Flat-wire winding having welding faces on folded line segments, flat-wire electric motor and stator, and power assembly

Abstract

Provided in the present application are a flat-wire winding having welding faces on folded line segments, a flat-wire electric motor and a stator, and a power assembly. The axial dimension of the flat-wire electric motor can be reduced. The stator of a flat-wire electric motor comprises a stator core and a stator winding, wherein the stator winding comprises a plurality of flat-wire windings, each flat-wire winding comprises at least one wire segment, and each wire segment comprises a straight line segment and two folded line segments, the straight line segment being configured to be embedded into a stator slot of the stator core in the flat-wire electric motor, and the folded line segments being configured to be exposed out of stator slots. The extension direction of each folded line segment intersects the extension direction of the straight line segment, and the extension directions of the two folded line segments are different from each other. The end portion of at least one folded line segment away from the straight line segment comprises a welding face, and the cross-sectional area of the end portion is less than the cross-sectional area of the straight line segment and the cross-sectional area of each folded line segment.

Description

Flat wire winding with a zigzag segment and a welding surface, flat wire motor and stator, power assembly

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to the Chinese patent application filed with the State Intellectual Property Office of the People's Republic of China on September 16, 2023, with application number 202311202167.1 and application name "Flat wire winding, flat wire motor and stator, and power assembly with broken line segments and welding surfaces", the entire contents of which are incorporated by reference into this application. Technical Field

[0003] The present application relates to the field of motor technology, and in particular to a flat wire winding with a broken line segment and a welding surface, a flat wire motor and a stator, and a power assembly. Background Art

[0004] Currently, electric vehicle drive motors typically use flat wire windings for their stator windings to increase slot fill rate. Because flat wire windings require twisting and welding during their manufacturing process, they protrude significantly from the stator core. This increases the axial dimensions of the stator winding and the flat wire motor, hindering the motor's structural layout and compromising its performance.

[0005] Summary of the Invention

[0006] The embodiments of the present application provide a flat wire winding with a zigzag segment and a welding surface, a flat wire motor, a stator, and a power assembly, which can reduce the size of the flat wire winding protruding from the end of the stator core, which is beneficial to reducing the axial size of the flat wire motor and improving the structural layout of the flat wire motor, thereby improving the performance of the flat wire motor.

[0007] In a first aspect, the present application provides a stator for a flat wire motor. The stator of the flat wire motor provided herein includes a stator core and a stator winding. The stator winding includes multiple flat wire windings, at least one flat wire winding includes at least one wire segment, and each wire segment includes a straight segment and two zigzag segments. The straight segment is embedded in a stator slot of the stator core of the flat wire motor, and the two zigzag segments are exposed outside the stator slot. The extension direction of each zigzag segment intersects the extension direction of the straight segment, and the two zigzag segments extend in different directions. At least one zigzag segment includes a weld surface at its end away from the straight segment, and the cross-sectional area of ​​the end is smaller than the cross-sectional area of ​​the straight segment.

[0008] In the stator provided by the present application, the flat wire winding can be formed into a structure having at least one wire segment through a bending process before being embedded in the stator slot, and the shape of the broken line segment is already formed. After the flat wire winding is embedded in the stator slot along the radial direction of the stator core, the broken line segment can be exposed outside the stator slot, without the need for twisting, flaring, and other processes. Therefore, there is no need to reserve a tip for tool clamping at the end of the flat wire winding, thereby reducing the size of the end winding, which is conducive to reducing the axial size of the flat wire motor and improving the structural layout of the flat wire motor. In the stator provided by the present application, the cross-sectional area of ​​the end of the broken line segment of the wire segment of the flat wire winding is larger than the cross-sectional area of ​​the straight line segment, which can improve the stability of welding and the convenience of operation, thereby improving the performance of the flat wire motor.

[0009] In one embodiment, the end surface of a zigzag segment facing the circumferential end surface of the flat wire motor includes a cut surface, the cut surface includes a welding surface, and the area of ​​the cut surface is greater than the cross-sectional area of ​​the zigzag segment. In the stator provided by the present application, the end surface of the zigzag segment of the flat wire winding facing the circumferential end surface of the flat wire motor is cut to form a cut surface, and the area of ​​the cut surface is greater than the cross-sectional area of ​​the wire segment. This can help increase the area of ​​the welding surface, improve welding stability and ease of operation, and thus improve the performance of the flat wire motor. In addition, the end surface of the end of the zigzag segment is cut to form a welding surface, eliminating the need for twisting, flaring, or other processes or reserving an end for tool clamping, thereby reducing the size of the end winding and helping to reduce the axial size of the flat wire motor. It also facilitates welding operations along the circumference of the flat wire motor, thereby improving welding stability and ease of operation.

[0010] In one embodiment, a cut surface or a weld surface includes two side edges arranged opposite each other along the thickness direction of a zigzag segment, with the length of the two side edges being greater than the width of the zigzag segment. In the stator provided herein, the end surfaces of the zigzag segments of the flat wire windings are cut radially along the flat wire motor to form cut surfaces. This not only reduces the size of the end windings and the axial dimensions of the flat wire motor, but also increases the area of ​​the weld surface, thereby improving welding stability and ease of operation.

[0011] In one embodiment, the end of a broken line segment facing the radial side of the flat wire motor includes a cut surface, the cut surface includes a welding surface, and the area of ​​the cut surface is greater than the cross-sectional area of ​​the broken line segment. In the stator provided by the present application, the end of the broken line segment of the flat wire winding facing the radial side of the flat wire motor is cut to form a cut surface, and the area of ​​the cut surface is greater than the cross-sectional area of ​​the wire segment. This can help increase the area of ​​the welding surface, improve welding stability and ease of operation, and thus improve the performance of the flat wire motor. In addition, the side surface of the end of the broken line segment is cut to form a welding surface, eliminating the need for twisting, flaring, or other processes or reserving an end for tool clamping, thereby reducing the size of the end winding and helping to reduce the axial size of the flat wire motor. It also facilitates welding along the radial direction of the flat wire motor, thereby improving welding stability and ease of operation.

[0012] In one embodiment, a cut surface or welding surface includes two side edges arranged opposite each other along the extension direction of a zigzag segment, with the length of the two side edges being greater than the width of the zigzag segment. In the stator provided by this application, the side faces of the ends of the zigzag segments of the flat wire windings are cut to form cut surfaces. This not only reduces the size of the end windings and the axial dimensions of the flat wire motor, but also increases the area of ​​the welding surface, thereby improving welding stability and ease of operation.

[0013] In one embodiment, the angle between a zigzag segment and a straight segment in a conductor segment is greater than 90 degrees, and two zigzag segments in a conductor segment are each connected to a straight segment via a curved segment. In the flat wire winding provided herein, the zigzag segments are connected to the straight segments via a curved segment, thereby forming an angle greater than 90 degrees. This can reduce the protrusion of the flat wire winding beyond the end of the stator core, thereby reducing the axial dimensions of the flat wire motor.

[0014] In one embodiment, the flat wire winding includes a plurality of wire segments connected in sequence, wherein a broken line segment of one wire segment is connected to a broken line segment of another wire segment by another curved segment, thereby reducing the size of the flat wire winding protruding from the end of the stator core, thereby reducing the axial size of the flat wire motor.

[0015] In one embodiment, the angle between two connected broken line segments in two connected wire segments is smaller than the angle between each broken line segment and the straight line segment in the same wire segment, which can reduce the size of the flat wire winding protruding from the end of the stator core, thereby reducing the axial size of the flat wire motor.

[0016] In one embodiment, the stator core includes a plurality of arc-shaped stator core blocks, each of which includes at least one stator slot. The at least one stator slot of each arc-shaped stator core block is respectively used to embed at least one straight segment, and the length of each straight segment along the axial direction of the flat wire motor is greater than the length of the arc-shaped stator core block. The plurality of arc-shaped stator core blocks embedded in at least one straight segment are sequentially spliced ​​together to form the stator core. In the stator provided in the present application, after the flat wire winding is embedded in the stator slot of the arc-shaped stator core block along the radial direction of the stator core, the plurality of arc-shaped stator core blocks are spliced ​​together to form the stator core. Compared with the solution of inserting the flat wire winding along the radial direction of the stator core, there is no need to go through processes such as twisting and flaring, so there is no need to reserve an end for tool clamping at the end of the flat wire winding, thereby reducing the size of the end winding, which is conducive to reducing the axial size of the flat wire motor and improving the structural layout of the flat wire motor.

[0017] In one embodiment, the stator core includes a plurality of stator teeth and an annular yoke. In the radial direction of the stator, the inner surface of the yoke faces the center hole of the stator core, and the outer surface of the yoke faces away from the center hole of the stator core. The inner surface of the yoke includes a plurality of mounting slots, which are spaced apart along the circumference of the stator. The gap between any two adjacent stator teeth along the circumference of the stator forms a stator slot. Each stator slot is configured to embed at least one straight segment in the radial direction of the stator. The plurality of stator teeth embedded in the at least one straight segment are configured to embed in the plurality of mounting slots of the yoke along the axial direction of the stator.

[0018] In a second aspect, the present application provides a flat wire motor. The flat wire motor provided by the present application includes a rotor and a stator as described in the first aspect and its various embodiments. The welding surface of one wire segment of one flat wire winding is welded to the welding surface of another wire segment of another flat wire winding. The welding planes of the two welded wire segments are arranged adjacent to each other along the radial direction of the flat wire motor or along the circumferential direction of the flat wire motor. In the flat wire motor provided by the present application, the welding platforms of the two welded wire segments are arranged adjacent to each other along the radial direction of the flat wire motor or along the circumferential direction of the flat wire motor, which can reduce the size of the flat wire winding protruding from the end of the stator core, thereby reducing the axial size of the flat wire motor.

[0019] In a third aspect, the present application provides a powertrain. The powertrain provided herein can be applied to an electric vehicle to provide power for the electric vehicle. The powertrain includes either a reducer or a transmission, and a flat wire motor as described in the second aspect and any embodiment. The motor shaft of the flat wire motor is configured to drively connect to the input shaft of the reducer or the input shaft of the transmission. The beneficial effects of the powertrain provided by this application are described in the first and second aspects and their embodiments above and are not further elaborated.

[0020] In a fourth aspect, the present application provides a flat wire winding with a zigzag segment and a welding surface. The flat wire winding provided by the present application includes at least one conductor segment, each of which includes a straight segment and two zigzag segments. One straight segment is embedded in a stator slot of a stator core in a flat wire motor, and the two zigzag segments are exposed outside the stator slot. The extension direction of each zigzag segment intersects the extension direction of the straight segment, and the two zigzag segments extend in different directions. At least one zigzag segment includes a welding surface at its end distal from the straight segment, and the cross-sectional area of ​​the end is smaller than the cross-sectional area of ​​the straight segment.

[0021] In the stator provided by the present application, the flat wire winding can be formed into a structure having at least one wire segment through a bending process before being embedded in the stator slot, and the shape of the broken line segment is already formed. After the flat wire winding is embedded in the stator slot along the radial direction of the stator core, the broken line segment can be exposed outside the stator slot, and no twisting, flaring, or other processes are required. Therefore, there is no need to reserve a tip for tool clamping at the end of the flat wire winding, thereby reducing the size of the end winding, which is beneficial to reducing the axial size of the flat wire motor and improving the structural layout of the flat wire motor. In the stator provided by the present application, the area of ​​the welding surface at the end of the broken line segment of the wire segment of the flat wire winding is larger than the cross-sectional area of ​​the wire segment, which can improve the stability of welding and the convenience of operation, thereby improving the performance of the flat wire motor. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] FIG1 is a schematic structural diagram of an electric vehicle provided in an embodiment of the present application;

[0023] FIG2 is a schematic structural diagram of a powertrain provided in an embodiment of the present application;

[0024] FIG3a is a schematic structural diagram of a stator provided in an embodiment of the present application;

[0025] Figure 3b is an enlarged view of point A in Figure 3a;

[0026] FIG3c is a front view of a stator provided in an embodiment of the present application;

[0027] FIG4 a is a schematic structural diagram of a flat wire winding provided in an embodiment of the present application;

[0028] FIG4 b is a schematic diagram of a structure in which a flat wire winding is embedded in a stator slot according to an embodiment of the present application;

[0029] FIG4c is a schematic structural diagram of a stator core block provided in an embodiment of the present application;

[0030] FIG5a is a simplified structural diagram of a flat wire winding provided in an embodiment of the present application;

[0031] FIG5 b is a schematic structural diagram of a flat wire winding provided in an embodiment of the present application;

[0032] FIG5c is a schematic structural diagram of a flat wire winding provided in an embodiment of the present application;

[0033] FIG5 d is a schematic structural diagram of a flat wire winding provided in an embodiment of the present application;

[0034] FIG6 is a schematic diagram of a flat wire winding welding principle provided by an embodiment of the present application;

[0035] FIG7 is a schematic diagram of a stator winding formed by welding a plurality of flat wire windings provided in an embodiment of the present application;

[0036] FIG8a is a schematic structural diagram of a flat wire winding provided in an embodiment of the present application;

[0037] FIG8 b is a schematic diagram of a partial structure of a flat wire winding provided in an embodiment of the present application;

[0038] FIG8c is a front view of a flat wire winding provided by an embodiment of the present application;

[0039] FIG8 d is a front view of two flat wire windings welded together along the circumferential direction of the stator core according to an embodiment of the present application;

[0040] FIG8e is a top view of the ends of two flat wire windings welded together along the circumferential direction of the stator core according to an embodiment of the present application;

[0041] FIG9a is a schematic structural diagram of a flat wire winding provided in an embodiment of the present application;

[0042] FIG9 b is a schematic diagram of a partial structure of a flat wire winding provided in an embodiment of the present application;

[0043] FIG9c is a front view of a flat wire winding provided in an embodiment of the present application;

[0044] FIG9 d is a front view of two flat wire windings welded together along the radial direction of the stator core according to an embodiment of the present application;

[0045] FIG9e is a top view of the ends of two flat wire windings welded together along the circumferential direction of the stator core according to an embodiment of the present application;

[0046] FIG10 a is a schematic structural diagram of two flat wire winding ends welded together along the circumferential direction of the stator core according to an embodiment of the present application;

[0047] FIG10 b is a schematic structural diagram of two flat wire winding ends welded together along the radial direction of the stator core according to an embodiment of the present application;

[0048] FIG11a is a schematic structural diagram of a flat wire winding provided in an embodiment of the present application;

[0049] FIG11 b is a simplified structural diagram of a flat wire winding provided in an embodiment of the present application;

[0050] FIG11c is a schematic diagram of a flat wire winding welding principle provided by an embodiment of the present application;

[0051] FIG12a is a schematic structural diagram of a flat wire winding provided in an embodiment of the present application;

[0052] FIG12 b is a simplified structural diagram of a flat wire winding provided in an embodiment of the present application;

[0053] FIG12c is a schematic diagram of a flat wire winding welding principle provided by an embodiment of the present application;

[0054] FIG13a is another schematic diagram of a motor stator provided in an embodiment of the present application;

[0055] FIG13b shows an enlarged view of point B in FIG13a;

[0056] FIG13c is another schematic diagram of the motor stator provided in an embodiment of the present application;

[0057] Figure 13d is another schematic diagram of the motor stator provided in an embodiment of the present application. DETAILED DESCRIPTION

[0058] The stator of a motor generally includes a stator core and stator windings. The stator core includes a central hole for accommodating the rotor and stator slots connected to the central hole. The stator winding is wound on the stator core, and the conductor used to form the stator winding is partially located within the stator slots and partially located at the axial ends outside the stator slots. The height of the stator winding at the axial ends of the stator affects the size of the stator and also has an impact on the structure of the motor. In traditional flat wire stator winding, the stator winding conductor is inserted into the stator slots along the axial direction of the stator core. The conductor is then processed into a preset shape through processes such as flaring, twisting, and cutting. The conductor is then welded and connected in sequence to form the stator winding. The processes of flaring and twisting the conductor require that the end of the conductor extending out of the stator slot have a certain extension to facilitate clamping for process operation. This extension causes the end winding height of the stator winding to be higher, affecting the axial size of the stator.

[0059] Based on this, the embodiments of the present application provide a flat wire winding, a flat wire motor, a stator, and a power assembly with a broken line segment and a welding surface, which can reduce the size of the flat wire winding protruding from the end of the stator core, which is beneficial to reducing the axial size of the flat wire motor and improving the structural layout of the flat wire motor, thereby improving the performance of the flat wire motor.

[0060] In order to make the purpose, technical solutions and advantages of this application clearer, this application will be further described in detail below with reference to the accompanying drawings.

[0061] The terms used in the following embodiments are only for the purpose of describing specific embodiments and are not intended to limit the present application. As used in the specification and appended claims of this application, the singular expressions "a", "an", "above", "the", and "this" are intended to also include expressions such as "one or more", unless the context clearly indicates otherwise.

[0062] References to "one embodiment" or "some embodiments" in this specification mean that a particular feature, structure, or characteristic described in conjunction with that embodiment is included in one or more embodiments of the present application. Thus, phrases such as "in one embodiment," "in some embodiments," "in other embodiments," and "in yet other embodiments" appearing in various places in this specification do not necessarily refer to the same embodiment, but rather mean "one or more but not all embodiments," unless otherwise specifically emphasized. The terms "including," "comprising," "having," and variations thereof mean "including but not limited to," unless otherwise specifically emphasized.

[0063] In one embodiment, the present application provides a flat wire winding with a zigzag segment and a welding surface. In this application, the flat wire winding with a zigzag segment and a welding surface includes at least one wire segment, each wire segment comprising a straight segment and two zigzag segments. The extension direction of each zigzag segment intersects the extension direction of the straight segment, and the two zigzag segments have different extension directions. At least one zigzag segment includes a welding surface at an end distal to the straight segment, and the cross-sectional area of ​​the end is smaller than the cross-sectional area of ​​the straight segment and the cross-sectional area of ​​each zigzag segment.

[0064] In one embodiment, the present application provides a stator for a flat wire motor. In the present application, the stator includes a stator core and a stator winding. The stator winding includes multiple flat wire windings. At least one flat wire winding includes at least one wire segment, each wire segment including a straight segment and two zigzag segments. The extension direction of each zigzag segment intersects the extension direction of the straight segment, and the two zigzag segments have different extension directions. At least one zigzag segment includes a weld surface at an end distal to the straight segment, and the cross-sectional area of ​​the end is smaller than the cross-sectional area of ​​the straight segment and the cross-sectional area of ​​each zigzag segment.

[0065] In one embodiment, the present application provides a flat wire motor. In the present application, the flat wire motor includes a rotor and a stator. The stator includes a stator core and a stator winding. The stator winding includes a plurality of flat wire windings. In one embodiment, at least one flat wire winding includes at least one wire segment, and each wire segment includes a straight line segment and two broken line segments. The extension direction of each broken line segment intersects with the extension direction of the straight line segment, and the extension directions of the two broken line segments are different. The end of at least one broken line segment away from the straight line segment includes a welding surface, and the cross-sectional area of ​​the end is smaller than the cross-sectional area of ​​the straight line segment and the cross-sectional area of ​​each broken line segment. The welding planes of the two welded wire segments are arranged adjacent to each other along the radial direction of the flat wire motor or along the circumferential direction of the flat wire motor.

[0066] In one embodiment, the present application provides a powertrain, which includes a reducer or a transmission and a flat wire motor provided in an embodiment of the present application, wherein the motor shaft of the flat wire motor is used for transmission connection to the input shaft of the reducer or the input shaft of the transmission.

[0067] Figure 1 is a schematic diagram of an electric vehicle provided in accordance with an embodiment of the present application. Referring to Figure 1 , the electric vehicle provided in accordance with an embodiment of the present application includes a powertrain 1000, a transmission mechanism 2000, and wheels 3000. Powertrain 1000 drives wheels 3000 via transmission mechanism 2000. Powertrain 1000 is used to convert electrical energy into mechanical energy. Transmission mechanism 2000 is used to provide a transmission connection between powertrain 1000 and wheels 3000.

[0068] FIG2 is a schematic diagram of a powertrain according to an embodiment of the present application. As shown in FIG2 , the powertrain 1000 according to an embodiment of the present application includes a flat wire motor 100 and a reducer 200. The flat wire motor 100 and the reducer 200 are in a transmission connection. The flat wire motor 100 is used to drive a transmission mechanism 2000 of an electric vehicle via the reducer 200. In the embodiment of the present application, the reducer 200 may also be a transmission.

[0069] As shown in Figure 2, the flat wire motor 100 includes a stator 10, a rotor 20, a motor shaft 30, and a housing 40. The motor shaft 30 is used for transmission connection to the reducer 200. The stator 10 includes a stator winding 1 and a stator core 2. The stator core 2 is used to fix or wind the stator winding 1, and the housing 40 is used to fix and accommodate the stator core 2. The rotor 20 is used to rotate relative to the stator 10 and drive the motor shaft 30.

[0070] Figure 3a shows the structure of stator 10. As shown in Figure 3a, stator 10 includes a stator core 2 and a stator winding 1. The stator core 2 is annular. The inner side of the stator core 2 includes a plurality of stator teeth 21. Along the circumference of the stator core 2, stator slots 22 are formed between any two adjacent stator teeth 21. The stator winding 1 is wound around the stator teeth 21 of the stator core 2.

[0071] A portion of the stator winding 1 is located within the stator slots 22, while another portion is located outside the stator slots 22. The portion of the stator winding 1 located outside the stator slots 22 protrudes from the axial end surface of the stator core 2 along the axial direction of the stator 10. The portion of the stator winding 1 that protrudes axially from the stator 10 is called the end winding, and the height H of the end winding affects the axial dimension of the stator 10.

[0072] In the embodiment of the present application, the axial direction of the stator 10, the axial direction of the stator core 2, and the axial direction of the motor 100 refer to the same direction, the circumferential direction of the stator 10, the circumferential direction of the stator core 2, and the circumferential direction of the motor 100 refer to the same direction, and the radial direction of the stator 10, the radial direction of the stator core 2, and the radial direction of the motor 100 refer to the same direction.

[0073] Figure 3b shows an enlarged view of point A in Figure 3a. As shown in Figure 3b, the stator winding 1 includes multiple flat wire windings 11. The stator winding 1 is formed by sequentially connecting multiple flat wire windings 11, with the ends of two flat wire windings 11 welded together. A portion of each flat wire winding 11 is embedded within a stator slot 22 of the stator core 2. Insulating paper 3 is provided between the flat wire windings 11 and the stator slots 22. For example, the multiple flat wire windings 11 are stacked within the stator slots 22 along the radial direction of the stator core 2.

[0074] Figure 3c shows the structure of stator 10 as viewed along its radial direction. Along the axial direction of stator 10, stator winding 1 partially protrudes beyond the end surface of stator core 2. The height between the end of stator winding 1 and the end surface of stator core 2 is defined as end winding height H. The outer circumferential surface of the end of stator winding 1 forms an angle φ with the end surface of stator core 2, which is less than 90 degrees.

[0075] The stator winding 1 provided in the embodiment of the present application is composed of a plurality of flat wire windings 11 with bent ends as shown in Figure 4a. The flat wire windings 11 are used to be embedded in the stator slots 22 of the stator core 2 as shown in Figure 3a along the radial direction of the stator core 2.

[0076] As shown in FIG4 a , the flat wire winding 11 includes at least one conductor segment 111. Each conductor segment 111 includes a straight segment 1111 and two zigzag segments 1112. The straight segment 1111 is embedded in the stator slot 22 of the stator core 2 of the flat wire motor 100, while the zigzag segments 1112 are exposed outside the stator slot 22. The extension direction of each zigzag segment 1112 intersects the extension direction of the straight segment 1111, and the two zigzag segments 1112 extend in different directions.

[0077] In one embodiment, the angle between a broken line segment 1112 and the straight line segment 1111 in a wire segment 111 is greater than 90 degrees, and two broken line segments 1112 in a wire segment 111 are connected to the straight line segment 1111 via a curved segment 1113 .

[0078] For example, Figure 4a shows a flat wire winding 11 having a conductor segment 111. As shown in Figure 4a, conductor segment 111 includes a straight segment 1111 and two folded line segments 1112 connected to both ends of straight segment 1111. The folded line segments 1112 bend relative to the straight segment 1111, with the two folded line segments 1112 bending in different directions. The angle between each folded line segment 1112 and the straight segment 1111 is greater than 90 degrees. Each folded line segment 1112 is connected to the straight segment 1111 via a curved segment 1113.

[0079] As shown in Figure 4a, the flat wire winding 11 includes an insulating layer 112. The insulating layer 112 wraps around the outer surface of the wire segment 111. The ends M of the zigzag segments 1112, away from the straight segments 1111, are exposed. These ends M are used for welding to the ends M of other zigzag segments 1112 in the flat wire winding 11.

[0080] In one embodiment, the cross-sectional area of ​​at least one of the broken line segments 1112 at an end M away from the straight line segment 1111 is smaller than the cross-sectional area of ​​the straight line segment 1111 and the cross-sectional area of ​​the broken line segment 1112. As shown in FIG4a , the cross-sectional area at the end M is smaller than the cross-sectional area of ​​the straight line segment 1111 and the cross-sectional area of ​​the broken line segment 1112.

[0081] FIG4 b is a schematic diagram showing the rectangular wire winding 11 shown in FIG4 a being embedded in the stator slot 22 of the stator core 2 along the radial direction of the stator core 2 .

[0082] As shown in Figure 4b , the flat wire winding 11 is radially embedded in the stator slots 22 of the stator core 2 . The straight segment 1111 of the conductor segment 111 is accommodated within the stator slots 22 and is not shown. The two zigzag segments 1112 of the conductor segment 111 extend beyond the stator slots 22 of the stator core 2 . As shown in Figure 4b , the angle between the zigzag segments 1112 and the straight segment 1111 is greater than 90°. The angles between the two zigzag segments 1112 and the straight segment 1111 can be equal or unequal.

[0083] Along the axial direction of the stator core 2, the distance between the end of the zigzag segment 1112 away from the straight segment 1111 and the end of the stator core 2 is the height of the end winding. The angle between the zigzag segment 1112 and the straight segment 1111 allows the zigzag segment 1112 to extend outside the stator slot 22.

[0084] The flat wire winding 11 provided in this application is preformed. Before the flat wire winding 11 is inserted into the stator slot 22 of the stator core 2 along the radial direction of the stator core 2, the folded line segment 1112 has already achieved a preset bending structure. Therefore, after the flat wire winding 11 is inserted into the stator slot 22 along the radial direction of the stator core 2, the flat wire winding 11 does not need to be subjected to further processing such as twisting, flaring, and cutting. There is also no need to reserve a wire segment that needs to be clamped at the end of the flat wire winding 11, thereby reducing the distance between the folded line segment 1112 and the axial end face of the stator core 2. Multiple flat wire windings 11 are welded together in sequence along the circumference of the stator core 2 to form the stator winding 1 shown in Figure 3a. This can reduce the height of the end of the stator winding 1, thereby reducing the axial size of the flat wire motor 100.

[0085] In one embodiment, the stator core 2 of the flat wire motor 100 includes a plurality of arcuate stator core blocks 201. Each arcuate stator core block 201 includes at least one stator slot 22. The at least one stator slot 22 of each arcuate stator core block 201 is respectively configured to be embedded in at least one straight segment 1111 along the radial direction of the flat wire motor 100. The length of each straight segment 1111 along the axial direction of the flat wire motor 100 is greater than the length of the arcuate stator core block 201. The plurality of arcuate stator core blocks 201 embedded in at least one straight segment 1111 are sequentially spliced ​​together to form the stator core 2 of the flat wire motor 100.

[0086] The stator core 2 provided in the embodiment of the present application can be formed by sequentially splicing stator core blocks 201 as shown in FIG. 4 b or FIG. 4 c along the circumference of the stator core 2 , thereby facilitating the radial embedding of the flat wire winding 11 into the stator slot 22 along the flat wire motor 100 .

[0087] As shown in Figure 4c, each stator core block 201 has an inner surface a1 and an outer surface a2. Along the circumference of the stator core 2, both the inner surface a1 and the outer surface a2 of the stator core block 201 are arcuate surfaces centered on the axis of the stator core 2. The central angles of the inner surface a1 and the outer surface a2 remain relatively consistent. Multiple stator core blocks 201 can be spliced ​​together circumferentially to form the center hole of the stator core 2.

[0088] The stator core block 201 includes a plurality of stator slots 22. Each stator slot 22 extends through the stator core block 201 axially along the stator core 2, and the plurality of stator slots 22 are spaced apart circumferentially along the stator core 2. Each stator slot 22 communicates with the center hole of the stator core block 201 radially along the stator core 2. The plurality of stator core blocks 201 are spliced ​​together to form the stator core 2. The inner surfaces a1 of the plurality of stator core blocks 201 are spliced ​​together circumferentially along the stator core 2 to form the center hole of the stator core 2. The outer surfaces a2 of the plurality of stator core blocks 201 are spliced ​​together circumferentially along the stator core 2 to form the outer circumferential surface of the stator core block 201.

[0089] Fig. 5a shows a simplified structural diagram of the flat wire winding 11 shown in Fig. 4a. For example, the broken line segment 1112 is straight and is arranged at an angle α with the intermediate segment 111, and the angle α is greater than 90 degrees.

[0090] To facilitate connection between the flat wire windings 11, the zigzag segments 1112 of the two flat wire windings 11 extend from one end away from the straight segment 1111 toward the axis of the straight segment 1111, with the two zigzag segments 1112 extending in different directions. For example, in the example of a flat wire winding 11 in FIG5 b , the two zigzag segments 1112 and the straight segment 1111 lie in the same plane, and the extension direction of the zigzag segments 1112 forms an angle α with the straight segment 1111. Alternatively, in another example of a flat wire winding 11 in FIG5 c , the two zigzag segments 1112 do not lie in the same plane, and the extension direction of the zigzag segments 1112 may also form an angle α with the straight segment 1111. Alternatively, in another example of a flat wire winding 11 in FIG5 d , the zigzag segments 1112 are arc-shaped, and the tangent of the zigzag segments 1112 at their connection with the straight segment 1111 forms an angle α with the extension direction of the straight segment 1111.

[0091] Taking the flat wire winding 11 shown in FIG5 a as an example, when multiple flat wire windings 11 are connected end to end to form the stator winding 1, the end of a broken line segment 1112 of the previous flat wire winding 11 can be docked and connected with the end of a broken line segment 1112 of the next flat wire winding 11.

[0092] As shown in Figure 6, along the circumference of the stator core 2, two adjacent flat wire windings 11 are arranged axially symmetrically. Along the axial direction of the stator core 2, the two zigzag segments 1112 of each flat wire winding 11 are divided into a zigzag segment 1112a and a zigzag segment 1112b. Along the axial direction of the stator core 2, the zigzag segments 1112a of the two flat wire windings 11 are located on the same side of the straight segment 1111, and the zigzag segments 1112b of the two flat wire windings 11 are located on the same side of the straight segment 1111. For example, the zigzag segment 1112a of the preceding flat wire winding 11 and the zigzag segment 1112a of the succeeding flat wire winding 11 are adjacent and connected at the dotted circle, thereby connecting the two flat wire windings 11. The zigzag segment 1112b of the preceding flat wire winding 11 is bent away from the succeeding flat wire winding 11 to facilitate connection to the succeeding flat wire winding 11. The fold line segment 1112b of the subsequent flat wire winding 11 is bent away from the previous flat wire winding 11 to facilitate connection to the subsequent flat wire winding 11. When multiple flat wire windings 11 are connected along the circumference of the stator core 2, the stator winding 1 shown in FIG7 can be formed. Of course, FIG7 only shows a portion of the stator winding 1.

[0093] The flat wire winding 11 can increase the design flexibility of the motor 100. By varying the structural design between the straight segments 1111 and the broken segments 1112 of the conductor segments 111, multiple flat wire windings 11 can be connected in various configurations to form stator windings 1 of various shapes, thereby increasing the design flexibility of the motor 100. For example, multiple flat wire windings 11 can be connected to form a stator with an odd number of winding layers, or to form stator windings with different winding layers connected across layers or across distances.

[0094] In the specific manufacturing of the stator 10, the flat wire windings 11 can be inserted into the stator slots 22 of the stator core 2 along the radial direction of the stator core 2. The straight line segments 1111 of the flat wire windings 11 inserted into the stator slots 22 are located within the stator slots 22, and the two zigzag segments 1112 are located outside the axial end surfaces of the stator core 2. After multiple flat wire windings 11 are inserted into the stator slots 22 of the stator core 2 according to the winding pattern, the stator winding 1 is obtained by welding the adjacent zigzag segments 1112 of any two adjacent flat wire windings 11 along the circumference of the stator core 2. The stator winding 1 formed by connecting these flat wire windings 11 has the zigzag segments 1112 located on one side of the axial end of the stator core 2. Along the axial direction of the stator core 2, the distance H between the end of the zigzag segment 1112 away from the straight line segment 1111 and the axial end surface of the stator core 2 is the end height of the stator winding 1.

[0095] In summary, the flat wire winding 11 provided in the embodiment of the present application already has a curved zigzag segment 1112 between its insertion into the stator slots 22. This eliminates the need to stretch, twist, or flare the ends of the flat wire winding 11 after insertion into the stator slots 22. The zigzag segment 1112 does not need to be sufficiently long to accommodate this. The end of the zigzag segment 1112 distal from the straight segment 1111 corresponds to the weld point of the flat wire winding 11. The distance from this weld point to the stator core 2 represents the height H of the end winding. Compared to the stator winding 1 in conventional technology, the stator winding 1 in the embodiment of the present application has a smaller height, which can reduce the axial dimension of the stator 10 and facilitate the miniaturization of the motor 100. Because the linear shape of the flat wire winding 11 eliminates the need for twisting and flaring after the flat wire winding 11 is inserted into the stator slot 22, the welded ends of multiple flat wire windings 11 can be welded together to form the stator winding 1 with greater freedom in design. This also simplifies the design of the busbars and busbars of the motor 100. For the motor 100, a smaller axial dimension facilitates miniaturization and improves its operating efficiency. Compared to traditional wave winding methods, the flat wire winding 11 production line provided by the embodiments of the present application requires less investment and offers greater compatibility.

[0096] In one embodiment, at least one zigzag segment 1112 of at least one wire segment 111 includes a welding surface P at an end M away from the straight segment 1111. The cross-sectional area of ​​the end M is smaller than the cross-sectional area of ​​the straight segment 1111 and the cross-sectional area of ​​the zigzag segment 1112. The welding surface P is used for welding to the welding surface P of the end M of the zigzag segment 1112 of the wire segment 111 of another flat wire winding 11.

[0097] As shown in FIG8 a , the end M of the folded line segment 1112 of the wire segment 111 includes a welding surface P. The welding surface P is used to weld the welding surface P of the end M of the folded line segment 1112 of the wire segment 111 of another rectangular wire winding 11 .

[0098] In one embodiment, a welding surface P of a conductor segment 111 of one flat wire winding 11 in the stator winding 1 is welded to a welding surface P of another conductor segment 111 of another flat wire winding 11. The two welded welding surfaces P are adjacently arranged along the radial direction or circumferential direction of the flat wire motor 100.

[0099] In one embodiment, the cross-sectional area of ​​the straight line segment 1111 and the cross-sectional area of ​​the two broken line segments 1112 in a wire segment 111 are smaller than the area of ​​the welding surface P.

[0100] In one embodiment, an end M of a broken line segment 1112 includes an end surface A facing the circumference of the flat wire motor 100 and a side surface B facing the radial direction of the flat wire motor 100 .

[0101] In one embodiment, the end M of a zigzag segment 1112, facing an end surface A circumferentially of the flat wire motor 100, includes a welding surface P. As shown in FIG8a , the end M of the zigzag segment 1112, facing an end surface A circumferentially of the flat wire motor 100, includes a welding surface P. The angle β at which the welding surface P intersects the extension direction of the zigzag segment 1112 is less than 90 degrees. The flat wire winding 11 illustrated in FIG8a is suitable for welding two adjacent flat wire windings 11 along the circumference of the stator core 2. The two wire segments 111 to be welded are embedded in the stator slots 22 of the stator core 2. The welding surfaces P of the two wire segments 111 to be welded are opposite each other along the radial direction or circumferential direction of the flat wire motor 100. This not only facilitates welding operations but also improves welding reliability, thereby enhancing the performance and reliability of the flat wire motor 100.

[0102] In one embodiment, the end M of a broken line segment 1112 in a wire segment 111 includes a section a. Section a includes a welding surface P, and the area of ​​section a is smaller than the cross-sectional area of ​​the straight line segment 1111 and the cross-sectional area of ​​the broken line segment 1112 in the wire segment 111. In one embodiment, the area of ​​section a is greater than or equal to the area of ​​the welding surface P.

[0103] As shown in Figure 8a, end surface A includes a section a formed by cutting a broken line segment 1112 along the axial direction of the flat wire motor 100. The area of ​​section a is larger than the cross-sectional area of ​​the straight line segment 1111 in the conductor segment 111 and the cross-sectional area of ​​the two broken line segments 1112. Accordingly, section a formed by obliquely cutting the broken line segment 1112 can increase the welding area and improve the stability of the flat wire motor 100.

[0104] As shown in FIG8b , the section a or welding surface P includes two side edges S arranged opposite to each other along the thickness direction of the fold line segment 1112 , and the length h of the two side edges S is greater than the width w of one fold line segment 1112 . The interval between the two side edges S is less than or equal to the thickness v of the fold line segment 1112 .

[0105] In the embodiment of the present application, the thickness of the straight line segment 1111 or the thickness of the broken line segment 1112 indicates the radial size of the flat wire motor 100 after the guide line segment 111 is embedded in the stator slot 22, and the thickness of the straight line segment 1111 or the thickness of the broken line segment 1112 indicates the circumferential size of the flat wire motor 100 after the guide line segment 111 is embedded in the stator slot 22.

[0106] In one embodiment, the cut surface a or welding surface P is oriented toward the circumference of the flat wire motor 100. Figure 8c shows a simplified schematic diagram of the flat wire winding 11, viewed parallel to the welding surface P. Referring to Figures 8a and 8c together, the zigzag segment 1112 is tilted or offset along the circumference of the stator core 2. The welding surface P forms an angle β with the extension direction of the zigzag segment 1112, and the welding surface P is substantially perpendicular to the circumference of the stator core 2. As shown in Figure 8c, the cut surface a or welding surface P is parallel to the thickness direction of the zigzag segment 1112 and perpendicular to the width direction of the zigzag segment 1112.

[0107] In one embodiment, the welding surfaces P at the ends M of the two folded line segments 1112 in the same wire segment 111 face substantially opposite directions along the circumference of the flat wire motor 100. As shown in FIG8c , the welding surfaces P at the ends M of the two folded line segments 1112 in the same wire segment 111 face opposite directions along the circumference of the flat wire motor 100.

[0108] In one embodiment, the end surfaces A or cut surfaces a of the two welded welding platforms P are arranged adjacent to each other along the circumference of the flat wire motor 100. As shown in Figure 8d, one weld surface P is welded to another weld surface P along the circumference of the stator core 2. The two weld surfaces P are arranged adjacent to each other along the circumference of the stator core 2. Figure 8e shows a top view of the welding of two flat wire windings 11. As shown in Figure 8e, the welded platforms P of the two flat wire windings 11 are welded to each other, and the two welded welded platforms P are arranged adjacent to each other along the circumference of the flat wire motor 100. The two welded welded platforms P are perpendicular to the circumference of the flat wire motor 100 and parallel to the radial direction of the flat wire motor 100 or the radial direction of the stator core 2. As shown in Figure 8e, two welding platforms P arranged adjacent to each other along the circumference of the flat wire motor 100 can facilitate the welding of two flat wire windings 11 arranged in the same layer along the radial direction of the flat wire motor 100. There is no need to perform twisting, flaring, cutting and other processing on the flat wire winding 11, and there is no need to reserve a wire segment that needs to be clamped at the end of the flat wire winding 11, thereby reducing the distance between the broken line segment 1112 and the axial end face of the stator core 2, thereby reducing the axial size of the flat wire motor 100.

[0109] In one embodiment, an end M of a zigzag line segment 1112, facing a radial side B of the flat wire motor 100, includes a welding surface P. As shown in FIG9a , the end M of the zigzag line segment 1112, facing a radial side B of the flat wire motor 100, includes the welding surface P. Exemplarily, the welding surface P is parallel to the extension direction of the zigzag line segment 1112. The welding surface P is located on the radial side of the end M of the zigzag line segment 1112 facing the flat wire motor 100, allowing the area of ​​the welding surface P to be larger than the cross-sectional area of ​​the straight segment 1111 in the wire segment 111 and the cross-sectional area of ​​the two zigzag line segments 1112. This increases the welding area and improves the stability of the flat wire motor 100.

[0110] In one embodiment, a side surface B of a broken line segment 1112 in a conductor segment 111, facing radially toward the flat wire motor 100, includes a cut surface b. Cut surface b includes a welding surface P, and the area of ​​cut surface b is equal to or greater than the cross-sectional area of ​​the straight line segment 1111 and the cross-sectional area of ​​the broken line segment 1112 in the conductor segment 111. In one embodiment, the area of ​​cut surface b is greater than or equal to the area of ​​the welding surface P. As shown in FIG9a , cut surface b is formed by cutting the side surface B of the end portion M of the broken line segment 1112. The area of ​​cut surface b is greater than the cross-sectional area of ​​the straight line segment 1111 and the cross-sectional area of ​​the two broken line segments 1112 in the conductor segment 111. Accordingly, the cut surface b formed by cutting the broken line segment 1112 can increase the welding area and improve the stability of the flat wire motor 100.

[0111] As shown in FIG. 9 b , the cutting surface a or the welding surface P includes two side edges S that are oppositely arranged along the extending direction of the fold line segment 1112 , and the length h of the two side edges S is greater than the width of one fold line segment 1112 .

[0112] In one embodiment, the cut surface a or welding surface P is radially oriented toward the flat wire motor 100. As shown in FIG9c , the simplified structure of the flat wire winding 11 is viewed perpendicular to the welding surface P. The welding surface P is located on a surface in the thickness direction of the broken line segment 1112 and is substantially perpendicular to the radial direction of the stator core 2.

[0113] In one embodiment, the welding surfaces P of the two ends M of the folded line segments 1112 in the same wire segment 111 face opposite or the same direction. As shown in FIG9c , the welding surfaces P of the two ends M of the folded line segments 1112 in the same wire segment 111 are located on the same side in the thickness direction of the flat wire winding 11, and the welding surfaces P of the two ends M of the folded line segments 1112 in the same wire segment 111 face the same direction. Accordingly, the welding surfaces P of the two ends M of the folded line segments 1112 in the same wire segment 111 are located on different sides in the thickness direction of the flat wire winding 11, and the welding surfaces P of the two ends M of the folded line segments 1112 in the same wire segment 111 face opposite directions.

[0114] In one embodiment, two welded welding platforms P are arranged adjacent to each other in the radial direction of the flat wire motor 100. As shown in Figure 9d, one weld surface P is welded to another weld surface P in the radial direction of the stator core 2. The two weld surfaces P are arranged adjacent to each other in the radial direction of the stator core 2. The shadow within the dashed box in Figure 9d illustrates the contact portion of the two weld surfaces P. Figure 9e shows a top view of the two flat wire windings 11. The welded welding platforms P of the two flat wire windings 11 are welded to each other, and the two welded welding platforms P are arranged adjacent to each other in the radial direction of the flat wire motor 100. The two welded welding platforms P are parallel to the circumference of the flat wire motor 100 and perpendicular to the radial direction of the flat wire motor 100 or the radial direction of the stator core 2. As shown in Figure 9e, two welding platforms P arranged adjacent to each other along the radial direction of the flat wire motor 100 can facilitate the welding of two flat wire windings 11 arranged across layers along the radial direction of the flat wire motor 100. There is no need to perform twisting, flaring, cutting and other processing on the flat wire winding 11, and there is no need to reserve a wire segment that needs to be clamped at the end of the flat wire winding 11, thereby reducing the distance between the broken line segment 1112 and the axial end face of the stator core 2, thereby reducing the axial size of the flat wire motor 100.

[0115] The two flat wire windings 11 are stacked radially along the stator core 2, allowing the welding surfaces P of the two flat wire windings 11 to face each other radially along the stator core 2 and be welded together. It should be understood that when the two flat wire windings 11 are welded radially along the stator core 2, the welding surfaces P of the two flat wire windings 11 must face each other radially along the stator core 2. Therefore, when inserting the flat wire windings 11 into the stator slots 22, the relative positional relationship between the two flat wire windings 11 to be welded must be designed and adjusted.

[0116] In one embodiment, an end portion of a broken line segment 1112 includes a section D in a radial direction of the flat wire motor 100 , and the section D is perpendicular to the welding surface P.

[0117] As shown in Figures 10a and 10b, the ends M of the two welded broken line segments 1112 are cut along the radial direction of the flat wire motor 100, away from the straight line segment 1111, to form a section D. Section D is perpendicular to the weld surface P and parallel to the circumference of the stator core 2. Section D shortens the height of the flat wire winding 11 extending out of the stator slots 22 and reduces the sharpness of the end of the flat wire winding 11 exposed outside the circumferential end surface of the stator core 2, thereby improving assembly safety.

[0118] As shown in Figure 11a, the flat wire winding 11 includes two wire segments 111 connected end to end. The end of the folded line segment 1112 of any wire segment 111 away from the other wire segment 111 serves as a welded end of the flat wire winding 11. The two ends of the flat wire winding 11 are the two welded ends. The flat wire winding 11 can be formed by bending a single wire. When used, the flat wire winding 11 needs to be arranged along the circumference of the stator core 2. Therefore, in the flat wire winding 11 here, the two folded line segments 1112 of the two wire segments 111 that are away from each other are arranged in a three-dimensional manner. In one embodiment, the angle or orientation of the folded line segment 1112 of one or more wire segments 111 in the flat wire winding 11 is different from the angle or orientation of the folded line segments 1112 of other wire segments 111 relative to the straight line segment 1111, thereby facilitating cross-layer connections between the flat wire windings 11.

[0119] For ease of understanding, Figure 11b shows a simplified plan view of the rectangular wire winding 11 shown in Figure 11a. In Figure 11b, the two conductor segments 111 of the rectangular wire winding 11 are symmetrical along the axis of the stator core 2. It should be understood that this axial symmetry is merely for ease of understanding and does not limit the specific structure of the two conductor segments 111 in practice.

[0120] As shown in FIG11 b , multiple flat wire windings 11 are connected end to end to form a stator winding 1 , and the end of a broken line segment 1112 of a preceding flat wire winding 11 can be butted and connected to the end of a broken line segment 1112 of a following flat wire winding 11 .

[0121] As shown in Figure 11c, two adjacent rectangular wire windings 11 are arranged axially symmetrically along the circumference of the stator core 2. Axially, the zigzag segments 1112 of the two rectangular wire windings 11 are located on the same side of the straight segment 1111. The zigzag segments of the two rectangular wire windings 11 are close together and connected at the dotted circle, effectively connecting the two rectangular wire windings 11.

[0122] In one embodiment, the flat wire winding 11 includes a plurality of conductor segments 111 , and a broken line segment 1112 of one conductor segment 111 and a broken line segment 1112 of another conductor segment 111 of any two adjacent conductor segments 111 are connected via another curved segment 1113 .

[0123] As shown in FIG12 a , the flat wire winding 11 includes three wire segments 111 connected end to end. Of any two adjacent wire segments 111 , a broken line segment 1112 of one wire segment 111 is connected to a broken line segment 1112 of another wire segment 111 via another curved segment 1113 .

[0124] In one embodiment, the angle between two connected broken line segments 1112 in two adjacent wire segments 111 is smaller than the angle between each broken line segment 1112 and the straight line segment 1111 in the same wire segment 111 .

[0125] As shown in FIG. 12 a , the angle δ between two connected broken line segments 1112 in two adjacent wire segments 111 is smaller than the angle α between each broken line segment 1112 and the straight line segment 1111 in the same wire segment 111 .

[0126] As shown in Figure 12a, the ends of the folded line segments 1112 of the first and last wire segments 111, away from the middle wire segment 111, serve as the weld ends of the flat wire winding 11. The two ends of the flat wire winding 11 constitute the two weld ends. The flat wire winding 11 can be formed by bending a single wire. For easier understanding, Figure 12b shows a simplified plan view of the flat wire winding 11 shown in Figure 12a.

[0127] When multiple flat wire windings 11 shown in Figure 12b are connected end-to-end to form the stator winding 1, the end of a broken line segment 1112 of the preceding flat wire winding 11 can be butted against and connected to the end of a broken line segment 1112 of the succeeding flat wire winding 11. As shown in Figure 12c, two adjacent flat wire windings 11 are arranged axially symmetrically around the circumference of the stator core 2. The adjacent broken line segments 1112 of the two flat wire windings 11 are connected at the dotted circle, effectively connecting the two flat wire windings 11.

[0128] It should be understood that the flat wire windings 11 shown in FIG. 11 a and FIG. 12 a differ from the flat wire winding 11 shown in FIG. 4 a only in the number of wire segments 111 . The welding connection method and structure between any two flat wire windings 11 can be implemented with reference to the above-mentioned embodiments and will not be described in detail here.

[0129] Figure 13a is another schematic diagram of the motor stator provided in an embodiment of the present application. Figure 13b is an enlarged view of point B in Figure 13a. Figure 13c is a schematic diagram of the stator core provided in an embodiment of the present application. Figure 13d is another schematic diagram of the motor stator provided in an embodiment of the present application.

[0130] Referring also to Figures 13a and 13b , the stator core 2 includes a plurality of stator teeth 21 and an annular yoke 23. In the radial direction of the stator 10, the inner surface of the yoke 23 faces the center hole of the stator core 2, while the outer surface of the yoke 23 faces away from the center hole of the stator core 2. The inner surface of the yoke 23 includes a plurality of mounting slots 231, which are spaced apart along the circumference of the stator 10.

[0131] As shown in Figures 13a and 13b, the yoke 23 is annular, and a plurality of stator teeth 21 are mounted on the inner side of the yoke 23. Along the circumference of the stator 10, the gap between any two stator teeth 21 is the stator slot 22. Along the radial direction of the stator 10, each stator tooth 21 has a protrusion 211 protruding along the circumference of the stator 10 at the end away from the yoke 23. The protrusion 211 can prevent the winding wire 1 embedded in the stator slot 22 from falling out of the stator slot 22. Due to the presence of the protrusion 211, the circumferential dimension w2 of the stator slot 22 near the yoke 23 is larger than the circumferential dimension w1 of the stator slot 22 away from the yoke 23. Further in conjunction with Figure 13c, along the radial direction of the stator 10, the yoke 23 includes an inner surface a1 and an outer surface a2. The inner surface a1 is provided with a plurality of mounting grooves 231, and the plurality of mounting grooves 231 are distributed at intervals along the circumference of the stator 10. The plurality of stator teeth 21 can be embedded in the plurality of mounting slots 231 in a one-to-one correspondence along the axial direction of the stator 10 , ultimately presenting the structure shown in FIG13 a . The one-to-one correspondence means that one stator tooth 21 is uniquely embedded in one mounting slot 231 .

[0132] As shown in Figure 13d, a fixture is first used to arrange multiple stator teeth 21 at intervals along the circumference of the stator 10, forming stator slots 22 between any two connected stator teeth 21. Insulation paper 3 is then placed in each stator slot 22, and multiple winding wires 11 are then inserted into the multiple stator slots 22 along the radial direction of the stator 10. The winding wires 11 are inserted into the stator slots 22 in the direction from the outer diameter to the inner diameter of the stator 10, that is, the winding wires 11 are inserted into the stator slots 22 from the stator slot 22 toward one end of the yoke 23, to prevent the protrusion 211 at the end of the stator slot 22 away from the yoke 23 from causing inconvenience to the radial insertion of the winding wires 11.

[0133] Among them, according to the final structural shape of the stator winding 1, one or more winding wires 11 can be embedded in each stator slot 22. Then, the operating fixture installs the multiple stator teeth 21 embedded with multiple winding wires 11 to the yoke 23 along the axial direction of the stator 10, so that each stator tooth 21 can be embedded in the installation slot 231 of the yoke 23 along the axial direction of the stator 10. After the stator teeth 21 and the yoke 23 are installed, the multiple winding wires 11 are welded together according to the winding requirements of the stator winding 1, and the stator 10 is completed after being coated with drop paint. It should be understood that for the convenience of illustration, the fixture used to fix the multiple stator teeth 21 is not shown in Figure 13d.

[0134] In one embodiment, the stator 10 provided by the present application is formed by splicing an annular yoke 23 and a plurality of stator teeth 21 to form a stator core 2. The plurality of winding wires 11 can be first respectively embedded in the plurality of stator slots 22 formed by the plurality of arranged stator teeth 21, and then the plurality of stator teeth 21 are spliced ​​to the yoke 23 along the axial direction of the stator 10. Then, the plurality of winding wires 11 are welded and connected according to the winding rules of the stator winding 1 to form the stator winding 1. In the process of forming the stator winding 1, the stator 10 provided by the present application does not require stretching, twisting, and flaring operations, and therefore does not require reserving a wire segment that needs to be clamped at the end of the winding wire 11, thereby reducing the end height of the stator winding 1.

[0135] In one embodiment, the stator 10 provided by the present application is formed by splicing an annular yoke 23 and a plurality of stator teeth 21 to form a stator core 2. The plurality of winding wires 11 can first be respectively embedded in the plurality of stator slots 22 formed by the plurality of arranged stator teeth 21. The plurality of winding wires 11 are then welded together according to the winding rules of the stator winding 1 to form the stator winding 1. The plurality of stator teeth 21 are then spliced ​​to the yoke 23 along the axial direction of the stator 10. In the process of forming the stator winding 1, the stator 10 provided by the present application does not require stretching, twisting, or flaring operations, and thus does not require reserving a wire segment that needs to be clamped at the end of the winding wire 11, thereby reducing the end height of the stator winding 1.

[0136] In one embodiment, a plurality of stator teeth 21 in the stator 10 provided by the present application together constitute the tooth portion 21 of the stator core 2, and the plurality of stator teeth 21 are connected to form an annular tooth portion. In one embodiment, the stator core 2 includes an annular tooth portion, which includes a plurality of stator teeth 21 spaced apart along the circumference of the stator 10. In the radial direction of the stator 10, the tooth portion includes an inner surface and an outer surface. The outer surface of the tooth portion 21 includes a plurality of stator teeth 21. The gap between any two adjacent stator teeth 21 along the circumference of the stator 10 is used to form a stator slot 22. Each stator slot 22 is used to embed at least one straight segment 1111 along the radial direction of the stator 10. The tooth portion embedded in at least one straight segment 1111 is embedded in the plurality of mounting slots 231 of the yoke 23 along the axial direction of the stator 10. In the plurality of stator teeth 21, the plurality of mounting slots 231 are respectively embedded. The stator 10 provided in the present application does not require stretching, twisting, or flaring during the process of forming the stator winding 1 , and thus does not require reserving a wire segment that needs to be clamped at the end of the winding wire 11 , thereby reducing the end height of the stator winding 1 .

[0137] Obviously, those skilled in the art may make various changes and modifications to the present application without departing from the scope of the present application. Thus, if these modifications and variations of the present application fall within the scope of the claims of the present application and their equivalents, the present application is intended to include these modifications and variations.

Claims

1. A stator of a flat wire motor, characterized in that: The stator comprises a stator core and a stator winding, wherein the stator winding comprises a plurality of flat wire windings, at least one of the flat wire windings comprises at least one wire segment, and each of the wire segments comprises: a straight line segment, wherein the straight line segment is used to be embedded in a stator slot of a stator core in a flat wire motor, Two fold line segments, the two fold line segments are used to be exposed outside the stator slot, the extension direction of each fold line segment intersects with the extension direction of the straight line segment, the extension directions of the two fold line segments are different, at least one of the fold line segments includes a welding surface at the end away from the straight line segment, and the cross-sectional area of ​​the end is smaller than the cross-sectional area of ​​the straight line segment.

2. The stator according to claim 1, characterized in that The end of one of the folded line segments includes a section surface facing the circumferential end surface of the flat wire motor, the section surface includes the welding surface, and the area of ​​the section surface is greater than the cross-sectional area of ​​the folded line segment.

3. The stator according to claim 2, characterized in that The one cut surface or the one welding surface comprises two side edges which are arranged opposite to each other along the thickness direction of the one fold line segment, and the length of the two side edges is greater than the width of the one fold line segment.

4. The stator according to claim 1, characterized in that The end of one of the folded line segments includes a section on the radial side facing the flat wire motor, the section includes the welding surface, and the area of ​​the section is larger than the cross-sectional area of ​​the folded line segment.

5. The stator according to claim 4, characterized in that The one cut surface or the one welding surface comprises two side edges which are arranged opposite to each other along the extension direction of the one fold line segment, and the length of the two side edges is greater than the width of the one fold line segment.

6. The stator according to any one of claims 2 to 5, characterized in that: The welding surfaces at the ends of the two broken line segments in the one conductor segment face in opposite directions.

7. The stator according to any one of claims 2 to 6, characterized in that: The end of the one broken line segment comprises another section facing the axial direction of the flat wire motor, and the other section is perpendicular to the welding surface.

8. The stator according to any one of claims 1 to 7, characterized in that: The angle between one of the broken line segments and the straight line segment in the conductor segment is greater than 90 degrees, and two of the broken line segments in the conductor segment are respectively connected to the straight line segment via a curved segment.

9. The stator according to any one of claims 1 to 8, characterized in that: The flat wire winding includes a plurality of wire segments connected in sequence, and one of the two connected wire segments has a broken line segment connected to one of the other wire segments via another bent segment.

10. The stator according to claim 9, characterized in that The angle between the two connected broken line segments in the two connected wire segments is smaller than the angle between each broken line segment and the straight line segment in the same wire segment.

11. The stator according to claim 1, characterized in that The stator core comprises a plurality of arc-shaped stator core blocks, each of which comprises at least one stator slot, wherein: The at least one stator slot of each of the arc-shaped stator core blocks is respectively used to embed at least one of the straight line segments, and the length of each of the straight line segments along the axial direction of the flat wire motor is greater than the length of the arc-shaped stator core block; The plurality of arc-shaped stator core blocks embedded in the at least one straight line segment are sequentially spliced ​​to form the stator core.

12. The stator according to claim 1, characterized in that The stator core comprises a plurality of stator teeth and an annular yoke, wherein: In the radial direction of the stator, the inner surface of the yoke faces the central hole of the stator core, and the outer surface of the yoke faces away from the central hole of the stator core. The inner surface of the yoke includes a plurality of mounting grooves, and the plurality of mounting grooves are spaced apart along the circumferential direction of the stator. The gap between any two adjacent stator teeth along the circumference of the stator is used to form the stator slot, each of the stator slots is used to embed the at least one straight line segment along the radial direction of the stator, and the multiple stator teeth embedded in the at least one straight line segment are respectively used to embed in the multiple mounting grooves of the yoke along the axial direction of the stator.

13. A flat wire motor, characterized in that: The flat wire motor comprises a rotor and a stator as described in any one of claims 1 to 12, the welding surface of one wire segment of one flat wire winding is welded to the welding surface of another wire segment of another flat wire winding, and the welding surfaces of the two welded wire segments are arranged adjacent to each other in the radial direction of the flat wire motor or in the circumferential direction of the flat wire motor.

14. A powertrain, characterized in that: The power assembly includes any one of a reducer or a transmission and the flat wire motor according to claim 13, wherein the motor shaft of the flat wire motor is used for transmission connection with the input shaft of the reducer or the input shaft of the transmission.

15. A flat wire winding with a zigzag segment and a welding surface, characterized in that: The flat wire winding comprises at least one wire segment, each of which comprises: a straight line segment, wherein the straight line segment is used to be embedded in a stator slot of a stator core in a flat wire motor, Two fold line segments, the two fold line segments are used to be exposed outside the stator slot, the extension direction of each fold line segment intersects with the extension direction of the straight line segment, the extension directions of the two fold line segments are different, at least one of the fold line segments includes a welding surface at the end away from the straight line segment, and the cross-sectional area of ​​the end is smaller than the cross-sectional area of ​​the straight line segment.

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