and improving the current passing amount between the first pin and the second pin.

[0026] In some embodiments, the first pin and the second pin are welded to one another in the overlap region.

[0027] In the above technical solution, welding is performed in the overlapping area of ​​the first pin and the second pin, which improves the stability of the relative position between the first pin and the second pin and makes the welding operation easier.

[0028] In some embodiments, the first pin and the second pin overlap and connect along the axial direction in an area that forms a connection structure, and the coil unit includes a plurality of connection structures spaced apart along the circumferential direction.

[0029] In the above technical solution, the multiple connection structures are spaced apart along the circumferential direction, and there are gaps between adjacent connection structures. When the first pin and the second pin are welded to each other to form the connection structure, the welding distance can be increased and the mutual influence during welding can be improved.

[0030] In some embodiments, the stator winding includes a plurality of coil units, the plurality of coil units being stacked along the axial direction, and the connection structures of two adjacent coil units being offset in the circumferential direction.

[0031] In the above technical solution, the connection structures of two adjacent coil units are spaced apart in the circumferential direction, thereby increasing the pitch between the connection structures of the two coil units; when the first pin and the second pin are welded together to form the connection structure, the welding distance can be increased to reduce mutual influence during welding; and when the coil units are inserted into the winding slots, the distance between the connection structures of different coil units is sufficiently large so that the first pin and the second pin in the connection structure do not need to be subjected to a flare deformation process, thereby reducing process complexity, further ensuring the stability of the positions of the first pin and the second pin without the need for a flare deformation process, reducing the risk of weld cracking, and further increasing the electrical gap between the connection structures to improve the safety performance of the stator.

[0032] In some embodiments, the first conductor further includes a first connection arm and a second connection arm, the first insertion portion and the first pin are connected via the first connection arm, the second pin and the second insertion portion are connected via the second connection arm, and the second connection arm of one of two first conductors adjacent to each other along the circumferential direction passes between the second pin of the other first conductor and the stator core.

[0033] In the above technical solution, on the one hand, the position of the first pin can be adjusted by controlling the shape and size of the first connecting arm, and the position of the second pin can be adjusted by controlling the shape and size of the second connecting arm, so that the first pin and the second pin can be positioned appropriately. The second connecting arm of one first conductor passes between the second pin of another first conductor and the stator core, i.e., the second pin of another first conductor is located on the side of one second connecting arm away from the center of the stator core, i.e., the second pin is located outside the second connecting arm of the other conductor, and when the first pin and the second pin are welded together, the influence of high temperatures on other parts of the conductors during welding can be reduced and the welding operation for the first pin and the second pin can be facilitated.

[0034] In some embodiments, the second connecting arm has a recess on the side facing away from the stator core for accommodating a second pin of another first conductor.

[0035] In the above technical solution, the relief recess on the second connecting arm allows the second pin to occupy a certain position, preventing the second pin from overlapping with the second connecting arm of another first conductor, thereby reducing the axial thickness of the coil unit. The relief recess minimizes the height of the end of the stator winding, reducing the size of the stator outer envelope and making the motor smaller and facilitating motor installation. Furthermore, the relief recess further reduces the interaction force caused by position interference between the second pin and the second connecting arm, which affects the stability of the second pin position and further influences the weld strength.

[0036] In some embodiments, the second connecting arm is bent at a position corresponding to the relief recess to form a protrusion that projects toward the stator core.

[0037] In the above embodiment, by providing a protrusion corresponding to the relief recess, the second connecting arm can form the relief recess and the protrusion through a bending process, thereby simplifying the molding process of the second connecting arm.

[0038] In some embodiments, the first pin and the second pin are formed to extend radially away from the center of the stator core, or the overlapping first pin and the second pin are formed to extend circumferentially toward each other.

[0039] In the above embodiment, if the first pin and the second pin are formed to extend in a radial direction away from the center of the stator core, the pitch between the first pin, the second pin, and components such as the first insertion portion can be increased, and if the overlapping first pin and the second pin are welded to each other, the impact of high temperatures on other components can be reduced.If the overlapping first pin and the second pin are formed to extend in a circumferential direction close to each other, the shape of the first conductor can be simplified, the size of the first conductor can be reduced, the height of the coil unit away from the end of the stator core can be reduced, the size of the outer envelope of the stator can be reduced, the weight of the first conductor can be reduced, and the arrangement of the stator can be facilitated.

[0040] In some embodiments, the coil unit further includes a second conductor having one insertion portion inserted into the winding slot, which can simplify the structure of the second conductor and facilitate manufacturing of the second conductor.

[0041] In some embodiments, each first conductor includes one insertion portion, or each first conductor is continuously bent and includes at least three insertion portions, and each of the at least three insertion portions of the first conductor is inserted into a different winding slot.

[0042] In the above embodiment, the three insertion portions of the same third conductor are inserted into different winding slots, thereby increasing the contact area between the third conductor and the stator core and improving the stability of the relative position between the third conductor and the stator core.

[0043] In some embodiments, the stator core has winding slots on both of its two axial end faces.

[0044] In the above embodiment, by installing winding slots on both sides of the stator core in the axial direction, the stator windings can be embedded on different sides of the stator core, and the same stator core can accommodate more coil units.

[0045] In some embodiments, the winding slot includes a bottom wall, two side wall surfaces connected to the bottom wall, and two sloped surfaces connected to the two side wall surfaces, respectively, the two side wall surfaces spaced apart along the circumferential direction, and the two sloped surfaces spaced apart from a groove opening formed between ends of the corresponding side wall surfaces.

[0046] In the above embodiment, by connecting the inclined surface to the side wall surface, the size of the groove opening can be increased, making it easier to embed the coil unit in the winding slot.

[0047] In some embodiments, the size of the groove opening along the circumferential direction is H1, the pitch of the two side wall surfaces along the circumferential direction is H2, and H1≧1.5H2.

[0048] In the above technical solution, the circumferential extension size of the groove opening is relatively large and is greater than 1.5 times the circumferential pitch of the two side wall surfaces, which makes it easier for the coil unit to be inserted into the winding slot, improves the efficiency of assembling the coil unit into the winding slot, significantly reduces the reserved space and conductor gap of the stator winding assembly, and enables the copper filling factor to reach 75% or more.

[0049] According to a second aspect, an embodiment of the present application provides a motor including a stator according to any one of the embodiments of the first aspect.

[0050] According to a third aspect, an embodiment of the present application further provides a method for manufacturing a stator, the method comprising: providing a stator core, the stator core having an end surface along its axial direction with a plurality of winding slots extending radially through the inner and outer walls of the stator core, the plurality of winding slots being spaced apart along the circumferential direction of the stator core; The method includes a step of inserting the insertion portion of each first conductor into the winding slot by pressing a coil unit pre-assembled by a plurality of first conductors into the plurality of winding slots along the circumferential direction.

[0051] In this embodiment, a stator core having winding slots is first provided, and then a plurality of first conductors are assembled into a coil unit, and the entire pre-assembled coil unit is then placed into the winding slot, which can effectively improve the assembly efficiency of the stator compared to inserting the plurality of first conductors into the winding slots one by one.

[0052] In some embodiments, a coil unit pre-assembled by a plurality of first conductors is press-fitted into a plurality of winding slots along a circumferential direction, so that before the step of inserting the insertion portions of each of the first conductors into the winding slots, providing a linear conductor including a conductor wire and an insulating layer covering the outside of the conductor wire; removing the insulating layer on both ends of the conductor; and bending the conductor to form a first conductor including two spaced apart inserts.

[0053] In the above technical solution, the conductor is formed by directly bending it after the insulating layers at both ends of a straight conductor have been removed, eliminating the need for later processes such as conductor cutting, thereby reducing the complexity of the conductor manufacturing process and improving the manufacturing efficiency of the stator.

[0054] In some embodiments, the stator pole number is 2p and the stator pole spacing is n winding slots; the method further includes a step of providing 2p·n first conductors before the step of inserting the insertion portions of the first conductors into the winding slots by press-fitting a coil unit pre-assembled by the plurality of first conductors into the plurality of winding slots along a circumferential direction, wherein each first conductor includes a first insertion portion and a second insertion portion, and the span between the first insertion portion and the second insertion portion is n winding slots; The step of pre-assembling a plurality of first conductors into a coil unit includes: providing an assembly mechanism, the assembly mechanism including 2p·n slots evenly spaced around a circumference of the assembly mechanism; stacking (2p-1)·n first conductors in the 2p·n slots along a counterclockwise direction; and a step of inserting the remaining n first conductors into slots of the assembly mechanism to form a coil unit, wherein in any one slot, a first insertion portion of one first conductor of the coil unit is positioned closer to a bottom wall of the slot than a second insertion portion of another first conductor of the coil unit.

[0055] In the above technical solution, the span between the first and second insertion portions is equal to the pole distance, which simplifies the winding structure of the first conductors. In any one winding slot, the first insertion portions of the first conductors are all closer to the bottom wall of the winding slot, so that the multiple first conductors can be sequentially arranged and overlapped and fitted together to form a coil unit with two layers of windings, and the first insertion portion of the first conductor is located in one layer of winding and the second insertion portion is located in the other layer of winding, so that the multiple first conductors are fitted and stopped with each other, which improves the stability of the relative positions of the multiple first conductors within the coil unit. [Brief explanation of the drawings]

[0056] In order to more clearly explain the technical solutions of the embodiments of the present application, the following briefly introduces the drawings that need to be used in the embodiments of the present application. It is obvious that the drawings described below are only some embodiments of the present application, and those skilled in the art can obtain other drawings based on the drawings without exerting any creative efforts. [Figure 1] 1 is a structural schematic diagram of a stator of a motor according to some embodiments of the present application. FIG. [Figure 2] FIG. 2 is a structural schematic diagram of a stator winding of a stator according to some embodiments of the present application. [Figure 3] FIG. 2 is a structural schematic diagram of a first conductor of a stator winding of a stator according to some embodiments of the present application. [Figure 4] 1 is a schematic diagram of an assembly process for a stator according to some embodiments of the present application. [Figure 5] 1A-1D are structural schematic diagrams of a stator in an assembly process according to some embodiments of the present application. [Figure 6] FIG. 2 is a structural schematic diagram of a stator from another perspective according to some embodiments of the present application. [Figure 7] FIG. 2 is a structural schematic diagram of a stator from another perspective according to some embodiments of the present application. [Figure 8] FIG. 8 is a schematic diagram of a locally enlarged structure at A in FIG. [Figure 9] 1 is a structural schematic diagram of a portion of a first conductor of a stator according to some embodiments of the present application. FIG. [Figure 10] FIG. 10 is a structural schematic diagram of a portion of a first conductor of a stator according to some other embodiments of the present application. [Figure 11] FIG. 10 is a structural schematic diagram of a first conductor portion of a stator according to still other embodiments of the present application. [Figure 12] 1 is a schematic diagram of a local structure of a coil unit of a stator according to some embodiments of the present application; [Figure 13] 10A and 10B are structural schematic diagrams of a first conductor of a stator according to some other embodiments of the present application. [Figure 14]FIG. 14 is a structural schematic diagram of FIG. 13 from another perspective. [Figure 15] FIG. 14 is a structural schematic diagram of a portion of the first conductor of the stator shown in FIG. 13. [Figure 16] 10A and 10B are structural schematic diagrams of a first conductor of a stator according to some other embodiments of the present application. [Figure 17] FIG. 17 is a structural schematic diagram of FIG. 16 from another viewpoint. [Figure 18] FIG. 17 is a structural schematic diagram of a portion of the first conductor of the stator shown in FIG. 16. [Figure 19] FIG. 2 is a structural schematic diagram of a second conductor of a stator according to some embodiments of the present application. [Figure 20] 10A-10C are structural schematic diagrams of a first conductor of a stator according to further some embodiments of the present application. [Figure 21] FIG. 15 is a structural schematic diagram of a stator including the first conductor shown in FIG. 14 according to some embodiments of the present application. [Figure 22] FIG. 4 is a schematic diagram of a stator core of a stator according to some further embodiments of the present application. [Figure 23] FIG. 10 is a schematic diagram of a stator according to some other embodiments of the present application. [Figure 24] FIG. 10 is a side view of a stator according to some alternative embodiments of the present application. [Figure 25] 1 is a local cross-sectional view of a stator core of a stator according to some embodiments of the present application. [Figure 26] 1 is a flowchart illustrating a method for manufacturing a stator according to some embodiments of the present application.

[0057] The drawings are not drawn to scale. DETAILED DESCRIPTION OF THE INVENTION

[0058] In order to clarify the objectives, technical solutions and advantages of the embodiments of the present application, the following will clearly describe the technical solutions in the embodiments of the present application in conjunction with the drawings in the embodiments of the present application, and it is obvious that the described embodiments are only some of the embodiments of the present application, and not all of the embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present application without any creative efforts fall within the scope of protection of the present application.

[0059] Unless otherwise defined, all technical and scientific terms used in this application have the same meaning as commonly understood by those skilled in the art of this application, and the terms used in the specification of this application are only for describing specific embodiments and are not intended to limit this application, and the terms "comprises," "has," and any variations thereof in the specification and claims of this application and the above drawings are intended to cover a non-exclusive "comprise." The terms "first," "second," etc. in the specification and claims of this application or the above drawings are not intended to describe a specific order or a hierarchical relationship, but are intended to distinguish different objects.

[0060] An "embodiment" referred to in this application means that a particular feature, structure, or characteristic described in connection with the embodiment may be included in at least one embodiment of the application. The appearances of this phrase in various places in the specification do not necessarily all refer to the same embodiment, nor are they mutually exclusive, separate, or alternative embodiments of other embodiments.

[0061] In the description of this application, it should be explained that unless otherwise clearly defined or limited, the terms "attached," "connected," "joined," and "attached" should be understood in a broad sense, and may refer to, for example, a fixed connection, a detachable connection, or an integral connection, a direct connection, an indirect connection via an intermediate medium, or internal communication between two elements. Those skilled in the art can understand the specific meanings of the above terms in this application according to specific circumstances.

[0062] The term "and / or" in this application merely describes the relationship between related objects and indicates that three relationships may exist, for example, A and / or B may represent three cases: A alone, a combination of A and B, and B alone. Also, the character " / " in this application generally indicates that the related objects before and after are in an "or" relationship.

[0063] In the embodiments of the present application, the same reference numerals represent the same elements, and for the sake of brevity, detailed descriptions of the same elements will be omitted in different embodiments. It should be understood that the thickness, length, width, etc. of various elements in the embodiments of the present application shown in the drawings, and the overall thickness, length, width, etc. of the integrated device, are merely illustrative and should not be construed as any limitation on the present application.

[0064] The term "plurality" as used herein refers to two or more (including two).

[0065] Currently, in the traction motor of a new energy vehicle, the inventor has found that, among the electrode stators, most of the conventional technical solutions adopt a concentrated stator winding and arrange a skew groove design to reduce the tooth gap torque. However, the skew groove makes the motor stator core production and wiring process very complicated, and the conventional stator has the disadvantages of having a complicated structure and wiring process, low assembly efficiency, and difficulty in realizing mass production and automated production.

[0066] Therefore, the embodiments of the present application provide a motor, a stator, and a method for manufacturing a stator that adjusts the wiring and winding method of the conductors to simplify the stator structure and improve the assembly efficiency of the motor.

[0067] For ease of understanding, the technical nouns appearing in this application will be first explained below.

[0068] Stator: The stationary, non-moving part of the motor whose function is to generate a rotating magnetic field.

[0069] Rotor: The rotating part in a motor, whose function is to realize the conversion of electrical energy to mechanical energy.

[0070] Span: The distance that two sides of the same element in a motor winding span across the armature surface, generally expressed as the number of winding slots opened in the stator core.

[0071] Number of magnetic pole pairs P: The number of magnetic pole pairs is abbreviated as the number of pole pairs. The magnetic poles formed after the motor windings are energized appear as pairs of north and south poles. The total number of magnetic poles is 2P.

[0072] Pole Spacing: Pole spacing is the distance each magnetic pole of a motor occupies around the circumference of the air gap. Pole spacing may be expressed as the number of winding slots in the stator core. Illustratively, pole spacing is Z / 2P, where Z is the total number of winding slots in the stator core.

[0073] Pole group: In an AC motor, when multiple conductors belonging to the same phase winding are connected in series under one pole distance to form a group, it is called a pole group, also called a coil unit. The current direction and electromagnetic action of each conductor in a pole group are all the same, and these several conductors jointly generate magnetic poles in this phase winding.

[0074] Phase Winding: A phase winding is a set of windings connected in series or parallel in a predetermined manner from one or more parallel-connected branches.

[0075] Fig. 1 is a structural schematic diagram of a stator according to some embodiments of the present application, Fig. 2 is a structural schematic diagram of a stator winding 200 of a stator according to some embodiments of the present application, Fig. 3 is a structural schematic diagram of a first conductor 210 of the stator winding 200 of a stator according to some embodiments of the present application, and Fig. 4 is a schematic diagram of an assembly process of a stator according to some embodiments of the present application.

[0076] 1 to 4 , some embodiments of the present application provide a stator including a stator core 100 and a stator winding 200. An end surface 110 of the stator core 100 along its axial direction is provided with a plurality of winding slots 120 that penetrate the inner and outer walls of the stator core 100 along the radial direction, and the plurality of winding slots 120 are disposed at intervals along the circumferential direction of the stator core 100. The stator winding 200 includes at least one coil unit 200a, and the coil unit 200a includes a plurality of first conductors 210 that are assembled together, and each first conductor 210 includes at least one insertion portion 2011 that is inserted into the winding slot 120.

[0077] The winding slots 120 extend radially through the stator core 100. For example, the stator core 100 has an inner wall surface and an outer wall surface, and both ends of the winding slots 120 along the radial direction form openings in the inner wall surface and the outer wall surface, respectively.

[0078] The multiple first conductors 210 of the coil unit 200a may be assembled by braiding, stacking, or other processes. For example, the first conductors 210 may be fixedly connected to each other, or may be stopped by their own structure.

[0079] The embodiments of the present application do not limit the number of insertion portions 2011 of the first conductors 210. The number of insertion portions 2011 of the multiple first conductors 210 may be the same or different. In some examples, the number of insertion portions 2011 of all the first conductors 210 may be the same, for example, one, two, four, eight, or more. In other examples, the number of insertion portions 2011 of some first conductors 210 may be different from the number of insertion portions 2011 of other first conductors 210, for example, some first conductors 210 include one insertion portion 2011, other first conductors 210 include two insertion portions 2011, and some first conductors 210 include three or more insertion portions 2011. The number of coil units 200a may be one or more. For example, there may be a plurality of coil units 200a, and the plurality of coil units 200a may be stacked along the axial direction of the stator core 100.

[0080] Each first conductor 210 may include one or more insertion portions 2011. The insertion portions 2011 are effective sides of the first conductor 210, are incorporated into the stator core 100, and play a role in electromagnetic pole energy conversion.

[0081] There are several types of configurations for the first conductor 210. The first conductor 210 may be a rectangular wire or a round wire. The cross section of the rectangular wire may be rectangular, and the cross section of the round wire may be circular. In the embodiments of the present application, a rectangular wire will be used as an example for illustrative purposes. In other embodiments, the first conductor 210 may be a round wire.

[0082] Optionally, the coil unit 200a is installed in the winding slot 120 along the axial direction, and wiring of the coil unit 200a along the axial direction makes the wiring process convenient and efficient.

[0083] In the above technical solution, the stator includes a stator core 100 and a stator winding 200, and the coil units 200a of the stator winding 200 are embedded in the winding slots 120 of the stator core 100. The coil units 200a are assembled and connected and molded by a plurality of first conductors 210. Therefore, when the stator winding 200 is attached to the stator core 100, the plurality of first conductors 210 can be connected to each other in advance to form the coil unit 200a, and then the entire coil unit 200a can be installed on the stator core 100. This simplifies the wiring process, facilitates automated mass production, simplifies the motor structure and assembly steps, and improves motor assembly efficiency. The multiple first conductors 210 of the coil unit 200a are connected to form a distributed winding, which can achieve high electromagnetic efficiency, reduce spatial harmonics, and improve technical effects such as NVH (noise, vibration, and acoustic harshness).

[0084] Referring to FIG. 2 to FIG. 5, FIG. 5 is a structural schematic diagram of an assembly process of a stator according to some embodiments of the present application.

[0085] 2 to 5, the multiple first conductors 210 of the coil unit 200a are distributed in a circumferentially offset manner. Each first conductor 210 includes a first insertion portion 211 and a second insertion portion 212 connected to each other. The first insertion portion 211 and the second insertion portion 212 are inserted into different winding slots 120, and the first insertion portion 211 of one first conductor 210 is stacked with the second insertion portion 212 of another first conductor 210 of the coil unit 200a within the same winding slot 120.

[0086] The fact that the first conductors 210 are distributed in a circumferentially offset manner means that the first conductors 210 do not completely overlap each other in the axial direction, and the first conductors 210 are at least partially offset from each other in the circumferential direction. For example, as shown in FIG. 5 , adjacent first conductors 210 are offset from each other by one winding slot 120 in the circumferential direction.

[0087] When the first insertion portion 211 of one first conductor 210 is stacked with the second insertion portion 212 of another first conductor 210 of the coil unit 200a, this means that the first insertion portion of one first conductor 210 and the second insertion portion 212 of another first conductor 210 of the coil unit 200a are stacked along the axial direction of the stator core 100.

[0088] In the above technical solution, the first insertion portion 211 and the second insertion portion 212 of the first conductor 210 are inserted into different winding slots 120, thereby improving the stability of the relative position between the first conductor 210 and the stator core 100. The first insertion portion of one first conductor 210 is stacked and installed with the second insertion portion 212 of another first conductor 210 of the coil unit 200a, so that the two first conductors 210 are stacked and fitted together, thereby improving the stability of the relative position between the multiple first conductors 210 in the coil unit 200a. Therefore, the embodiments of the present application can not only simplify the motor structure and improve the assembly efficiency of the motor, but also improve the stability of the relative position between each component in the stator and extend the service life of the stator.

[0089] In some embodiments, as shown in Figures 1 to 5, the first insertion portion 211 and the second insertion portion 212 of the same first conductor 210 are arranged along the circumferential direction, and in any one winding slot 120, the first insertion portion 211 of one first conductor 210 of the coil unit 200a is located on the side closer to the bottom wall of the winding slot 120 than the second insertion portion 212 of another first conductor 210 of the coil unit 200a.

[0090] The circumferential direction may be clockwise or counterclockwise.

[0091] Optionally, as shown in Figures 4 and 5, one or more additional winding slots 120 may be provided between the winding slot 120 corresponding to the first insertion portion 211 and the winding slot 120 corresponding to the second insertion portion 212. In the above technical solution, the first conductor 210 is arranged to straddle the multiple winding slots 120 via the first insertion portion 211 and the second insertion portion 212, which allows the size of the first conductor 210 itself to be increased, while at least a portion of other first conductors 210 of the same coil unit 200a can be inserted into these multiple winding slots 120, thereby allowing the multiple first conductors 210 to be fitted together and improving the stability of the relative positions of the multiple first conductors 210.

[0092] In the above technical solution, in any one of the winding slots 120, the first insertion portions 211 of the first conductors 210 are all closer to the bottom wall of the winding slot 120, so that the multiple first conductors 210 can be arranged in sequence, overlapped and fitted together to form a coil unit 200a having two layers of winding, and the first insertion portion 211 of the first conductor 210 is located in one of the winding layers, and the second insertion portion 212 is located in the other winding layer, so that the multiple first conductors 210 are fitted together with stoppers, thereby improving the stability of the relative positions of the multiple first conductors 210 in the coil unit 200a.

[0093] In a stator according to an embodiment of the present application, the coil unit 200a of the stator winding 200 may be considered to include two layers of winding, with the first and second insertion portions 211 and 212 of the same first conductor 210 being located in different winding layers. For example, the coil unit 200a may include a high-layer winding and a low-layer winding, with the first insertion portion 211 of the same first conductor 210 being located in the low-layer winding and the second insertion portion 212 being located in the high-layer winding, thereby allowing the multiple first conductors 210 to be interdigitated with each other. The low-layer winding is, for example, a winding layer closer to the bottom wall of the winding slot 120, and the high-layer winding is, for example, a winding layer further from the bottom wall of the winding slot 120. In another embodiment, the first insertion portion 211 of the same first conductor 210 may also be located in the high-layer winding, with the second insertion portion 212 being located in the low-layer winding.

[0094] 4 and 5, the span between the first insertion portion 211 and the second insertion portion 212 of the same first conductor 210 is equal to the pole distance, which can simplify the winding structure of the first conductor 210. For example, if the span between the first insertion portion 211 and the second insertion portion 212 of the same first conductor 210 is six winding slots 120, the pole distance is six winding slots 120.

[0095] Fig. 6 is a structural schematic diagram of a stator according to some embodiments of the present application from another perspective, Fig. 7 is a structural schematic diagram of a stator according to some embodiments of the present application from yet another perspective, and Fig. 8 is a locally enlarged structural schematic diagram of A in Fig. 7.

[0096] In some embodiments, as shown in FIGS. 1 to 8, the stator winding 200 includes a plurality of coil units 200a arranged in layers along the axial direction of the stator core 100.

[0097] In the above technical solution, the amount of magnetic flux of the stator can be increased by installing a plurality of coil units 200a.

[0098] When the stator winding 200 includes multiple coil units 200a, the multiple coil units 200a may be inserted into the winding slots 120 of the stator core 100 in the same step. Alternatively, the process may be divided into multiple steps, with one coil unit 200a being inserted into the winding slot 120 of the stator core 100 each time. When inserting one coil unit 200a into the winding slot 120 of the stator core 100, first, multiple first conductors 210 may be connected to one coil unit 200a, and the entire coil unit 200a may then be inserted into the multiple winding slots 120 of the stator core 100. Alternatively, the process may be divided into multiple steps, with one first conductor 210 being inserted into the winding slot 120 each time.

[0099] 1 to 8, the first and second mounting portions 211 and 212 of the same first conductor 210 are arranged along the circumferential direction. The first conductor 210 further includes a connecting portion 213 connecting the first and second mounting portions 211 and 212.

[0100] Alternatively, the connection portion 213 may be integrally formed with the first insertion portion 211 and the second insertion portion 212. In other embodiments, the connection portion 213 may be formed separately from the first insertion portion 211 and the second insertion portion 212.

[0101] In the above technical solution, the first inserting part 211 and the second inserting part 212 can be connected via the connecting part 213 at the end of the curl clip.

[0102] In some embodiments, the connection portion 213 is located on the side of the first insertion portion 211 and the second insertion portion 212 toward the center of the stator core 100 .

[0103] In the above technical solution, the connection part 213 is installed inside the stator core 100, so that the number of first conductors 210 to be welded inside the stator core 100 can be reduced, and the process difficulty can be reduced.

[0104] In some embodiments, as shown in Figures 1 to 8, the connection portion 213 includes a first connection portion 213a and a second connection portion 213b, where the first connection portion 213a extends from an end of the first insertion portion 211 that is close to the center of the stator core 100 and the first connection portion 213a is bent obliquely toward the second insertion portion 212, and the second connection portion 213b extends from an end of the second insertion portion 212 that is close to the center of the stator core 100 and the second connection portion 213b is bent obliquely toward the first insertion portion 211, and the first connection portion 213a is connected to the second connection portion 213b.

[0105] In the above technical solution, the first connecting portion 213a and the second connecting portion 213b are formed to extend along a direction close to each other, which reduces the overall size of the connecting portion 213 and the space occupied by the connecting portion 213 within the center of the stator core 100.

[0106] Optionally, of two adjacent first conductors 210 in the same coil unit 200a, the first connection portion 213a of one first conductor 210 and the second connection portion 213b of the other first conductor 210 are arranged to cross and be stacked along the axial direction, thereby preventing the first connection portion 213a and the second connection portion 213b of the two first conductors 210 from contacting each other, thereby improving the stability of the relative positions of the multiple first conductors 210.

[0107] Optionally, among three first conductors 210 adjacent to each other along the circumferential direction within the same coil unit 200a, the first connection portion 213a of one of the first conductors 210 is located on the side closer to the bottom wall of the winding slot 120 than the second connection portion 213b of the previous first conductor 210, and the second connection portion 213b of one of the first conductors 210 is located on the side farther from the bottom wall of the winding slot 120 than the first connection portion 213a of the subsequent first conductor 210.

[0108] In the above solution, the first connecting portion 213a of one of the first conductors 210 is located closer to the bottom wall of the winding slot 120 than the second connecting portion 213b of the previous first conductor 210, and the axial positional relationship between the first connecting portion 213a and the second connecting portion 213b will be described with reference only to the bottom wall of the winding slot 120. Similarly, if the second connecting portion 213b of one of the first conductors 210 is located farther from the bottom wall of the winding slot 120 than the first connecting portion 213a of the subsequent first conductor 210, the positional relationship between the second connecting portion 213b and the first connecting portion 213a will be described with reference only to the bottom wall of the winding slot 120.

[0109] As described above, the circumferential direction may be a clockwise direction or a counterclockwise direction. When the circumferential direction is a clockwise direction, the first conductor 210 located in front of one of the first conductors 210 is the first conductor 210 located on the counterclockwise side of that one of the first conductors 210, and the first conductor 210 located behind one of the first conductors 210 is the first conductor 210 located on the clockwise side of that one of the first conductors 210.

[0110] In the embodiment of the present application, of the three first conductors 210 arranged along the circumferential direction in the same coil unit 200a, the three first conductors 210 are, for example, conductor X1, conductor X2, and conductor X3 in order along the circumferential direction, and the first connection portion 213a of the conductor X2 is located on the side of the second connection portion 213b of the conductor X1 facing the bottom wall of the winding slot 120, and the second connection portion 213b of the conductor X2 is located on the side of the first connection portion 213a of the conductor X3 facing the bottom wall of the winding slot 120. The first conductors 210 are positioned on the side where the second connection portion 213b of the conductor X2 is crimped onto the first connection portion 213a of the conductor X3 toward the bottom wall of the winding slot 120, while the first connection portion 213a of the conductor X1 is crimped onto the second connection portion 213b of the conductor X2 toward the bottom wall of the winding slot 120, i.e., the first connection portion 213a of the conductor X2 is crimped, and the second connection portion 213b of the conductor X2 is crimped onto another first connection portion 213a, so that the multiple first conductors 210 are fitted together in sequence.

[0111] Alternatively, the conductor X1, the conductor X2 and the conductor X3 may be adjacently arranged, or another first conductor 210 may be arranged between the conductor X1 and the conductor X2, and another first conductor 210 may be arranged between the conductor X2 and the conductor X3.

[0112] In some embodiments, the multiple first conductors 210 are arranged alternately, and along the circumferential direction, the first connection portion 213a of one of the first conductors 210 is located on the side closer to the bottom wall of the winding slot 120 than the second connection portion 213b of the previous multiple first conductors 210, and the second connection portion 213b of one of the first conductors 210 is located on the side farther from the bottom wall of the winding slot 120 than the first connection portion 213a of the next multiple first conductors 210.

[0113] In the above technical solution, the first connecting portion 213a of the first conductor 210 is pressed against the bottom wall of the winding slot 120 by the second connecting portions 213b of the other first conductors 210, and the second connecting portion 213b of the first conductor 210 presses the first connecting portions 213a of the other first conductors 210 toward the bottom wall of the winding slot 120, and the multiple first conductors 210 are laminated and fitted together in sequence, thereby improving the stability of the relative positions between the multiple first conductors 210.

[0114] Referring to Figures 3 to 11, Figure 9 is a structural schematic diagram of a portion of a first conductor 210 of a stator according to some embodiments of the present application, Figure 10 is a structural schematic diagram of a portion of a first conductor 210 of a stator according to some other embodiments of the present application, and Figure 11 is a structural schematic diagram of a portion of a first conductor 210 of a stator according to some other embodiments of the present application.

[0115] In some embodiments, as shown in FIGS. 3 to 11, the connecting portion 213 further includes a bent portion 213c connecting the first connecting portion 213a and the second connecting portion 213b.

[0116] The installation manner of the bent portion 213c may be various. As shown in Figures 9 to 11, the bent portion 213c may be formed by twisting, folding or bending the first connecting portion 213a relative to the second connecting portion 213b, that is, the bent portion 213c may be twisted, folded or stepped.

[0117] In the above technical solution, by installing the bending portion 213c, the axial distance between the first insertion portion 211 and the second insertion portion 212 is changed, and it is easier to install the first insertion portion 211 and the second insertion portion 212 in different winding layers, which further improves the problem of the space being cramped in the center of the stator core 100, and reduces the risk of interference between different first conductors 210 and the risk of damage to the insulating coating of the first conductor 210 when the first insertion portion 211 and the second insertion portion 212 cross over layers.

[0118] In some embodiments, first electrical conductor 210 is a unitary structure, for example, first insert portion 211, second insert portion 212 and connecting portion 213 are a unitary structure.

[0119] Alternatively, the first mounting portion 211, the second mounting portion 212 and the connecting portion 213 are an integrally molded structure, presenting a U-shaped structure, the first mounting portion 211 and the second mounting portion 212 being two walls of the U-shaped structure, and the connecting portion 213 being the bottom of the U-shaped structure.

[0120] In the above technical solution, if the first conductor 210 is integrally molded, for example, if the first insertion portion 211, the second insertion portion 212 and the connection portion 213 are integrally molded, the first conductor 210 has a relatively high connection strength, which can improve the service life of the first conductor 210.

[0121] Alternatively, the integrally formed first insertion portion 211, second insertion portion 212, and connection portion 213 may be formed by deforming the conductor. For example, if the first conductor 210 is a rectangular wire, the first conductor 210 may be formed by a die after being devarnished and punched using a rectangular conductor. The wound rectangular conductor is leveled and then laser-devarnished at a position corresponding to the length. After the devarnishment is completed, the punched rectangular conductor is precisely punched. The punched rectangular conductor is then formed using a die 3D molding and one-time 3D press molding to form the first conductor 210, which is then assembled into the winding slot 120. The punching, devarnishment, and 3D molding processes of the 3D-molded first conductor 210 are easily controlled, eliminating the need for conductor cutting, reducing process complexity and improving production line operation efficiency.

[0122] In some embodiments, as shown in Figures 3 to 8, the first conductor 210 further includes a first pin 214 and a second pin 215, where the first pin 214 is connected to an end of the first insertion portion 211 away from the connection portion 213, and the second pin 215 is connected to an end of the second insertion portion 212 away from the connection portion 213, and the coil unit 200a includes a plurality of conductive branches 201 including a plurality of first conductors 210 connected in series, and among any two adjacent first conductors 210 of the conductive branch 201, the first pin 214 of one first conductor 210 is connected to the second pin 215 of the other first conductor 210.

[0123] Optionally, the first pin 214 and the second pin 215 are formed to extend along the radial direction of the stator core 100 in a direction away from the center of the stator core 100 .

[0124] In the above technical solution, the first pin 214 and the second pin 215 are further extended from the first conductor 210, so that the first conductor 210 can be connected to other first conductors 210 via the first pin 214 and the second pin 215. At least two first conductors 210 in the coil unit 200a are connected to each other via the first pin 214 and the second pin 215, and are connected in series to form the conductive branch 201.

[0125] 3 to 8, the first pin 214 of one of the first conductors 210 and the second pin 215 of the other of the first conductors 210 adjacent to each other in the conductive branch 201 are connected to each other in an axially overlapping manner, which can increase the contact area between the first pin 214 and the second pin 215, ensure the stability of the relative positions of the first pin 214 and the second pin 215, and improve the current passing capacity between the first pin 214 and the second pin 215.

[0126] Optionally, of the at least two first conductors 210, the first pin 214 of one of them and the second pin 215 of the other of them are completely overlapped along the axial direction of the stator core 100 and connected to each other.

[0127] In the above technical solution, the first pin 214 and the second pin 215 of the two first conductors 210 are fully overlapped with each other, thereby improving the contact area between the first pin 214 and the second pin 215 and ensuring a sufficient current-passing area between the two first conductors 210. In addition, the first pin 214 and the second pin 215 of the first conductor 210 can also be connected in series with each other, thereby forming a complete conductive branch 201.

[0128] Optionally, the first pin 214 and the second pin 215 of any two adjacent first conductors 210 of the conductive branch 201 are welded to each other in the overlapping region. Illustratively, the first pin 214 and the second pin 215 are welded by TIG (non-fusible electrode gas-shielded arc welding), laser welding, or other methods.

[0129] In some embodiments, automatic welding identification can be achieved by rotating the stator axially or rotating the welding head during welding, and single-point or multiple-point simultaneous welding can be achieved, resulting in high production efficiency. The positioning of the welded portion of the pre-molded coil unit 200a is good, and the first conductor 210 is in its natural state during welding, with relatively small springback and internal stress, reducing the risk of cracking.

[0130] In some embodiments, as shown in Figures 3 to 8, the first pin 214 and the second pin 215 form a connection structure 2145 in an area where they overlap and connect along the axial direction, and the coil unit 200a includes multiple connection structures 2145 spaced apart along the circumferential direction.

[0131] The connecting structure 2145 refers to the overlapping region of the interconnected first pin 214 and second pin 215. Optionally, the first pin 214 and the second pin 215 may be welded together in the region where the connecting structure 2145 is located.

[0132] In the above technical solution, the multiple connecting structures 2145 are spaced apart along the circumferential direction, and there are gaps between adjacent connecting structures 2145. When the first pin 214 and the second pin 215 are welded to each other to form the connecting structure 2145, the welding distance can be increased and the mutual influence during welding can be improved.

[0133] In some embodiments, as shown in Figures 3 to 8, the stator winding 200 includes multiple coil units 200a stacked along the axial direction, and the connection structures 2145 of two adjacent coil units 200a are offset in the circumferential direction.

[0134] In the above technical solution, the connecting structures 2145 of two adjacent coil units 200a are spaced apart in the circumferential direction, allowing for a large pitch between the connecting structures 2145 of the two coil units 200a; while when the first pins 214 and the second pins 215 are welded to each other to form the connecting structures 2145, the welding distance can be increased, thereby reducing mutual influence during welding. Furthermore, when the coil units 200a are inserted into the winding slots 120, the distance between the connecting structures 2145 of different coil units 200a is sufficiently large, eliminating the need for continuous flaring of the first pins 214 and the second pins 215 in the connecting structures 2145, thereby reducing process complexity and further ensuring the positional stability of the first pins 214 and the second pins 215 without the need for flaring, thereby reducing the risk of weld cracking; and, on the other hand, the electrical gap between the connecting structures 2145 can be increased, improving the safety performance of the stator.

[0135] The above technical solution can further shorten the axial size of the stator, make the axial size of the motor smaller, and make it lighter. In the finished vehicle, the unsprung mass can be reduced. The arrangement of multi-link + dummy spring is more conducive to the operability of the chassis. By circumferentially offsetting the connection structures 2145 of two adjacent coil units 200a, the electrical gap between the connection structures 2145 can be increased, reducing the requirements for insulation of the connection structures 2145, reducing process complexity, saving raw materials, and improving the production line operating cycle.

[0136] Optionally, the connection structures 2145 of two axially adjacent coil units 200a are spaced apart from each other in the circumferential direction.

[0137] Optionally, the connection structures 2145 of the coil units 200a located on both axial sides of the same coil unit 200a can be stacked on top of each other along the axial direction, thereby making the circumferential pitch of the connection structures 2145 of two adjacent coil units 200a as large as possible.

[0138] For example, the number of coil units 200a is four, and the four coil units 200a are respectively a first coil unit, a second coil unit, a third coil unit, and a fourth coil unit in the direction away from the bottom wall of the winding slot 120, and the connection structures 2145 between the first coil unit and the second coil unit, the second coil unit and the third coil unit, and the third coil unit and the fourth coil unit are installed at intervals along the circumferential direction, and the connection structures 2145 between the first coil unit and the third coil unit, and the second coil unit and the fourth coil unit are installed stacked on top of each other along the axial direction.

[0139] Optionally, the plurality of connecting structures 2145 of each coil unit 200a are uniformly distributed along the circumferential direction to increase the pitch between the abutting portions of two adjacent coil units 200a.

[0140] In some embodiments, as shown in Figures 3 to 8, the first conductor 210 further includes a first connection arm 216 and a second connection arm 217, the first insertion portion 211 and the first pin 214 are connected via the first connection arm 216, the second pin 215 and the second insertion portion 212 are connected via the second connection arm 217, and of two first conductors 210 adjacent to each other along the circumferential direction, the second connection arm 217 of one first conductor 210 passes between the second pin 215 of the other first conductor 210 and the stator core 100.

[0141] Optionally, the first and second insertion portions 211 and 212 of the first conductor 210 are spaced apart along the circumferential direction and connected to each other to form a generally U-shaped structure, the first insertion portion 211 being one wall of the U-shaped structure, the second insertion portion 212 being another wall of the U-shaped structure, and the first connecting arm 216 extending in a direction away from the second insertion portion 212 in the circumferential direction, i.e., the first connecting arm 216 extending in a direction away from the interior of the U-shaped structure. Similarly, the second connecting arm 217 extending in a direction away from the interior of the U-shaped structure.

[0142] Optionally, the first connecting arm 216 and the second connecting arm 217 are located outside the stator core 100 .

[0143] Optionally, the first connecting arm 216 and the first insert portion 211 are integrally molded to improve the connection strength between the first connecting arm 216 and the first insert portion 211. Optionally, the second connecting arm 217 and the second insert portion 212 are integrally molded to improve the connection strength between the second connecting arm 217 and the second insert portion 212.

[0144] Optionally, the first connecting arm 216 and the first pin 214 are integrally molded to improve the connection strength between the first connecting arm 216 and the first pin 214. Optionally, the second connecting arm 217 and the second pin 215 are integrally molded to improve the connection strength between the second connecting arm 217 and the second pin 215.

[0145] Optionally, the first pin 214 is formed to extend radially from an end of the first connecting arm 216 that is remote from the first insertion portion 211, in a direction away from the center of the stator core 100. Optionally, the second pin 215 is formed to extend from an end of the second connecting arm 217 that is remote from the second insertion portion 212, in a second direction away from the second insertion portion 212.

[0146] In the above technical solution, on the one hand, the position of the first pin 214 can be adjusted by controlling the shape and size of the first connecting arm 216, and the position of the second pin 215 can be adjusted by controlling the shape and size of the second connecting arm 217, thereby enabling the first pin 214 and the second pin 215 to be positioned appropriately. The second connecting arm 217 of one first conductor 210 passes between the second pin 215 of another first conductor 210 and the stator core 100, i.e., the second pin 215 of the other first conductor 210 is located on the side of the one second connecting arm 217 away from the center of the stator core 100, i.e., the second pin 215 is located outside the second connecting arm 217 of the other first conductor 210. When the first pin 214 and the second pin 215 are welded together, this reduces the effect of high temperatures during welding on other components of the first conductor 210 and facilitates the welding operation for the first pin 214 and the second pin 215.

[0147] Referring to FIGS. 3 to 12, FIG. 12 is a schematic diagram of the local structure of a coil unit 200a of a stator according to some embodiments of the present application.

[0148] In some embodiments, as shown in Figures 3 to 12, the second connecting arm 217 has an escape recess 217a on the side facing away from the stator core 100 to allow the second pin 215 of another first conductor 210 to escape.

[0149] Optionally, the second pins 215 are located on the side of the corresponding relief recesses 217a that is away from the center of the stator core 100. Optionally, at least some of the second pins 215 are located in the corresponding relief recesses 217a.

[0150] The shape of the relief recess 217a can be configured in various ways. When the second pin 215 and the second connecting arm 217 are connected smoothly and smoothly, the relief recess 217a may be arc-shaped, which makes it easier to process and form the relief recess 217a, and also makes the shape of the relief recess 217a more compatible with the connection shape of the second pin 215 and the second connecting arm 217, so that the relief recess 217a can better yield its position to the second pin 215.

[0151] In the above technical solution, the relief recess 217a is provided on the second connecting arm 217, which allows the second pin 215 to move freely, preventing the second pin 215 from overlapping with the second connecting arm 217 of another first conductor 210, and reducing the axial thickness of the coil unit 200a. The relief recess 217a reduces the height of the end of the stator winding 200, making the size of the stator outer envelope smaller, further reducing the size of the motor and facilitating motor placement. Furthermore, the relief recess 217a further reduces the interaction force caused by positional interference between the second pin 215 and the second connecting arm 217, which affects the positional stability of the second pin 215 and further affects the welding strength.

[0152] Optionally, of two first conductors 210 adjacent to each other in the circumferential direction, the first connection arm 216 of one first conductor 210 passes between the first pin 214 of the other first conductor 210 and the stator core 100. Optionally, a relief portion is provided on the side of the first connection arm 216 that faces away from the stator core 100 to allow the first pin 214 of the other first conductor 210 to escape.

[0153] In some embodiments, as shown in FIG. 12, the second connecting arm 217 is bent at a position corresponding to the relief recess 217a to form a protrusion 217b that protrudes toward the stator core 100.

[0154] In the above embodiment, by providing the protrusion 217b corresponding to the relief recess 217a, the second connecting arm 217 forms the relief recess 217a and the protrusion 217b through the bending process, which simplifies the molding process of the second connecting arm 217.

[0155] In some embodiments, as shown in FIG. 3, first pin 214 and second pin 215 are formed to extend radially in a direction away from the center of stator core 100 .

[0156] In the above embodiment, if the first pins 214 and the second pins 215 are formed to extend radially away from the center of the stator core 100, the pitch between the first pins 214, the second pins 215, and the first insertion portion 211 can be increased, and if the overlapping first pins 214 and the second pins 215 are welded to each other, the impact of high temperatures on other components can be reduced. If the overlapping first pins 214 and the second pins 215 are formed to extend circumferentially closer to each other, the shape of the first conductor 210 can be simplified, the size of the first conductor 210 can be reduced, the height of the coil unit 200a away from the end of the stator core 100 can be reduced, the size of the outer envelope of the stator can be reduced, the weight of the first conductor 210 can be reduced, and the arrangement of the stator can be facilitated.

[0157] In some other embodiments, as shown in FIGS. 13 to 18, the first pin 214 and the second pin 215 that overlap each other are formed to extend along a direction that is close to each other in the circumferential direction.

[0158] When the overlapping first pin 214 and second pin 215 are formed to extend in a direction close to each other in the circumferential direction, a structural form such as circumferential overlap or cross overlap can be selected for the overlapping first pin 214 and second pin 215. The first pin 214 and second pin 215 may be directly overlapped with each other, or alternatively, as shown in Figures 13 to 15, the first pin 214 and second pin 215 may have a welding protrusion 218 formed thereon, which protrudes in a direction away from the center of the stator core 100, and the orthogonal projection shape of the welding protrusion 218 along the axial direction may be a semicircle or a polygon. The welding protrusions 218 of the first pin 214 and second pin 215 are stacked with each other along the axial direction. During the manufacturing process of the stator, the first pin 214 and the second pin 215 can be clamped at the overlapping position of the welding protrusions 218 and then welded together, and the welding may be performed by laser or arc welding. Directly wrapping the first pin 214 and the second pin 215 in the circumferential direction can save the radial space of the stator, and further reduce the height of the end of the coil unit 200a, thereby reducing the size of the outer envelope of the stator and the weight of the stator.

[0159] Referring to FIG. 19, FIG. 19 is a structural schematic diagram of a first conductor 210 of a stator according to some embodiments of the present application.

[0160] 19, the coil unit further includes a second conductor 220 including one insertion portion 2011 that is inserted into the winding slot 120. This simplifies the structure of the second conductor 220 and makes it easier to manufacture the second conductor 220.

[0161] Optionally, the second conductor 220 includes one insertion portion 2011 and one connection portion 221, and the insertion portion 2011 and the connection portion 221 are integrally formed to form an I-shaped structure, and the insertion portion 2011 and the connection portion 221 are sequentially distributed along the extending direction of the I-shaped structure. Two second conductors 220 are connected to each other by the connection portion 221 to form a shape similar to that of the first conductor 210.

[0162] Referring to Figures 20 and 21, Figure 20 is a structural schematic diagram of another first conductor 210 of a stator according to some embodiments of the present application, and Figure 21 is a structural schematic diagram of a stator including the first conductor 210 shown in Figure 20.

[0163] In some embodiments, as shown in FIGS. 20 and 21 , each first conductor 210 includes one insertion portion 2011, or each first conductor 210 is continuously bent and includes at least three insertion portions 2011, and the at least three insertion portions 2011 of each first conductor 210 are inserted into different winding slots 120.

[0164] In the above embodiment, by inserting the three insertion portions 2011 of the same first conductor 210 into different winding slots 120, the contact area between the first conductor 210 and the stator core 100 can be increased, and the stability of the relative position between the first conductor 210 and the stator core 100 can be improved.

[0165] Optionally, the first electrical conductor 210 may include eight inserts 2011 .

[0166] The embodiments of the present application can employ combinations of different types of first conductors 210 and second conductors 220, thereby reducing the number of types of distributed coil units 200a that are pre-molded, reducing process complexity, and minimizing mold input costs.

[0167] In some embodiments, as shown in FIGS. 22 to 24, winding slots 120 are provided on both of the two end faces 110 of the stator core 100 along its axial direction.

[0168] In the above embodiment, by installing winding slots 120 on both axial sides of the stator core 100, the stator windings 200 can be embedded on different sides of the stator core 100, and the same stator core 100 can accommodate more coil units 200a.

[0169] In some embodiments, the first insertion portion 211 and the second insertion portion 212 of the same first conductor 210 are symmetrically positioned.

[0170] Optionally, when the first conductor 210 includes a first pin 214 and a second pin 215, the first pin 214, the first insertion portion 211 and the second pin 215, the second insertion portion 212 of the same first conductor 210 are arranged symmetrically.

[0171] Alternatively, when the first conductor 210 includes a first pin 214, a first connecting arm 216, a second pin 215, and a second connecting arm 217, the first pin 214, the first connecting arm 216, the first insertion portion 211, and the second pin 215, the second connecting arm 217, and the second insertion portion 212 of the same first conductor 210 are arranged symmetrically.

[0172] In the above technical solution, the first insertion portion 211 and the second insertion portion 212, which are installed symmetrically, can balance the force bearing of the first conductor 210, thereby making the position between the multiple first conductors 210 that are inserted and fitted more stable.

[0173] In some embodiments, the stator core 100 has two end faces 110 along its axial direction, each of which has a winding slot 120 formed thereon.

[0174] In the above embodiment, by installing winding slots 120 on both axial sides of the stator core 100, the stator windings 200 can be embedded on different sides of the stator core 100, and the same stator core 100 can accommodate more coil units 200a.

[0175] In some embodiments, as shown in FIG. 25 , the winding slot 120 includes a bottom wall 121, two side wall 122 connected to the bottom wall 121, and two inclined surfaces 123 connected to the two side wall 122, respectively, the two side wall 122 being spaced apart along the circumferential direction, and a groove opening 124 being formed between the ends of the two inclined surfaces 123 that are away from the corresponding side wall 122.

[0176] In the above embodiment, by connecting the inclined surface 123 to the side wall surface 122, the size of the groove opening 124 can be increased, and the coil unit 200a can be easily embedded in the winding slot 120.

[0177] In some embodiments, the size of the groove opening 124 along the circumferential direction is H1, the pitch of the two side wall surfaces 122 in the circumferential direction is H2, and H1≧1.5H2.

[0178] In the above technical solution, the circumferential extension size of the groove opening 124 is relatively large, and is greater than 1.5 times the circumferential pitch of the two side wall surfaces 122, which makes it easier for the coil unit 200a to be inserted into the winding slot 120, improves the efficiency of assembling the coil unit 200a into the winding slot 120, significantly reduces the assembly space reserved for the stator winding 200 and the conductor gap, and enables the copper filling factor to reach 75% or more.

[0179] Alternatively, in the embodiment of the present application, when there are multiple coil units 200a, the coil units 200a can be laminated sequentially through the slot openings 124 of the winding slots 120 and then inserted into the winding slots 120. Alternatively, the multiple coil units 200a can be press-fitted into the winding slots 120 through the entire slot openings 124 of the winding slots 120. In the stator according to the embodiment of the present application, the structure of the coil units 200a is simple, and the wiring method is convenient and simple, which facilitates the realization of automated production.

[0180] Optionally, the number of winding slots 120 and the number of first conductors 210 in the stator core 100 may be adjusted according to actual needs. In the embodiment of the present application, the number of winding slots 120 is exemplarily described as 48, and the 48 winding slots 120 are evenly distributed around the stator core 100 along the circumferential direction. In the wiring process of the coil units 200a, i.e., in the process of installing the coil units 200a in the winding slots 120, up to 42 first conductors 210 are stacked in the winding slot 120 each time, and the entirety from the 43rd to 48th first conductors 210 are clamped by a robot hand and inserted through the groove openings 124 of the winding slot 120 until they are attached to the first conductors 210 located in the winding slots 120. After wiring one coil unit 200a is completed, wiring is performed on the second and third coil units 200a in sequence.

[0181] The stator core 100 can be selected to be wound and molded, which solves the problem of waste of scrap material and intermediate cylinder material in the conventional process. The scrap only contains the portions corresponding to the winding slots 120, i.e., the portion of material removed to form the winding slots 120, improving material utilization. Furthermore, the stator core 100 molding process is simple, making automation easy to achieve. Alternatively, the stator core 100 can be die-cast from a composite material such as sheet-shaped molded plastic with high magnetic permeability and low loss, which simplifies the molding of the stator core 100 and simplifies the heat treatment process. Alternatively, the stator core 100 can be further assembled with a split core, which allows the stator core 100 to have a relatively high size and precision, stable quality, high production efficiency, high material utilization, and reduced material costs.

[0182] Alternatively, the stator core 100 may have one-sided or two-sided slots, i.e., the winding slots 120 are provided on one or both axial sides of the stator core 100. In this way, the coil unit 200a can be wired on one or both sides. The wiring method of the one-sided slot of the stator core 100 has a yoke part on the stator core 100 that makes it easy to install and fix the stator, while the wiring method of the two-sided slot of the stator core 100 has technical advantages such as improved material utilization, motor efficiency, and power density, and reduced weight and volume.

[0183] The stators of the embodiments of the present application can be applied to motors with different numbers of phases and fit different voltage and power ranges.

[0184] In some embodiments, the stator winding 200 includes three phase windings, each of which is a first phase winding, a second phase winding, and a third phase winding. Optionally, the first phase winding is a U-phase winding, the second phase winding is a V-phase winding, and the third phase winding is a W-phase winding.

[0185] Each phase winding may include only one branch or multiple branches, which may be referred to as parallel-connected branches.

[0186] The number of branches in a phase winding can be any integer, extending the usable range of winding designs to fit different voltage and power ranges.

[0187] In some embodiments, the stator windings 200 may be connected in full-length, short-length, or multi-layer windings.

[0188] Alternatively, when the stator winding 200 is a three-phase stator winding, the three-phase distribution style within each winding slot 120 may vary, for example, it may be a 12-pole, 36-slot structure, with the number of slots per pole per phase, Q, being 1. Taking 12 poles as an example, the number of slots in the winding slots 120 may be 36, 72, etc. Adjusting Q can eliminate and thus reduce harmonics of different orders, such as the 5th, 7th, 11th, and 13th orders, thereby reducing torque pulsation and improving NVH.

[0189] An embodiment of the present application further provides a motor including a rotor and a stator according to any one of the above embodiments, where the rotor is installed in a space surrounded by the inner wall of the stator core 100.

[0190] The motor in the embodiments of the present application may be a generator or an electric motor.

[0191] The present invention also provides a powertrain including a motor and a reducer. The motor and the reducer are connected through a transmission. Specifically, the drive shaft of the motor and the input shaft of the reducer are connected through a transmission member such as a coupling, so that the driving force can be output from the rectangular wire motor to the reducer.

[0192] An embodiment of the present application further provides a vehicle including the above-mentioned powertrain, where the above-mentioned powertrain is installed in the vehicle to provide driving power for the vehicle. Specifically, in this embodiment, the vehicle may be a new energy vehicle driven by electric energy, for example. Here, the new energy vehicle may be a hybrid electric vehicle, a pure electric vehicle, a fuel cell electric vehicle, etc., and may be a vehicle that uses a high-efficiency energy storage device such as a supercapacitor, a flywheel battery, or a flywheel energy storage device as an electric energy source.

[0193] Referring to FIG. 26, an embodiment of the present application further provides a method for manufacturing a stator, including the following steps.

[0194] Step S01: Provide a stator core, the stator core having a plurality of winding slots on its axial end surface, the plurality of winding slots spaced apart along the circumferential direction of the stator core, and each winding slot extending along the radial direction of the stator core.

[0195] Step S02: A coil unit pre-assembled by a plurality of first conductors is press-fitted into a plurality of winding slots along the circumferential direction, so that the insertion portions of the conductors are inserted into the winding slots.

[0196] In this embodiment, a stator core having winding slots is first provided, and then a plurality of first conductors are assembled into a coil unit, and the entire pre-assembled coil unit is then placed into the winding slot, which can effectively improve the assembly efficiency of the stator compared to inserting the plurality of first conductors into the winding slots one by one.

[0197] In some embodiments, before step S02, providing a linear conductor including a conductor wire and an insulating layer covering the outside of the conductor wire; removing the insulating layer on both ends of the conductor; and bending the conductor to form a first conductor including two spaced apart inserts.

[0198] In the above technical solution, the first conductor is formed by directly bending the straight conductor after the insulating layers at both ends are removed, eliminating the need for processes such as conductor cutting at a later stage, which reduces the complexity of the conductor manufacturing process and improves the manufacturing efficiency of the stator.

[0199] In some embodiments, the stator pole number is 2p and the stator pole spacing is n winding slots; Before step S02, the method may further include a step of providing 2p·n first conductors, each of which includes a first insertion portion and a second insertion portion, and a span between the first insertion portion and the second insertion portion is n winding slots.

[0200] The step of pre-assembling a plurality of first conductors into a coil unit includes: providing an assembly mechanism, the assembly mechanism including 2p·n slots evenly spaced around a circumference of the assembly mechanism; stacking (2p-1)·n first conductors in the 2p·n slots along a counterclockwise direction; and a step of inserting the remaining n first conductors into slots of the assembly mechanism to form a coil unit, wherein in any one slot, a first insertion portion of one first conductor of the coil unit is positioned closer to a bottom wall of the slot than a second insertion portion of another first conductor of the coil unit.

[0201] In some embodiments, the further step includes:

[0202] The pre-assembled coil unit is removed from the machine mechanism. After the coil unit is removed from the machine structure, step S02 can be proceeded to. In the above technical solution, the span between the first and second insertion portions is equal to the pole distance, which simplifies the winding structure of the first conductor. In any one winding slot, the first insertion portions of the first conductors are all closer to the bottom wall of the winding slot, so that the multiple first conductors can be sequentially arranged and overlapped and fitted together to form a coil unit with two layers of windings. The first insertion portion of the first conductor is located in one layer of winding and the second insertion portion is located in the other layer of winding, and the multiple first conductors are fitted with stoppers, which improves the stability of the relative positions of the multiple first conductors within the coil unit.

[0203] According to some embodiments of the present application, referring to FIGS. 1 to 14 and 25 , a stator includes a stator core 100 and a stator winding 200. An end surface 110 of the stator core 100 along its axial direction is provided with a plurality of winding slots 120 spaced apart along the circumferential direction of the stator core 100, and each winding slot 120 extends along the radial direction of the stator core 100. The stator winding 200 includes at least one coil unit 200 a. The coil unit 200 a includes a plurality of first conductors 210 assembled thereto, and a first insertion portion 211 and a second insertion portion 212 are arranged along the circumferential direction. Each first conductor 201 includes a first insertion portion 211 and a second insertion portion 212 that are inserted into a different winding slot 120. In any one of the winding slots 120, the first insertion portion 211 of one first conductor 210 of the coil unit 200a is located on the side of the second insertion portion 212 of another first conductor 210 of the coil unit 200a that is closer to the bottom wall of the winding slot 120. The first conductor 210 further includes a connection portion 213 that connects the first insertion portion 211 and the second insertion portion 212. The connection portion 213 is located on the side of the first insertion portion 211 and the second insertion portion 212 that faces the center of the stator core 100. The connecting portion 213 includes a first connecting portion 213a, a second connecting portion 213b, and a bent portion 213c connecting the first connecting portion 213a and the second connecting portion 213b, the first connecting portion 213a extending from an end of the first inserting portion 211 close to the center of the stator core 100 and the first connecting portion 213a being bent obliquely toward the second inserting portion 212, and the second connecting portion 213b extending from an end of the second inserting portion 212 close to the center of the stator core 100 and the second connecting portion 213b being bent obliquely toward the first inserting portion 211. The first conductor 210 has an integrally molded structure.The first conductor 210 further includes a first pin 214 and a second pin 215, the first pin 214 being connected to an end of the first insertion portion 211 remote from the connection portion 213, and the second pin 215 being connected to an end of the second insertion portion 212 remote from the connection portion 213. The coil unit 200a includes a plurality of conductive branches 201 including a plurality of first conductors 210 connected in series, and of any two adjacent first conductors 210 in the conductive branch 201, the first pin 214 of one first conductor 210 is connected to the second pin 215 of the other first conductor 210. Of any two adjacent first conductors 210 in the conductive branch 201, the first pin 214 of one first conductor 210 and the second pin 215 of the other first conductor 210 are connected in an overlapping manner along the axial direction. A connecting structure 2145 is formed in the region where the first pin 214 and the second pin 215 overlap each other along the axial direction, and the coil unit 200a includes multiple connecting structures 2145 spaced apart along the circumferential direction. The stator winding 200 includes multiple coil units 200a stacked along the axial direction, and the connecting structures 2145 of adjacent coil units 200a are offset in the circumferential direction. The first conductor 210 further includes a first connecting arm 216 and a second connecting arm 217. The first insertion portion 211 and the first pin 214 are connected via the first connecting arm 216, and the second pin 215 and the second insertion portion 212 are connected via the second connecting arm 217. Of two circumferentially adjacent first conductors 210, the second connecting arm 217 of one first conductor 210 passes between the second pin 215 of the other first conductor 210 and the stator core 100. A relief recess 217a is provided on the side of the second connecting arm 217 away from the stator core 100 to accommodate the second pin 215 of another first conductor 210. A winding slot 120 is formed on each of the two end faces 110 of the stator core 100 along its own axial direction. The winding slot 120 includes a bottom wall surface 121, two side wall surfaces 122 connected to the bottom wall surface 121, and two inclined surfaces 123 connected to the two side wall surfaces 122, respectively. The two side wall surfaces 122 are spaced apart in the circumferential direction, and a groove 124 is formed between the ends of the two inclined surfaces 123 that are away from the corresponding side wall surfaces 122.The winding slot 120 includes a bottom wall surface 121, two side wall surfaces 122 connected to the bottom wall surface 121, and two inclined surfaces 123 connected to the two side wall surfaces 122, respectively. The two side wall surfaces 122 are spaced apart along the circumferential direction, and a groove opening 124 is formed between the ends of the two inclined surfaces 123 that are away from the corresponding side wall surfaces 122.

[0204] It should be noted that, unless there is a conflict, the embodiments and features in the embodiments in the present application can be combined with each other.

[0205] Finally, it should be noted that the above examples are only for illustrating the technical solutions of the present application, and are not intended to limit the same. Although the present application has been described in detail with reference to the above examples, those skilled in the art may still modify the technical solutions described in the above examples or replace some of the technical features therein with equivalents, but it should be understood that such modifications or replacements do not deviate from the essence of the corresponding technical solutions and the spirit and scope of the technical solutions of the examples of the present application. [Explanation of symbols]

[0206] 100, stator core, 110, end face, 120, winding slot, 121, bottom wall surface, 122, side wall surface, 123, inclined surface, 124, groove opening, 200, stator winding, 200a, coil unit, 201, conductive branch, 2011, insertion portion, 210, first conductor, 211, first insertion portion, 212, second insertion portion, 213, connection portion, 213a, first connection portion, 213b, second connection portion, 213c, bending portion, 214, first pin, 215, second pin, 2145, connection structure, 216, first connection arm, 217, second connection arm, 217a, relief recess, 217b, protrusion, 218, welding protrusion, 220, second conductor, 221, connection portion.

Claims

1. A stator of a motor, a stator core, wherein a plurality of winding slots are provided on an end surface of the stator core along its axial direction, the winding slots passing through an inner wall and an outer wall of the stator core along a radial direction, the plurality of winding slots being arranged at intervals along a circumferential direction of the stator core; a stator winding including at least one coil unit, the coil unit including a plurality of first conductors assembled thereto, each of the first conductors including at least one insertion portion inserted into the winding slot;

2. the first conductors of the coil unit are distributed in a shifted manner along the circumferential direction, 2. The stator according to claim 1, wherein each of the first conductors includes a first insertion portion and a second insertion portion connected to each other, the first insertion portion and the second insertion portion are inserted into different winding slots, and the first insertion portion of one of the first conductors is stacked with the second insertion portion of another of the first conductors in the same winding slot.

3. the first insertion portion and the second insertion portion of the same first conductor are arranged along the circumferential direction; 3. The stator according to claim 2, wherein, in any one of the winding slots, the first insertion portion of the first conductor of one of the coil units is located on a side closer to a bottom wall of the winding slot than the second insertion portion of the first conductor of another of the coil units.

4. 4. The stator according to claim 2, wherein the span between the first and second insertion portions of the same first conductor is equal to the pole distance.

5. The stator according to claim 1 , wherein the stator winding includes a plurality of the coil units stacked along the axial direction of the stator core.

6. the first insertion portion and the second insertion portion of the same first conductor are arranged along the circumferential direction; The stator according to claim 2 , wherein the first conductor further includes a connection portion connecting the first insertion portion and the second insertion portion.

7. The stator according to claim 6 , wherein the connection portions are located on sides of the first and second insertion portions toward the center of the stator core.

8. the connecting portion includes a first connecting portion and a second connecting portion, the first connecting portion extending from an end of the first insertion portion close to the center of the stator core and bent obliquely toward the second insertion portion, the second connecting portion extending from an end of the second insertion portion close to the center of the stator core and bent obliquely toward the first insertion portion, The stator of claim 6 , wherein the first connecting portion is connected to the second connecting portion.

9. The stator according to claim 8 , wherein the connection portion further includes a bent portion connecting the first connection portion and the second connection portion.

10. The stator of claim 8 , wherein the first conductor is a unitary structure.

11. the first conductor further includes a first pin and a second pin, the first pin being connected to an end of the first insertion portion remote from the connection portion, and the second pin being connected to an end of the second insertion portion remote from the connection portion; 11. The stator according to claim 6, wherein the coil unit includes a plurality of conductive branches each including a plurality of the first conductors connected in series, and the first pin of one of the first conductors among any two adjacent first conductors of the conductive branch is connected to the second pin of another of the first conductors.

12. 12. The stator according to claim 11, wherein, of any two adjacent first conductors of the conductive branch, the first pin of one first conductor and the second pin of another first conductor are overlapped and connected along the axial direction.

13. The stator of claim 12 , wherein the first pin and the second pin are welded to one another in the overlap region.

14. a region where the first pin and the second pin are connected by overlapping along the axial direction constitutes a connection structure; The stator according to claim 12 , wherein the coil unit includes a plurality of the connection structures spaced apart along the circumferential direction.

15. the stator winding includes a plurality of coil units stacked along the axial direction, The stator according to claim 14 , wherein the connection structures of two adjacent coil units are offset in the circumferential direction.

16. the first conductor further includes a first connection arm and a second connection arm, the first insertion portion and the first pin are connected via the first connection arm, and the second pin and the second insertion portion are connected via the second connection arm; 16. The stator according to claim 11, wherein, of two of the first conductors adjacent to each other in the circumferential direction, the second connection arm of one of the first conductors passes between the second pin of another of the first conductors and the stator core.

17. 17. The stator according to claim 16, wherein a relief recess is provided on a side of the second connection arm that is away from the stator core, for accommodating the second pin of another first conductor.

18. The stator according to claim 17 , wherein the second connecting arm is bent at a position corresponding to the relief recess to form a protrusion that protrudes toward the stator core.

19. the first pin and the second pin are formed to extend in the radial direction away from the center of the stator core, Alternatively, the first pin and the second pin that overlap each other are formed to extend in a direction approaching each other in the circumferential direction.

20. 20. The stator according to claim 2, wherein the coil unit further includes a second conductor having one insertion portion that is inserted into the winding slot.

21. each of the first conductors includes one of the insertion portions; or 2. The stator according to claim 1, wherein each of the first conductors is continuously bent and includes at least three of the insertion portions, and the at least three insertion portions of the first conductors are inserted into different of the winding slots.

22. 2. The stator according to claim 1, wherein the winding slots are provided on both of the two end faces of the stator core along its axial direction.

23. the winding slot includes a bottom wall surface, two side wall surfaces connected to the bottom wall surface, and two inclined surfaces connected to the two side wall surfaces, respectively; The stator according to claim 1 , wherein the two side wall surfaces are spaced apart along the circumferential direction, and the two inclined surfaces are spaced apart from a groove formed between ends of the corresponding side wall surfaces.

24. 24. The stator according to claim 23, wherein the size of the groove opening along the circumferential direction is H1, the pitch of the two side wall surfaces in the circumferential direction is H2, and H1≧1.5H2.

25. A motor comprising a stator according to any one of claims 1 to 23.

26. A method for manufacturing a stator, comprising: providing a stator core, the stator core having an end surface along its axial direction with a plurality of winding slots extending radially through inner and outer walls of the stator core, the plurality of winding slots being spaced apart along a circumferential direction of the stator core; and press-fitting a coil unit pre-assembled with a plurality of first conductors into the plurality of winding slots along the circumferential direction, thereby inserting the insertion portions of each of the first conductors into the winding slots.

27. a coil unit pre-assembled by a plurality of first conductors is press-fitted into the plurality of winding slots along the circumferential direction, so that before the insertion portions of the first conductors are inserted into the winding slots, providing a linear conductor including a conductor wire and an insulating layer covering the outside of the conductor wire; removing the insulating layer on both ends of the conductor; 27. The method of claim 26, further comprising bending the conductor to form the first conductor including two spaced apart inserts.

28. the number of poles of the stator is 2p, and the pole distance of the stator is n the winding slots; the method further includes a step of press-fitting a coil unit pre-assembled by a plurality of first conductors into the plurality of winding slots along the circumferential direction to provide 2p·n first conductors before arranging the insertion portions of the first conductors into the winding slots, each first conductor including a first insertion portion and a second insertion portion, and a span between the first insertion portion and the second insertion portion is n winding slots; The step of assembling the plurality of first conductors into a coil unit in advance includes: providing an assembly mechanism including 2p·n slots evenly spaced around the circumference of the assembly mechanism; stacking (2p-1)·n first conductors in a counterclockwise direction into the 2p·n opened slots; 28. The manufacturing method of claim 26 or 27, further comprising a step of inserting the remaining n first conductors into the slots of the assembly mechanism to form a coil unit, wherein in any one of the slots, the first insertion portion of one of the first conductors of the coil unit is positioned closer to the bottom wall of the slot than the second insertion portion of another of the first conductors of the coil unit.

Images