CN107786022B - Square wire stator and cross wire insulating support thereof - Google Patents

Square wire stator and cross wire insulating support thereof Download PDF

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Publication number
CN107786022B
CN107786022B CN201610770874.4A CN201610770874A CN107786022B CN 107786022 B CN107786022 B CN 107786022B CN 201610770874 A CN201610770874 A CN 201610770874A CN 107786022 B CN107786022 B CN 107786022B
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Prior art keywords
winding
wire
square
insulation support
stator
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CN107786022A (en
Inventor
侯志刚
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Prestolite Electric Beijing Ltd
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Prestolite Electric Beijing Ltd
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    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K3/00Details of windings
    • H02K3/46Fastening of windings on the stator or rotor structure
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K3/00Details of windings
    • H02K3/04Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02TCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00Road transport of goods or passengers
    • Y02T10/60Other road transportation technologies with climate change mitigation effect
    • Y02T10/64Electric machine technologies in electromobility

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Insulation, Fastening Of Motor, Generator Windings (AREA)

Abstract

The invention discloses a square wire stator and a cross wire insulating support thereof, wherein the cross wire insulating support is connected to the square wire stator, the square wire stator is provided with a stator core and square wire windings wound on the stator core, the square wire winding comprises winding welding ends and phase wire outlet ends led out from the winding welding ends, the winding welding ends comprise a plurality of coil square wires, the cross wire insulating support is arranged at the winding welding ends and is provided with a plurality of separation parts and a plurality of wire outlet end holes, the separation parts are arranged between adjacent coil square wires so as to separate the coil square wires, and the phase wire outlet ends are respectively penetrated out from the wire outlet end holes and then connected. The invention not only prevents the short circuit between welding spots of each phase terminal of the square wire stator, but also is beneficial to the overline connection between phase leads, and simultaneously avoids the direct contact between the overline and other stator winding leads, thereby preventing the short circuit between phases or turns.

Description

Square wire stator and cross wire insulating support thereof
Technical Field
The present invention relates to a stator for a motor vehicle rotating electrical machine, and more particularly, to a square wire stator for a rotating electrical machine, and a flying lead insulation support for the square wire stator.
Background
In order to improve the output power and the power density of the existing motor vehicle rotating electric machines, especially automotive alternators, square wire winding stators are commonly used for improving the slot filling rate of the stators, so that the output power is increased. The winding of each phase of the square-wire stator is wound by a preset winding method, and all slot leads are needed to be connected with the phase winding by welding at one end of the stator winding, so that the stator with welded multi-phase windings forms a comb-like structure at one end; the phase windings then also need to be connected by an end-to-end connection or a neutral connection, which necessarily requires an overline connection.
In order to prevent the solder joint from being shorted during transportation or use, the conventional method is to apply epoxy glue or insulating paint to insulate and protect the solder joint. One of the disadvantages of using the method is that the stator is easy to collide during transportation, transportation or installation, and the resin adhesive and the insulating paint on the surface are easy to fall off or damage; the other disadvantage is that the glue and the insulating paint on the surface of the stator often age and fall off under the conditions of high temperature or rain and the like in the use of the vehicle, and mud water and the like accumulated between welding spots cause early short circuit failure of the stator.
Also, to prevent inter-phase and inter-turn shorts caused by the flying lead connection, the flying lead is usually fixed by being coated with an adhesive, and the surface is also required to be coated with epoxy glue or resin paint. This also presents the drawbacks described above.
Disclosure of Invention
The invention aims to provide a cross-wire insulating support and a square-wire stator with the cross-wire insulating support, which solve the problems of direct contact of cross wires and other stator winding leads, and phase-to-phase and turn-to-turn short circuits possibly occurring in the stator.
In order to achieve the above object, the jumper insulation support of the present invention is connected to a square wire stator, the square wire stator has a stator core and square wire windings wound around the stator core, the square wire winding includes a winding welding end and a phase wire outlet end led out from the winding welding end, the winding welding end includes a plurality of coil square wires, wherein the jumper insulation support is disposed at the winding welding end and has a plurality of separation parts and a plurality of wire outlet end holes, the separation parts are located between adjacent coil square wires to separate the coil square wires from each other, and the phase wire outlet ends are connected after passing out from the wire outlet end holes, respectively.
In an embodiment of the above-mentioned flying lead insulation support, the flying lead insulation support is in a circular arc shape, is locally arranged along a circumferential direction of the winding welding end, and is arranged around the winding welding end with the phase outgoing end.
In an embodiment of the above-mentioned flying lead insulation support, the flying lead insulation support is in a ring shape and is disposed along the whole circumference of the welding end of the winding.
In an embodiment of the above-mentioned flying lead insulation support, the flying lead insulation support is split into a plurality of segments along a circumferential direction of the winding welding end.
In an embodiment of the above-mentioned line-crossing insulating support, the line-crossing insulating support further includes a body portion and a receiving hole portion, the receiving hole portion is disposed on the body portion to receive each of the coil square lines, and the partition portion is formed between adjacent receiving hole portions.
In an embodiment of the above-mentioned flying lead insulation support, the insulation support further includes a top portion, and the partition portion is a bump extending from the top portion.
In an embodiment of the above-mentioned jumper insulation support, the jumper insulation support further includes an outer side wall portion, and the outer side wall portion is connected to the outer side of the partition portion and wraps the circumferential outer side of the winding welding end.
In an embodiment of the above-mentioned overline insulating support, the winding wire comprises a winding wire, and the winding wire comprises a winding wire welding end, wherein the winding wire is welded on the winding wire, and the winding wire is welded on the winding wire.
In an embodiment of the above-mentioned overline insulating support, the separating portion has a length c along a radial direction of the winding welding end, and the length c is not less than half of a square wire width d of the square wire winding.
The square wire stator comprises a cross wire insulation support, a stator core and a square wire winding wound on the stator core, wherein the square wire winding comprises a winding welding end and a phase outlet end led out from the winding welding end, and the winding welding end comprises a plurality of coil square wires, and the cross wire insulation support is the cross wire insulation support.
The invention has the beneficial effects that the short circuit between welding spots of each phase terminal of the square wire stator is prevented, the cross wire connection between phase leads is facilitated, meanwhile, the direct contact between the cross wire and other stator winding leads is avoided, and the short circuit between phases or turns is prevented.
The jumper insulating support can adopt a split structure, and is convenient to install and manufacture.
The invention will now be described in more detail with reference to the drawings and specific examples, which are not intended to limit the invention thereto.
Drawings
Fig. 1 is a schematic perspective view of a square-wire stator according to a first embodiment of the present invention;
fig. 2 is a front view of a first embodiment of a square-wire stator of the present invention;
FIG. 3 is a cut-away view of a stator winding of a square wire stator of the present invention;
FIG. 4 is an enlarged view of a portion of a stator winding of a square wire stator of the present invention;
fig. 5 is a front view of a first embodiment of the flying lead insulation support of the present invention;
fig. 6 is an enlarged view of a portion of a first embodiment of the flying lead insulation support of the present invention;
fig. 7 is a schematic perspective view of a first embodiment of a flying lead insulation support according to the present invention;
fig. 8 is a schematic perspective view of a square-wire stator according to a second embodiment of the present invention;
fig. 9 is a schematic perspective view of a second embodiment of a flying lead insulation support according to the present invention;
fig. 10 is a schematic perspective view of a third embodiment of a square-wire stator according to the present invention;
fig. 11 is a schematic perspective view of a third embodiment of a flying lead insulation support according to the present invention;
fig. 12 is a schematic perspective view of a fourth embodiment of a square wire stator according to the present invention;
fig. 13 is a schematic perspective view of a fourth embodiment of a flying lead insulation support according to the present invention;
fig. 14 is a front view of a fifth embodiment of the flying lead insulation support of the present invention.
Wherein reference numerals are used to refer to
100. Square wire stator
110. Stator core
111. Stator tooth
112. Stator groove
120. Square wire winding group
121. Winding welding end
122. Winding bending end
123. Phase outlet end
123U U phase outlet end
123V V phase outlet end
123W W phase outlet end
130. 230, 330, 430, 530 overline insulation support
131. 231, 331, 431 partitions
132. 232, 332 top
133. Outer side wall
134. 234 inner peripheral portion
135. 235, 335, 435 wire outlet end hole
140. Slot insulating paper
241. 243U phase head terminal
242. 244U phase tail end
432. Body part
433. Accommodation hole part
Detailed Description
The following detailed description of the present invention is provided with reference to the accompanying drawings and specific embodiments, so as to further understand the purpose, the scheme and the effects of the present invention, but not to limit the scope of the appended claims.
As shown in fig. 1 to 7, a square-wire stator 100 of a rotary electric machine for a vehicle according to the present invention includes: stator core 110, square wire winding 120, and flying lead insulation support 130. The stator core 110 is formed by stacking or winding a plurality of steel plates in the axial direction into a cylindrical structure. In the radially inner surface of the stator core 110, stator tooth portions 111 and stator slot portions 112 (refer to fig. 4) are formed which are uniformly arranged in the circumferential direction of the stator core 110 at a constant pitch.
The square wire winding 120 is wound on the stator core 110 according to a certain rule, and the square wire winding 120 has a slot receiving portion and a coil end portion. The slot receiving portion is accommodated in the stator slot portion 112 of the stator core. The coil end portion includes a winding welding end 121 and a winding bending end 122, which extend from the respective groove receiving portions toward both sides in the circumferential direction, one side coil ends are connected to each other by welding to form a comb-tooth (Hair-pin) shaped winding welding end 121, and one side coil ends are arranged uniformly by bending to form winding bending ends 122. The winding welding end 121 has a plurality of coil square wires forming a comb tooth shape. The square wire winding 120 further includes a phase lead-out terminal 123, the phase lead-out terminal 123 leading from the winding weld terminal 121.
The square wire stator 100 of the present invention adds a flying lead insulation support 130, which also has a "comb tooth" feature, at the winding weld end 121, and all of the phase outgoing wire ends 123 exit from the winding weld end 121 of the square wire winding 120 and pass through the flying lead insulation support 130. Thus, the short circuit between welding spots is prevented, the overline connection between phase leads is facilitated, meanwhile, the direct contact between the overline and other stator winding leads is avoided, and the inter-phase or inter-turn short circuit is prevented.
Specifically, the flying lead insulation support 130 is disposed at the winding welding end 121, and has a plurality of partitions and a plurality of wire outlet end holes, the partitions are disposed between adjacent coil square wires of the winding welding end 121 to separate the coil square wires from each other, and the wire outlet ends 123 are respectively connected after passing out from the wire outlet end holes of the flying lead insulation support 130.
The flying lead insulation support of the present invention will be described in more detail with reference to the following examples.
First embodiment
The square-wire stator 100 further includes slot insulating paper 140 (see fig. 1 and 4), and the slot insulating paper 140 is interposed between the square-wire winding 120 and the inner wall gap of the stator slot 112 of the stator core 110 to form an "S" shape.
The square wire winding 120 is formed by connecting wires of the stator groove 112 in a predetermined manner. In this embodiment, the stator core 110 has 96 slots, and after each of the molded wires is inserted into the stator slot 112 at five slots intervals, one end of the wire extending out of the stator core is connected to another molded wire, and the other molded wire is connected to the next molded wire, so that the two U-phase head and tail terminals 241 and 242 extend after being sequentially inserted and connected clockwise. Similarly, adjacent grooves are inserted with the same formed wire and connected in this way, and also extend out of the two U-phase head and tail terminals 243 and 244. Thus, the ends 242 and 244 of two adjacent slots are connected to form the U-phase output end 123U of the U-phase winding, and the V-phase output end 123V and the W-phase output end 123W can be formed in the same manner.
As described above, the square-wire stator wire is formed to have the front winding welding end 121 protruding from one axial end surface of the stator core 110 and the rear winding bending end 122 protruding from the other axial side of the stator core 110 during insertion and connection to form the stator winding 120, wherein the formed slot receiving portion without leakage is enclosed by the stator core 110.
As shown in fig. 1 and 2, the U-phase wire end 123U, V and the W-phase wire end 123V of the square wire winding 120 are disposed at the winding welding end 121 of the square wire winding 120, and since the winding welding end 121 forms a regular "hair-pin" shape (as shown in fig. 3), a split type flying lead insulation bracket 130 having a "comb tooth" feature is added to the winding welding end 121 of the square wire winding 120, so that various connections of the stator can be achieved after each phase wire end 123 of the square wire winding 120 passes through the flying lead insulation bracket 130.
As shown in fig. 2 and 7, the flying lead insulation support 130 includes a partition 131, a top 132, an outer peripheral portion 133, and an inner peripheral portion 134. The top 132 is in a circular ring shape, the separating parts 131 are protruding blocks extending from the top 132 and are in a comb tooth shape like the winding welding ends 121, and each separating part 131 is positioned between adjacent coil square wires in the comb tooth shape of the winding welding ends 121 so as to separate the coil square wires from each other. The outer side wall portion 133 and the inner side wall portion 134 are annular shapes corresponding to the outer circumference and the inner circumference of the winding welding end 121. The outer wall portion 133 is connected to the outside of the partition portion 131, and covers the circumferential outer sides of the coil square wires of the winding weld end 121. The inner side wall portion 134 is connected to the inner side of the top portion 132 and covers the inner side in the circumferential direction of each coil square wire of the winding weld end 121. The overline insulating holder 130 further includes wire outlet holes 135, and the wire outlet holes 135 are in one-to-one correspondence with the respective phase wire outlet ends 123 led out from the winding welding ends 121 of the square wire winding 120.
In this embodiment, the jumper insulation brackets 1303 are arranged along the entire circumference of the winding welding ends 121, and are of a split type structure, and are split into multiple segments along the circumference of the winding welding ends 121.
As shown in fig. 5, the flying lead insulation support 130 is composed of three parts P1, P2, P3, each arranged along the circumferential direction of the square wire winding 120. Wherein, the diameter Φh of the inner side wall of the outer peripheral portion 133 is larger than the outer circular diameter of the winding welding end 121 of the square wire winding 120, and the diameter Φg of the outer side wall of the inner peripheral portion 134 is smaller than the inner circular diameter of the winding welding end 121. As shown in fig. 4 and 6, the interval e of the adjacent spacers 131 of the flying lead insulating holder 130 is greater than the width f of the square coil of the winding welding end 121, and the tooth angle a of the spacers 131 of the flying lead insulating holder 130 is equal to or smaller than the angle B of the adjacent coil Fang Xianjian of the winding welding end 121. Thus, the mounting of the flying lead insulation support 130 is facilitated without interference with the square wire winding 120.
In order to better perform the functions of insulating and positioning the winding wire, the distance part 131 of the jumper insulating support 130 has a length c along the radial direction of the winding welding end 121, the length c is not smaller than the width d/2 of the square coil wire of the winding welding end 121, and the depth of the distance part 131 of the jumper insulating support 130 in the axial direction of the winding welding end 121 is not smaller than the wire stripping height of the winding welding end 121, so that the winding is effectively isolated, and inter-phase short circuit is prevented.
Because all the phase wire outlets 123 of the square wire winding 120 pass through the phase wire outlet holes 135 of the overwire insulating support 130, overwire connection between the wire outlet terminals is easy, overwire welding can be performed on the upper surface of the top 132 of the overwire insulating support 130 by using square wires, direct contact between the overwires and other stator winding leads is avoided, and inter-phase or inter-turn short circuits are prevented.
The jumper insulation support 130 is injection molded from a thermoplastic material, such as PPS, etc. It is mounted to the winding weld end 121 of the square wire winding 120 prior to stator varnish impregnation. After the stator is painted, the crossover insulation support 130 may be secured to the winding weld 121. The flying lead insulating holder 130 can also prevent short circuits of the winding wire due to severe collision deformation in the later transportation or transportation.
Second embodiment
As shown in fig. 8 and 9, in the present embodiment, the flying lead insulation support 230 is also composed of three parts, and the flying lead insulation support 230 includes a partition 231, a top 232, and an inner peripheral portion 234. The top 232 is in a circular ring shape as a whole, the separation parts 231 are protruding blocks extending from the top 232 and are in a comb tooth shape as the same as the winding welding ends 121 as a whole, and each separation part 231 is positioned between adjacent coil square wires in the comb tooth shape of the winding welding ends 121 so as to separate the coil square wires from each other. The inner side wall 234 is connected to the inner side of the top 232 and covers the inner side in the circumferential direction of each coil square wire of the winding weld end 121. The jumper insulation support 230 further includes wire outlet holes 235, and the wire outlet holes 235 are in one-to-one correspondence with the wire outlet ends 123 of each phase of the square wire winding 120.
Compared to the first embodiment, the jumper insulation support 230 of the present embodiment omits the outer side wall portion, which is more beneficial to the installation of the jumper insulation support 230 and is more beneficial to the heat dissipation of the square wire winding 120.
Third embodiment
As shown in fig. 10 and 11, in the present embodiment, the flying lead insulation support 330 is also composed of three parts, and the flying lead insulation support 330 includes a partition 331 and a top 332. The top 332 is generally annular, the separating portions 331 are protruding blocks extending from the top 332 and are generally comb-shaped like the winding welding ends 121, and each separating portion 331 is located between adjacent coil square wires of the winding welding ends 121 in the comb-shaped form, so that the coil square wires are separated from each other. The jumper insulation support 230 further includes wire outlet holes 235, and the wire outlet holes 235 are in one-to-one correspondence with the wire outlet ends 123 of each phase of the square wire winding 120.
Compared to the second embodiment, the jumper insulation support 330 of the present embodiment eliminates the inner side wall, which is more beneficial to the installation of the jumper insulation support 330 and the heat dissipation of the square wire winding 120.
Fourth embodiment
As shown in fig. 12 and 13, in the present embodiment, the spacing portion 431 of the flying lead insulating holder 430 is elongated to be integrally connected to the inside, thereby forming a ring-shaped grill. Specifically, the jumper insulating holder 430 includes a body portion 432 and a receiving hole portion 433, the receiving hole portion 433 is disposed on the body portion 432 to receive each coil square wire, and a partition portion 431 is formed between adjacent receiving hole portions 433. The wire outlet holes 435 are in one-to-one correspondence with the wire outlet ends 123 of each phase of the square wire winding 120, and the wire outlet holes 435 are overlapped or partially overlapped with the accommodating hole parts 433.
Fifth embodiment
As shown in fig. 14, in the present embodiment, the jumper insulation support 530 is the same as that of the first embodiment, but it is not entirely circumferentially distributed over the end face of the winding welding end 121, but is only partially disposed along the circumference of the winding welding end 121, and is partially disposed around the phase wire end 123, that is, where jumper connection is not required may be omitted.
The flying lead insulation support in the second to fourth embodiments may also be provided in a circular arc shape.
Of course, the present invention is capable of other various embodiments and its several details are capable of modification and variation in light of the present invention, as will be apparent to those skilled in the art, without departing from the spirit and scope of the invention as defined in the appended claims.

Claims (10)

1. The square wire winding comprises a winding welding end and a phase wire outlet end led out from the winding welding end, wherein the winding welding end comprises a plurality of coil square wires.
2. The flying lead insulation support according to claim 1, wherein the flying lead insulation support is in a circular arc shape, is partially arranged along a circumference of the winding welding end, and is arranged around the winding welding end having the phase outgoing terminal.
3. The flying lead insulation support of claim 1, wherein the flying lead insulation support is annular and is disposed along the entire circumference of the winding weld end.
4. A flying lead insulation support according to claim 3, wherein the flying lead insulation support is split into a plurality of segments along the circumference of the winding weld end.
5. The flying lead insulation support of claim 1, further comprising a body portion and a receiving hole portion provided on the body portion to receive each of the coil square wires, the partition portion being formed between adjacent receiving hole portions.
6. The flying lead insulation support of claim 1, further comprising a top portion, the divider being a tab extending from the top portion.
7. The flying lead insulation support of claim 6, further comprising an outer peripheral portion connected to an outer side of the partition portion and covering a circumferential outer side of the winding weld end.
8. The flying lead insulation support of claim 6, further comprising an inner side wall portion connected to an inner side of the top portion and surrounding a circumferential inner side of the winding weld end.
9. The flying lead insulation support of claim 6, wherein the divider has a length c in a radial direction of the winding weld end, the length c being not less than half a square wire width d of the square wire winding.
10. A square wire stator comprising a cross wire insulating support, a stator core and a square wire winding wound on the stator core, wherein the square wire winding comprises a winding welding end and a phase outlet end led out from the winding welding end, and the winding welding end comprises a plurality of coil square wires.
CN201610770874.4A 2016-08-30 2016-08-30 Square wire stator and cross wire insulating support thereof Active CN107786022B (en)

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CN201610770874.4A CN107786022B (en) 2016-08-30 2016-08-30 Square wire stator and cross wire insulating support thereof

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Application Number Priority Date Filing Date Title
CN201610770874.4A CN107786022B (en) 2016-08-30 2016-08-30 Square wire stator and cross wire insulating support thereof

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CN107786022B true CN107786022B (en) 2023-08-25

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN109067053B (en) * 2018-07-26 2023-09-15 珠海格力电器股份有限公司 Stator framework, stator, assembly method of stator and magnetic suspension bearing
DE102019207665A1 (en) * 2018-09-26 2020-03-26 Zf Friedrichshafen Ag Isolation unit for an electrical machine

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WO2009102015A1 (en) * 2008-02-14 2009-08-20 Hitachi, Ltd. Coil, rotary electric machine, and method of manufacturing rotary electric machine
CN103532280A (en) * 2012-06-20 2014-01-22 法雷奥电机设备公司 Interconnector for stator of an electric machine and associated electric machine stator
CN104836387A (en) * 2014-12-19 2015-08-12 广东威灵电机制造有限公司 Motor
CN105226864A (en) * 2015-11-10 2016-01-06 珠海凯邦电机制造有限公司 Plastic packaging stator and Insulating frame, plastic packaging motor
CN206023412U (en) * 2016-08-30 2017-03-15 北京佩特来电器有限公司 A kind of side's line stator and its cross-line insulating support

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Publication number Priority date Publication date Assignee Title
WO2009102015A1 (en) * 2008-02-14 2009-08-20 Hitachi, Ltd. Coil, rotary electric machine, and method of manufacturing rotary electric machine
CN103532280A (en) * 2012-06-20 2014-01-22 法雷奥电机设备公司 Interconnector for stator of an electric machine and associated electric machine stator
CN104836387A (en) * 2014-12-19 2015-08-12 广东威灵电机制造有限公司 Motor
CN105226864A (en) * 2015-11-10 2016-01-06 珠海凯邦电机制造有限公司 Plastic packaging stator and Insulating frame, plastic packaging motor
CN206023412U (en) * 2016-08-30 2017-03-15 北京佩特来电器有限公司 A kind of side's line stator and its cross-line insulating support

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