Motor stator assembly, motor and vehicle power system

Abstract

A motor stator assembly. Annular cavities (3p, 4p) for inflow of cooling fluids are respectively defined in two annular components (3, 4) located on two axial sides of an iron core (1), and extended portions (22, 23) of a winding (2) extending out of the iron core (1) are located in corresponding annular cavities (3p, 4p). Furthermore, inlet ports (3i, 4i) are respectively formed in the two annular components (3, 4). A discharge port (4o) is further formed in the motor stator assembly. The cooling fluids entering through the two inlet ports (3i, 4i) can be discharged from the discharge port (4o) only after at least cooling the corresponding extended portions (22, 23). In this way, the cooling effect on the extended portions of the winding of the motor stator assembly is effectively improved, and the adverse effect possibly caused by excessive temperature during the operation of the motor stator assembly is reduced. Also provided are a motor comprising the motor stator assembly and a vehicle power system comprising the motor.

Description

Motor stator assembly, motor, and vehicle power system Technical Field

[0001] The present application relates to the field of motors, and in particular to a motor stator assembly with a cooling structure, a motor including the motor stator assembly, and a vehicle power system including the motor. Background Art

[0002] Motors are used to output torque and power, and motor cooling is crucial for achieving these desired outputs. When a motor is operating at high efficiency, much of the energy lost is copper loss. Therefore, the cooling capacity of the motor's cooling structure for the windings is a significant factor influencing the motor's sustained output power under these conditions.

[0003] In existing motors, some cooling structures are constructed to adopt a splash cooling mechanism, for example, the cooling structure can be designed to have a nozzle to spray a cooling fluid (such as cooling oil) directly onto the winding to remove heat; some cooling structures are designed to adopt an immersion cooling mechanism, for example, a cooling cavity extending along the circumference is formed inside the motor stator assembly, so that at least a portion of the winding can be immersed in the cooling fluid in the cooling cavity, thereby cooling the winding. For example, in the U.S. invention patent application with publication number US20230155446A1 and titled "Direct Slot Cooling System for Motor", the motor is provided with an inlet on one side of the motor stator and an outlet on the other side of the motor stator. The cooling oil entering from the inlet can flow along the slots of the motor stator and then flow out from the outlet, thereby cooling the motor stator.

[0004] However, in the prior art, as exemplified by the aforementioned patent application, the cooling fluid does not provide sufficient cooling. This is because the cooling fluid entering through an inlet on one side of the motor stator first travels a considerable length of path to cool the windings before reaching the other side of the stator. By this time, the cooling fluid is already very hot, making it difficult to effectively cool the portion of the windings located on the other side of the stator.

[0005] Summary of the Invention

[0006] This application is made in light of the aforementioned state of the prior art. One object of this application is to provide a motor stator assembly and a motor including the same, wherein the cooling structure of the motor stator assembly facilitates more efficient cooling of the motor stator assembly, thereby reducing the adverse effects of excessively high temperatures of the motor stator assembly during operation. Another object of this application is to provide a vehicle power system including the aforementioned motor.

[0007] In order to achieve the above-mentioned purpose of the invention, this application adopts the following technical solutions.

[0008] The present application provides a motor stator assembly as follows, comprising:

[0009] an iron core having a plurality of winding slots spaced apart and distributed in a circumferential direction thereof;

[0010] a winding mounted on the core, the winding comprising an in-slot portion, a first extending portion, and a second extending portion, the in-slot portion being located in the winding slot, the first extending portion extending from the core to one axial side of the core, and the second extending portion extending from the core to the other axial side of the core;

[0011] a first annular component mounted on the core and located on one axial side of the core, the first annular component forming a first annular cavity for accommodating the first extension portion and a first inlet communicating with the first annular cavity; and

[0012] a second annular component mounted on the core and located on the other axial side of the core, the second annular component forming a second annular cavity for accommodating the second extension portion and a second inlet communicating with the second annular cavity;

[0013] The motor stator assembly is further formed with an exhaust port, so that the cooling fluid entering through the first inlet port cools at least the first extension portion and then is exhausted from the exhaust port, and the cooling fluid entering through the second inlet port cools at least the second extension portion and then is exhausted from the exhaust port.

[0014] In an optional solution, an axial flow path connecting the first annular cavity and the second annular cavity is formed in each of the winding grooves.

[0015] In another optional solution, the exhaust port is formed in one of the first annular component and the second annular component, so that the cooling fluid entering through the first inlet port or the second inlet port is discharged from the exhaust port after flowing through the axial flow path.

[0016] In another optional solution, in an installation posture where the axial direction of the motor stator assembly is parallel to a horizontal plane, the exhaust port is formed at the top of one of the first annular assembly and the second annular assembly.

[0017] In another optional solution, a busbar is further included, and the winding can be electrically connected to an external power supply via the busbar, and the busbar extends from the winding through the discharge port to the outside.

[0018] In another optional solution, the discharge port is formed in the iron core, and the discharge port is communicated with all the axial flow paths.

[0019] In another optional solution, in the installation posture where the axial direction of the motor stator assembly is parallel to the horizontal plane,

[0020] The first inlet is located at the bottom of the first annular component in a vertical direction, and / or the second inlet is located at the bottom of the second annular component in a vertical direction.

[0021] In another optional solution, the first annular component includes a first annular peripheral wall and a first side wall, the first annular peripheral wall and the first side wall surround and form the first annular cavity, the first inlet is formed in the first side wall, and

[0022] The second annular component includes a second annular circumferential wall and a second side wall. The second annular circumferential wall and the second side wall surround and form the second annular cavity. The second inlet is formed in the second side wall.

[0023] The present application also provides the following motor, comprising the motor stator assembly described in any one of the above technical solutions.

[0024] The present application also provides a vehicle power system as follows, comprising the motor described in the above technical solution.

[0025] By adopting the above-mentioned technical solution, the present application provides a motor stator assembly, a motor, and a vehicle power system including the motor. In the motor stator assembly of the present application, two annular assemblies located on both axial sides of the iron core respectively surround and form an annular cavity for the cooling fluid to enter, and the protruding portions of the winding extending from the iron core toward the axial sides are located in the corresponding annular cavity. Furthermore, the two annular assemblies are respectively formed with an inlet, and the motor stator assembly is also formed with an outlet. The cooling fluid entering through the inlet of the two annular assemblies can be discharged from the outlet only after cooling at least the corresponding protruding portions.

[0026] In this way, in the cooling structure of the motor stator assembly of the present application, the cooling fluid entering the corresponding annular cavity from the inlet can first cool the protruding portion of the winding and then be discharged from the outlet. Thereby, at least the cooling effect on the protruding portion of the winding of the motor stator assembly is effectively improved, and the adverse effects that may be caused by excessive temperature during the operation of the motor stator assembly are reduced. Moreover, effective cooling of the motor stator assembly can increase the continuous output power of the motor and at the same time increase the service life of the motor. Furthermore, the cooling structure of the motor stator assembly of the present application is less modified than the cooling structure of the prior art, and does not require complex structural adjustments, thereby saving related costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] FIG1 is a perspective schematic diagram showing a stator assembly of a motor according to an embodiment of the present application.

[0028] FIG. 2 is another perspective schematic diagram showing the stator assembly of the motor in FIG. 1 .

[0029] FIG. 3 is a schematic side view showing a stator assembly of the motor in FIG. 1 .

[0030] FIG4 is a schematic cross-sectional view of a vehicle power system according to an embodiment of the present application, which includes the motor stator assembly in FIG1 .

[0031] Explanation of the reference numerals 1 iron core; 1p axial flow path; 2 winding; 21 slot inner portion; 22 first protruding portion; 23 second protruding portion; 3 first annular component; 3p first annular cavity; 3i first inlet; 31 first annular outer circumferential wall; 32 first annular inner circumferential wall; 33 first side wall; 4 second annular component; 4p second annular cavity; 4i second inlet; 4o outlet; 41 second annular outer circumferential wall; 42 second annular inner circumferential wall; 43 second side wall; 5 busbar; A axial direction; R radial direction. DETAILED DESCRIPTION

[0032] The specific embodiments of the present application will be described in detail below in conjunction with the accompanying drawings. It should be understood that these specific descriptions are only used to teach those skilled in the art how to implement the present application, and are not intended to exhaust all possible methods of the present application, nor to limit the scope of the present application.

[0033] In this application, unless otherwise specified, "axial," "radial," and "circumferential" refer to the axial, radial, and circumferential directions of the motor stator assembly, respectively. "Axial side" refers to the left side in Figures 3 and 4 , and "axial opposite side" refers to the right side in Figures 3 and 4 . "Radially outer side" refers to the side radially away from the central axis of the motor stator assembly, and "radially inner side" refers to the side radially closer to the central axis of the motor stator assembly.

[0034] The specific structure of the motor stator assembly according to an embodiment of the present application will be described below with reference to the accompanying drawings, especially the cooling structure for cooling the motor stator assembly.

[0035] As shown in Figures 1 to 4, a motor stator assembly according to an embodiment of the present application includes an assembled iron core 1, a winding 2, a first annular assembly 3, a second annular assembly 4, and a busbar 5. The winding 2, the first annular assembly 3, and the second annular assembly 4 are all fixed to the iron core 1. The first annular assembly 3 and the second annular assembly 4 can be relatively fixed to the iron core 1 by other connectors or limiting components.

[0036] In this embodiment, as shown in Figures 1 to 4, the core 1 may include a yoke and a plurality of winding teeth. The yoke extends continuously along the entire circumference, and the plurality of winding teeth protrude radially inward from the yoke and are evenly distributed in the circumferential direction. A winding slot is defined between every two circumferentially adjacent winding teeth. Each winding slot extends through the core 1 along the axial direction A and may have a radial opening that opens radially inward.

[0037] In this embodiment, as shown in Figures 1 and 4, the winding 2 can be installed on the iron core 1 by being wound on the corresponding winding teeth. The winding 2 can be composed of a copper wire coated with an insulating material, and the coil of the winding 2 will pass through the winding slot adjacent to the winding tooth during the winding process. In this way, the winding 2 includes a slot portion 21 located in the winding slot of the iron core 1 and a first protruding portion 22 and a second protruding portion 23 extending from the iron core 1 toward both sides in the axial direction. A gap can be set between the slot portions 21 of the winding 2 or between the slot portions 21 and the wall of the winding slot, thereby forming an axial flow path 1p in each winding slot that extends through the iron core 1 along the axial direction A (including approximately along the axial direction A), so that the first annular cavity 3p formed by the first annular component 3 and the second annular cavity 4p formed by the second annular component 4 are connected via these axial flow paths 1p, and the cooling fluid can flow between the first annular cavity 3p and the second annular cavity 4p via the axial flow paths 1p. Furthermore, the first extension portion 22 extends from the core 1 to one axial side of the core 1 , and the second extension portion 23 extends from the core 1 to the other axial side of the core 1 .

[0038] In this embodiment, as shown in Figures 1 to 4, the first annular component 3 is fixedly mounted on the iron core 1 and is located on one axial side of the iron core 1. The first annular component 3 extends continuously along the entire circumference, and the first annular component 3 includes a first annular outer peripheral wall 31, a first annular inner peripheral wall 32, and a first side wall 33 that are formed as one body. The first annular outer peripheral wall 31 is located radially outside the first annular inner peripheral wall 32, and the two are spaced apart in the radial direction R. The first side wall 33 is connected to one axial side end of the first annular outer peripheral wall 31 and the first annular inner peripheral wall 32, thereby forming a first annular cavity 3p for accommodating the first extension portion 22 of the winding 2, as shown in Figure 4, so that when the first annular cavity 3p is filled with cooling fluid, the first extension portion 22 can be immersed in the cooling fluid. Furthermore, the first sidewall 33 of the first annular component 3 is formed with a first inlet 3i, which communicates with the first annular cavity 3p, allowing cooling fluid to enter the first annular cavity 3p through the first inlet 3i. Furthermore, when the motor stator assembly is installed with the axial direction A parallel to the horizontal plane, the first inlet 3i is located at the bottom of the first annular component 3 in the vertical direction. Because the exhaust port 4o described later is located at the top of the second annular component 4 in the vertical direction, this configuration facilitates the cooling fluid entering the first annular cavity 3p through the first inlet 3i to fully fill the first annular cavity 3p.

[0039] In this embodiment, as shown in Figures 1 to 4, the second annular component 4 is fixedly mounted on the iron core 1 and is located on the other axial side of the iron core 1. The second annular component 4 extends continuously along the entire circumference, and the second annular component 4 includes a second annular outer peripheral wall 41, a second annular inner peripheral wall 42, and a second side wall 43 formed as one body. The second annular outer peripheral wall 41 is located radially outside the second annular inner peripheral wall 42, and the two are spaced apart in the radial direction R. The second side wall 43 is connected to the other axial side ends of the second annular outer peripheral wall 41 and the second annular inner peripheral wall 42, thereby forming a second annular cavity 4p for accommodating the second extension portion 23 of the winding 2, as shown in Figure 4, so that when the second annular cavity 4p is filled with cooling fluid, the second extension portion 23 can be immersed in the cooling fluid. Furthermore, on the one hand, the second sidewall 43 of the second annular component 4 also forms a second inlet 4i that is open toward one axial side. The second inlet 4i communicates with the second annular cavity 4p, allowing cooling fluid to enter the second annular cavity 4p through the second inlet 4i. On the other hand, the second annular outer wall 41 of the second annular component 4 also forms an outlet 4o that communicates with the second annular cavity 4p, allowing cooling fluid to be discharged from the second annular cavity 4p through the outlet 4o. Furthermore, when the motor stator assembly is installed with the axial direction A parallel to the horizontal plane, the second inlet 4i is located at the bottom of the second annular component 4 in the vertical direction, and the outlet 4o is located at the top of the second annular component 4 in the vertical direction. This configuration facilitates the cooling fluid that enters the second annular cavity 4p through the second inlet 4i to fill the second annular cavity 4p.

[0040] In this embodiment, as shown in Figures 1 to 4, a busbar 5 extends from the winding 2 through the outlet 4o, thereby enabling the winding 2 to be electrically connected to an external power source via the busbar 5. The structure of the busbar 5 can be adaptively adjusted based on the desired circuit topology of the winding 2 (e.g., a Y-shaped topology or a delta-shaped topology) and the number and connection relationship of the sub-windings.

[0041] By adopting the above solution, the first annular component 3 forms a first annular cavity 3p for accommodating the first extension 22 of the winding 2, and the second annular component 4 forms a second annular cavity 4p for accommodating the second extension 23 of the winding 2. The first annular cavity 3p and the second annular cavity 4p are connected by an axial flow path 1p within the winding slots of the iron core 1. As a result, cooling fluid entering the first annular cavity 3p through the first inlet 3i primarily cools the first extension 22. The cooling fluid in the first annular cavity 3p then flows through the axial flow path 1p into the second annular cavity 4p before being discharged through the outlet 4o. Cooling fluid entering the second annular cavity 4p through the second inlet 4i first cools the second extension 23 before being discharged through the outlet 4o. Furthermore, by providing only one outlet 4o, the cooling fluid entering through the inlets 3i and 4i can flow through the entire stator assembly of the motor before being discharged through the outlet 4o. In this way, the cooling structure of the motor stator assembly effectively improves the cooling effect on at least the extended portions 22 and 23 of the winding 2 of the motor stator assembly, thereby reducing the adverse effects that may arise from excessive temperatures during operation of the motor stator assembly. Compared to conventional cooling structures, the cooling structure of the motor stator assembly of the present application requires minimal modification, eliminating the need for complex structural adjustments and thus saving associated costs.

[0042] In addition, the present application also provides a motor including the motor stator assembly described above and a vehicle power system including the motor.

[0043] The motor according to the present application can be a centralized winding motor or a distributed winding motor. As shown in Figure 4, the motor mainly includes a housing, the above-mentioned motor stator assembly, a motor rotor and a shaft. The motor stator assembly, the motor rotor and the shaft can be configured in a coaxial manner and are basically located in the space surrounded by the housing. The motor stator assembly is fixed to the housing. The motor rotor is located radially inward of the motor stator assembly and can rotate relative to the motor stator assembly. There is an air gap between the motor rotor and the motor stator assembly. The shaft and the motor rotor can be fixed together, and the shaft is located radially inward of the motor rotor. Furthermore, since the above-mentioned cooling structure is provided, cooling oil is used as a cooling fluid to cool the iron core 1 and the winding 2 of the motor stator assembly. Therefore, the motor according to the present application is an oil-cooled motor. Moreover, effective cooling of the motor stator assembly can increase the continuous output power of the motor while increasing the service life of the motor.

[0044] As shown in Figure 4 , the vehicle power system according to one embodiment of the present application is an electric bridge drive system. In addition to the motor according to the present application, the electric bridge drive system may also include a transmission mechanism, such as a transmission. The motor is coupled to the input shaft of the transmission to achieve bidirectional torque transmission. This electric bridge drive system can serve as the drive system for a pure electric vehicle or, in conjunction with an engine, form a hybrid power system for a hybrid vehicle.

[0045] It should be understood that the above embodiments are merely illustrative and are not intended to limit the present application. Those skilled in the art may, based on the teachings of this application, make various modifications and alterations to the above embodiments without departing from the scope of this application. The following is a supplementary explanation of the technical solution of this application.

[0046] i. It can be understood that in the technical solution of the motor of the present application, an oil supply system connected to the first inlet port 3i and the second inlet port 4i can be provided on the outside of the motor housing. The oil supply system can include a pump and an oil circuit (oil pipe), etc., so that cooling oil serving as a cooling fluid can be supplied to the cooling structure by using the oil supply system.

[0047] ii. In a variant example of the motor stator assembly of the present application, the inlet ports 3i, 4i can be formed at other locations such as the inner circumferential wall 32, 42 of the annular assembly, and the structures of other components can be appropriately changed so that the cooling fluid can flow smoothly into the annular cavities 3p, 4p through the inlet ports 3i, 4i and then be discharged.

[0048] iii. In the above embodiment, the discharge port 4o is formed in the second annular component 4, but the present application is not limited thereto. In other optional solutions, the discharge port 4o can be formed in the first annular component 3, or the discharge port 4o can be formed in the central portion of the iron core 1 and communicate with the axial flow path 1p. When the discharge port 4o is formed in the central portion of the iron core 1, the discharge port 4o can communicate with all axial flow paths 1p through an annular groove formed in the iron core 1.

[0049] iv. When the technical solution of the present application is adopted, it is found through thermal simulation experiments that the temperature of the hottest part of the motor stator assembly is greatly reduced (for example, by 11 degrees), thereby improving the cooling effect of the motor stator assembly and effectively cooling the motor stator assembly.

Claims

1. A motor stator assembly, comprising: An iron core (1) having a plurality of winding slots spaced apart and distributed in a circumferential direction thereof; A winding (2) is mounted on the iron core (1), and the winding (2) includes an in-slot portion (21), a first protruding portion (22), and a second protruding portion (23), wherein the in-slot portion (21) is located in the winding slot, the first protruding portion (22) protrudes from the iron core (1) to one axial side of the iron core (1), and the second protruding portion (23) protrudes from the iron core (1) to the other axial side of the iron core (1); a first annular component (3) mounted on the iron core (1) and located on one axial side of the iron core (1), the first annular component (3) being formed with a first annular cavity (3p) for accommodating the first protruding portion (22) and a first inlet (3i) communicating with the first annular cavity (3p); and a second annular component (4) mounted on the iron core (1) and located on the other axial side of the iron core (1), the second annular component (4) being formed with a second annular cavity (4p) for accommodating the second extension portion (23) and a second inlet (4i) communicating with the second annular cavity (4p); The motor stator assembly is further formed with an exhaust port (4o), so that the cooling fluid entering through the first inlet port (3i) cools at least the first protruding portion and then is exhausted from the exhaust port (4o), and the cooling fluid entering through the second inlet port (4i) cools at least the second protruding portion and then is exhausted from the exhaust port (4o).

2. The motor stator assembly according to claim 1, characterized in that In each of the winding grooves, an axial flow path (1p) is formed that communicates the first annular cavity (3p) and the second annular cavity (4p).

3. The motor stator assembly according to claim 2, characterized in that: The exhaust port (4o) is formed in one of the first annular component (3) and the second annular component (4), so that the cooling fluid entering through the first inlet port (3i) or the second inlet port (4i) flows through the axial flow path (1p) and then is discharged from the exhaust port (4o).

4. The motor stator assembly according to claim 3, characterized in that: In an installation posture where the axial direction (A) of the motor stator assembly is parallel to a horizontal plane, the discharge port (4o) is formed at the top of one of the first annular assembly (3) and the second annular assembly (4).

5. The motor stator assembly according to claim 4, characterized in that: The winding (2) further comprises a busbar (5), through which the winding (2) can be electrically connected to an external power source, and the busbar (5) extends from the winding (2) to the outside through the discharge port (4o).

6. The motor stator assembly according to claim 2, characterized in that: The discharge port (4o) is formed in the iron core (1), and the discharge port (4o) is communicated with all the axial flow paths (1p).

7. The motor stator assembly according to any one of claims 1 to 6, characterized in that: In the installation posture where the axial direction (A) of the motor stator assembly is parallel to the horizontal plane, The first inlet (3i) is located at the bottom of the first annular component (3) in the vertical direction, and / or the second inlet (4i) is located at the bottom of the second annular component (4) in the vertical direction.

8. The motor stator assembly according to claim 7, characterized in that: The first annular component (3) comprises a first annular peripheral wall (31, 32) and a first side wall (33), wherein the first annular peripheral wall (31, 32) and the first side wall (33) surround and form the first annular cavity (3p), and the first inlet (3i) is formed on the first side wall (33), and The second annular component (4) comprises a second annular peripheral wall (41, 42) and a second side wall (43), wherein the second annular peripheral wall (41, 42) and the second side wall (43) surround and form the second annular cavity (4p), and the second inlet (4i) is formed on the second side wall (43).

9. An electric motor comprising the electric motor stator assembly according to any one of claims 1 to 8.

10. A vehicle power system comprising the motor according to claim 9.

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