CN109586455B

CN109586455B - Stator assembly and motor and vehicle with same

Info

Publication number: CN109586455B
Application number: CN201710910210.8A
Authority: CN
Inventors: 陈晓平; 陈园辉; 游斌
Original assignee: BYD Co Ltd
Current assignee: BYD Co Ltd
Priority date: 2017-09-29
Filing date: 2017-09-29
Publication date: 2021-11-12
Anticipated expiration: 2037-09-29
Also published as: WO2019062897A1; CN109586455A

Abstract

The invention discloses a stator assembly, a motor with the same and a vehicle, wherein the stator assembly comprises: a cylindrical stator core having a plurality of stator slots arranged at intervals in a circumferential direction of the stator core; a stator winding including a plurality of conductor segments, each of the conductor segments including an in-slot portion disposed in a stator slot, a first end and a second end disposed outside the stator core, the in-slot portion being connected between the first end and the second end, the second ends of the plurality of conductor segments forming a welded end, a star point outgoing line of each phase of the stator winding being located on the welded end; and the neutral line circumferentially surrounds the welding end of the stator winding and is directly connected with the star point outgoing line of each phase. According to the stator assembly provided by the invention, the connection structure of the star point outgoing line and the neutral line can be simplified, the axial and radial spaces of the stator assembly occupied by the star point outgoing line and the neutral line are reduced, and the structure is compact.

Description

Stator assembly and motor and vehicle with same

Technical Field

The invention relates to the technical field of motors, in particular to a stator assembly, a motor with the stator assembly and a vehicle with the stator assembly.

Background

In the related art, the neutral wire has a UV connection wire connecting the neutral point connection portion of the U-phase winding with the neutral point connection portion of the V-phase winding, and a VW connection wire connecting the neutral point connection portion of the V-phase winding with the neutral point connection portion of the W-phase winding. The neutral line in the technology is formed by connecting two U-shaped lines with three connecting parts in pairs, so that the middle welding part is thick, the occupied space is large, and the welding performance is difficult to guarantee.

Disclosure of Invention

The present invention is directed to solving at least one of the problems of the prior art. Therefore, the invention provides the stator assembly, the star point outgoing line and the neutral line of the stator assembly are simply connected, and the occupied space is small.

A second aspect of the invention is directed to an electric machine having the stator assembly described above.

A third aspect of the invention is to propose a vehicle having the above-mentioned electric machine.

The stator assembly according to the present invention comprises: a cylindrical stator core having a plurality of stator slots arranged at intervals in a circumferential direction of the stator core; a stator winding including a plurality of conductor segments, each of the conductor segments including an in-slot portion disposed in a stator slot, a first end and a second end disposed outside the stator core, the in-slot portion being connected between the first end and the second end, the second ends of the plurality of conductor segments forming a welded end, a star point outgoing line of each phase of the stator winding being located on the welded end; and the neutral line circumferentially surrounds the welding end of the stator winding and is directly connected with the star point outgoing line of each phase.

According to the stator assembly, the neutral line is arranged, and the star point outgoing lines of all phases are directly connected with the neutral line, so that compared with the related technology, welding positions are reduced, the connection between the neutral line and the star point outgoing lines is more stable, the connection structure between the star point outgoing lines and the neutral line is simplified, the welding positions are reduced, the axial and radial spaces of the stator assembly occupied by the star point outgoing lines and the neutral line are reduced, the structure is compact, the space occupied by the shell and the end cover of the motor is reduced as much as possible, and the requirement of motor miniaturization is met.

In some embodiments of the invention, the conductor segments are rectangular in cross-section.

In some embodiments of the invention, the conductor segments are U-shaped conductor segments, the U-shaped conductor segments comprise a first in-slot portion and a second in-slot portion arranged in a stator slot, the first end is a U-bend connecting the first in-slot portion and the second in-slot portion, the U-bends in the plurality of U-shaped conductor segments form a hairpin end of the stator winding, and the second ends of the first in-slot portion and the second in-slot portion form a weld end of the stator winding.

In some embodiments of the present invention, each phase star point outgoing line of the stator winding is in surface contact with the neutral line and is fixed by welding.

In some embodiments of the invention, the wire ends of the star point outgoing wires of each phase of the stator winding extend outwards along the axial direction of the stator core and form axial protrusions, and the neutral wires are respectively connected with the axial protrusions.

Further, the axial protrusion exceeds an end of the weld end by a predetermined distance, and the predetermined distance is equal to or greater than a dimension of the neutral line in an axial direction of the stator core.

In some embodiments of the present invention, the line ends of the star point outgoing lines of each phase of the stator winding extend radially outward along the stator core and are bent by a predetermined angle to form radial protrusions, and the neutral lines are respectively connected to the radial protrusions.

Further, the radial protrusion exceeds a winding outermost layer of the weld end by a predetermined distance, which is equal to or greater than a dimension of the neutral wire in a stator core radial direction.

In some embodiments of the invention, the neutral line comprises an arc-shaped connector and a plurality of antennas, the plurality of antennas being respectively connected to the respective phase star point outgoing lines of the stator winding.

Further, the arc-shaped connecting piece has a gap between the radial direction and the radially outermost winding on the welding end.

An electric machine according to a second aspect of the invention comprises a stator assembly according to the first aspect of the invention.

According to the motor of the second aspect of the invention, the stator assembly of the first aspect of the invention is arranged, so that the overall performance of the motor is improved.

A vehicle according to a third aspect of the invention includes the motor according to the second aspect of the invention.

According to the vehicle of the third aspect of the invention, by providing the motor of the second aspect of the invention, the overall performance of the vehicle is improved.

Additional aspects and advantages of the invention will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the invention.

Drawings

The above and/or additional aspects and advantages of the present invention will become apparent and readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings of which:

FIG. 1 is a schematic view of a stator assembly according to an embodiment of the present invention with the wire ends of the star point lead-out wires extending upwardly;

FIG. 2 is a schematic view of a stator assembly according to an embodiment of the present invention with the wire ends of the star point outgoing wires bent outward;

FIG. 3 is a schematic illustration of the star point outlet and neutral connections shown in FIG. 2;

FIG. 4 is a schematic view of a stator assembly according to an embodiment of the present invention, wherein the neutral line has an antenna;

FIG. 5 is a schematic diagram of a star point outgoing line of a stator assembly according to an embodiment of the present invention connected to a neutral line, wherein the motor is three-phase and one for each phase, the neutral line being of an antennal type;

FIG. 6 is a schematic view of a stator assembly according to an embodiment of the present invention, wherein the antenna of the neutral line is a straight line;

FIG. 7 is a schematic view of a stator core in a stator assembly according to an embodiment of the present invention;

FIG. 8 is a schematic view of a U-shaped conductor segment of a stator assembly according to an embodiment of the present invention;

9 a-9 d are schematic views of first through fourth U-shaped conductor segments employed in winding a stator assembly in accordance with an embodiment of the present invention;

FIG. 10 is a schematic view of a stator assembly according to an embodiment of the present invention as an initial setup, illustrated with an 8-pole 48 slot 3 phase as an example;

FIG. 11 is a winding pattern diagram of the stator assembly of FIG. 10, illustrating a U-phase 1-path by way of example;

FIG. 12 is the final stator assembly of FIG. 10 after the stator assembly has been machined to form a 2-way connection;

fig. 13 is a final stator assembly of fig. 10 processed to form a 1-way wire connection.

Reference numerals:

the stator assembly 100 is provided with,

the stator core 1 is provided with a stator core,

the stator winding 2 is wound in a stator,

a conductor section 21, a U-shaped bend 211, a first in-slot portion 212, a second in-slot portion 213,

the length of the hairpin end 22, the weld end 23,

the star point outlet 24, the outlet 25,

the neutral line 3, the arc-shaped connecting piece 31, the antenna 32, the first connecting section 321, the second connecting section 322, the bent section 323 and the avoiding space 5.

Detailed Description

Reference will now be made in detail to embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like or similar reference numerals refer to the same or similar elements or elements having the same or similar function throughout. The embodiments described below with reference to the accompanying drawings are illustrative only for the purpose of explaining the present invention, and are not to be construed as limiting the present invention.

In the description of the present invention, it is to be understood that the terms "center", "length", "width", "thickness", "upper", "lower", "vertical", "horizontal", "top", "bottom", "inner", "outer", "axial", "radial", "circumferential", and the like, indicate orientations or positional relationships based on those shown in the drawings, and are used only for convenience in describing the present invention and for simplicity in description, and do not indicate or imply that the referenced device or element must have a particular orientation, be constructed and operated in a particular orientation, and thus, are not to be construed as limiting the present invention. Furthermore, the terms "first", "second" and "first" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of the present invention, "a plurality" means two or more unless otherwise specified.

In the description of the present invention, it should be noted that, unless otherwise explicitly specified or limited, the terms "mounted," "connected," and "connected" are to be construed broadly, e.g., as meaning either a fixed connection, a removable connection, or an integral connection; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meanings of the above terms in the present invention can be understood in specific cases to those skilled in the art.

A stator assembly 100 according to an embodiment of the present invention is described below with reference to fig. 1-6. The stator assembly 100 of the embodiment of the invention can be used in an m-phase motor, and m is 1, 2 and 3 … …. That is, the stator assembly 100 may be used for a one-phase motor, a two-phase motor, a three-phase motor, and the like. In the following, only the m-phase motor is taken as an example for description, and of course, it is obvious that those skilled in the art can understand that the m-phase motor is a technical scheme of other phase motors after reading the following technical scheme, and therefore, details are not described here.

As shown in fig. 1, a stator assembly 100 of an embodiment of the present invention includes a stator core 1, a stator winding 2, and a neutral wire 3.

Specifically, the stator core is cylindrical, and a plurality of stator slots are formed in the stator core 1; the stator slots are formed on the inner circumferential wall of the stator core 1 and penetrate the stator core 1 in the axial direction (for example, the up-down direction shown in fig. 1), and a plurality of stator slots are arranged at intervals in the circumferential direction of the stator core 1, the depth direction of the stator slots being in accordance with the radial direction of the stator core.

In one embodiment, the rotor of a three-phase electric machine comprises eight poles, and correspondingly the total number of stator slots provided on the stator core is 48.

The stator winding, stator winding 2 includes a plurality of conductor sections 21, and each conductor section 21 includes the in-slot portion that sets up in the stator slot of stator core, sets up first end and the second end outside the stator core, and the in-slot portion is connected between first end and second end, and the second end of a plurality of conductor sections 21 forms welding end 23, and the star point lead-out wire 24 of stator winding 2 each phase all is located welding end 23.

As shown in fig. 1, each conductor segment 21 includes: an in-slot portion (e.g., a first in-slot portion 212 and a second in-slot portion 213 described below) disposed in the stator slot, and a bend connecting the in-slot portion, which passes through the stator slot with its end (e.g., the upper end of the in-slot portion shown in fig. 1) beyond the stator core 1, and an end (e.g., the upper end of the in-slot portion shown in fig. 1) where the end of the in-slot portion is located forms the weld end 23 of the stator winding 2. The star point outgoing lines of the respective phases of the stator winding 2 are all located on the welding terminals 23, that is, the star point outgoing lines 24 of the respective phases of the stator winding 2 are all led out from the welding terminals 23.

Advantageously, the neutral wire 3 surrounds the weld terminals 23 of the stator winding 2 in the circumferential direction of the stator core, whereby the distance between the star point lead-out wires 24 and the neutral wire 3 can be reduced, facilitating the connection of the neutral wire 3 with the star point lead-out wires 24 of the weld terminals 23.

Further, the neutral line 3 is connected to the star point outgoing line 24 of each phase. That is, each phase star point outgoing line 24 is connected to the neutral line 3. Thus, the connection position of each star point outgoing line 24 and the neutral line 3 occupies a small space, and the connection mode is simpler.

Further, the star point outgoing line 24 of each phase of the stator winding 2 is directly connected to the neutral line 3. That is, the star point outgoing lines 24 are directly connected to the neutral line 3, and the plurality of star point outgoing lines 24 are connected together by being connected to the neutral line 3, rather than being indirectly connected to the neutral line 3 through an intermediate transition connector, in short, all the star point outgoing lines 24 in the stator winding 2 are directly connected together by using the neutral line 3, so that the number of welding positions is reduced, and the connection between the neutral line and the star point outgoing lines is more stable. Therefore, the connection is convenient, simple and quick. For example, each of the star point lines 24 in each of the phase windings in the stator winding 2 is directly welded to the neutral line 3.

One specific embodiment of a stator assembly 100 of the present invention is described below.

As shown in fig. 1 and 2, the stator assembly 100 of the present embodiment is used for a three-phase motor, and the stator winding 2 of the three-phase motor is a three-phase winding: the winding comprises a U-phase winding, a V-phase winding and a W-phase winding, wherein the number of parallel branches in each phase of winding is 2, namely 2 parallel branches are connected in parallel. Of course, the number of parallel branches of each phase of winding may be 1, 3, 4, or 5 or more, and so on. In the following, the number of parallel branches of each phase winding is only 2 for example, and it is obvious that a person skilled in the art can understand the technical scheme that the number of parallel branches of each phase winding is 1, 3, 4 or 5 after reading the following technical scheme, and therefore, detailed description is omitted here.

When the three-phase windings are connected in a Y-shape (i.e., star connection), one end of each path in each phase winding is an outgoing line 25 and the other end is a star point outgoing line 24, that is: the stator winding 2 has six outgoing lines 25 and six star point outgoing lines 24, the outgoing lines 25 are used for being electrically connected with an external circuit, and the star point outgoing lines are connected together to lead out a central line.

Specifically, as shown in fig. 2, the six outgoing lines 25 of the three-phase winding are respectively: a U-phase one-way outgoing line 25a, a U-phase two-way outgoing line 25b, a V-phase one-way outgoing line 25c, a V-phase two-way outgoing line 25d, a W-phase one-way outgoing line 25e, and a W-phase two-way outgoing line 25 f. Six star point outgoing lines 24 of the three-phase winding are respectively as follows: a U-phase one-star point line 24a, a U-phase two-star point line 24b, a V-phase one-star point line 24c, a V-phase two-star point line 24d, a W-phase one-star point line 24e, and a W-phase two-star point line 24 f.

Further, six star point outgoing lines 24 are respectively connected with the neutral line 3, that is, the star point outgoing line 24 of each phase is respectively connected with the neutral line 3.

In the related art, the neutral line has a UV connection line connecting the neutral point connection portion of the U-phase winding with the neutral point connection portion of the V-phase winding and a VW connection line connecting the neutral point connection portion of the V-phase winding with the neutral point connection portion of the W-phase winding, and the neutral line in the above-described technique is formed by connecting two lines of U-shaped lines with three connection portions two by two, respectively, which results in a thicker middle welding portion, a larger occupied space, and difficulty in ensuring welding performance. Therefore, in the embodiment of the present invention, the axial and radial spaces of the stator assembly 100 occupied by the connection portion between the neutral line 3 and the star point lead-out line 24 can be reduced, and the structure can be made more compact. And the connection mode is simple, and the batch production is convenient.

According to the stator assembly 100 provided by the embodiment of the invention, the neutral line 3 is arranged, and the star point outgoing lines 24 are respectively connected with the neutral line 3, so that the connection positions of three star point outgoing lines are connected with each other by two U-shaped lines instead of the prior art, the connection structure of the star point outgoing lines 24 and the neutral line 3 can be simplified, the welding positions are reduced, the axial and radial spaces of the stator assembly 100 occupied by the welding positions are reduced, the structure is compact, the space occupied by the shell and the end cover of the motor is reduced as much as possible, the requirement of motor miniaturization is met, and the connection of the neutral line and the star point outgoing lines is more stable.

In some embodiments, the conductor segments 21 are non-circular in cross-section. Preferably, the conductor segments 21 are rectangular in cross-sectional shape. The conductor segments 21 have a rectangular cross section perpendicular to their length direction, whereby the slot filling factor of the coil in the stator slot can be increased, i.e. by providing the conductor segments 21 with a rectangular cross section, more conductor segments 21 can be arranged in a stator slot of the same volume, thereby making the arrangement of a plurality of conductor segments 21 in the stator slot more compact. Of course, the conductor segments 21 may also have other shapes in cross-section perpendicular to their length direction, such as trapezoidal, etc.

In some embodiments, the conductor segment 21 may be a U-shaped conductor segment comprising a first in-slot portion and a second in-slot portion disposed in the stator slot, the first end being a U-shaped bend connecting the first in-slot portion and the second in-slot portion; the U-shaped bends in the plurality of U-shaped conductor segments form a hairpin end of the stator winding, and the second ends of the first in-slot portion and the second in-slot portion form a weld end of the stator winding.

As shown in fig. 1, the U-shaped conductor segments 21 each include: the stator core comprises a U-shaped bending part 211, a first in-slot part 212 and a second in-slot part 213, wherein the first in-slot part 212 and the second in-slot part 213 are arranged in the stator slot, the first in-slot part 212 and the second in-slot part 213 are respectively connected with the U-shaped bending part 211, and the end parts of the first in-slot part 212 and the second in-slot part 213 exceed the stator core 1 after penetrating through the stator slot. For example, as shown in fig. 3, the lower end of the first in-slot portion 212 and the lower end of the second in-slot portion 213 are both connected to the U-shaped bent portion 211, and the upper end of the first in-slot portion 212 and the upper end of the second in-slot portion 213 both pass through the stator slot and protrude out of the axial end portion of the stator core 1 (e.g., the upper end of the stator core 1 shown in fig. 1) to facilitate connection of the plurality of conductor segments 21.

In the present invention, for clarity of description, it is assumed that the end where the U-shaped bent part 211 in the plurality of conductor segments 21 is located is an upper end and the end where the ends of the first in-slot portion 212 and the second in-slot portion 213 are located is a welding end 23 of the stator winding 2, and the end where the welding end 23 is located is a lower end in the figure.

In some embodiments, when multiple star point outlets are included in each phase, the multiple star point outlets in each phase may be individually connected to the neutral line.

In addition, the multi-path star point outgoing lines in each phase can also be connected with the neutral line after being combined and connected. Specifically, the multiple star point leading-out wires in each phase can be directly welded or welded through a connecting strip.

For example, the line ends of the multiple star point outgoing lines in each phase extend vertically upwards, and the line ends of the multiple star point outgoing lines in each phase are welded and connected and then welded with the neutral line.

In some examples, each phase star point lead-out wire 24 of the stator winding 2 is in surface contact with the neutral wire 3 and is fixed by welding. Thereby, the connection efficiency and the connection reliability can be improved. Here, the surface contact of the star point outgoing line with the neutral line means that one side surface of the star point outgoing line is attached to and in contact with one side surface of the neutral line to increase a contact area between the star point outgoing line and the neutral line and improve reliability of welding. For example, the surface of the star point outgoing line on the side facing the neutral line and the surface of the neutral line on the side facing the star point outgoing line are brought into contact with each other and then welded together.

In some examples, as shown in fig. 1, the wire ends of the respective phase star point outgoing wires 24 of the stator winding 2 extend outward in the axial direction of the stator core (for example, in the upward direction shown in fig. 1) and form axial protrusions to which the neutral wires 3 are respectively connected.

Further, the axial protrusion exceeds the end of the weld end 23 by a predetermined distance, which is equal to or greater than the dimension of the neutral line 3 in the axial direction (e.g., the up-down direction in the drawing) of the stator core 1. Preferably, the predetermined distance is larger than the distance of the neutral line 3 in the axial direction of the stator core 1. Here, the dimension of the neutral line 3 in the axial direction of the stator core 1 means the height or dimension of the neutral line 3 in the axial direction of the stator core 1.

Further, the neutral wire is welded and fixed to the radially outer surface of the axial protrusion. The structure is simplified, welding is convenient, and the radial occupied space is reduced.

Specifically, as shown in fig. 1, in the up-down direction shown in fig. 1, the wire end of the star point lead-out wire 24 extends upward and its upper end face is higher than the upper end face of the solder terminal 23, and the distance between the upper end face of the star point lead-out wire 24 and the upper end face of the solder terminal 23 is not less than the height of the neutral wire 3 in the up-down direction. Thus, when the end of the star point outgoing line 24 and the neutral line 3 are connected to each other in the radial direction of the stator core 1, the outermost line at the weld end 23 and the neutral line 3 can be spaced apart from each other in the axial direction of the stator core 1, and interference can be avoided.

Here, the neutral wire 3 may be soldered to the end portion of the star point lead wire 24 or may be connected to the middle portion of the end portion, and there is no great difference in the electrical connection effect.

Preferably, as shown in fig. 1, each phase lead-out wire 25 of the stator winding is located at the radially outermost layer.

Preferably, as shown in fig. 1, each phase star point outgoing line 24 of the stator winding is located at the radially last outer layer, that is, the star point outgoing line 24 is located at the second outer layer of the stator winding 2 in the radial direction of the stator core 1.

Here, the positions of the star point lead wires and the positions of the lead wires depend on the winding method of the stator winding. The specific winding method adopted by the stator assembly of this embodiment will be described in detail below, and when the stator assembly of the embodiment of the present invention adopts the following winding method, and after the final winding is completed, each phase star point outgoing line is located on the next outer layer of the stator winding, and each phase outgoing line is located on the outermost layer of the stator winding. When other winding methods are adopted, the outgoing line of each phase star point can be positioned at the outermost layer of the stator winding.

In some examples, as shown in fig. 2 and 3, the wire ends of the respective phase star point outgoing wires 24 of the stator winding 2 may extend outward in the radial direction of the stator core 1 and be bent at a predetermined angle to form radial protrusions to which the neutral wires 3 are respectively connected. Thereby, the neutral wire 3 is facilitated to avoid the outermost wire on the weld end 23 in the radial direction of the stator core 1 to avoid interference.

When each phase comprises multiple paths of star point outgoing lines, the line ends of the multiple paths of star point outgoing lines in each phase can extend outwards along the radial direction of the stator core 1, are bent by a preset angle, are welded and connected, and then are welded with the neutral line. Thereby, the neutral wire 3 is facilitated to avoid the outermost wire on the weld end 23 in the radial direction of the stator core 1 to avoid interference.

Further, the radial protrusion exceeds the outermost winding layer of the weld end by a predetermined distance, which is equal to or greater than the dimension of the neutral wire in the radial direction of the stator core. Preferably, the predetermined distance is greater than a dimension of the neutral line in a radial direction of the stator core. Here, the dimension of the neutral line in the radial direction of the stator core means a thickness dimension of the neutral line in the radial direction of the stator core.

Further, the neutral line is welded and fixed to the radially outer surface of the radially protruding portion. The structure is simplified, welding is convenient, and the occupied space in the axial direction is reduced.

Furthermore, the outward extending and bending angle of each phase star point outgoing line 24 of the stator winding is 60-150 degrees. Furthermore, the angle of outward bending of each phase star point outgoing line 24 of the stator winding is 90 degrees.

The neutral line 3 is further described below with reference to the drawings.

In some embodiments, the neutral line 3 may be formed in the shape of an arc line segment, as shown in fig. 1 and 3. At this time, the segment-arc shaped neutral line 3 may be substantially parallel to the circumferential direction of the stator core 1 to facilitate connection of the neutral line 3 with a plurality of star point outgoing lines 24 spaced along the circumferential direction of the stator core 1.

Further, as shown in fig. 3, the cross section of the neutral line 3 perpendicular to the length direction thereof may be circular; the cross section of the neutral line 3 perpendicular to its length direction may also be rectangular, as shown in fig. 1. Of course, the present invention is not limited thereto, and the cross section of the neutral line 3 perpendicular to the longitudinal direction thereof may have other shapes such as an oblate shape, a polygonal shape, and the like.

As shown in fig. 4 and 5, in some embodiments, the neutral line 3 may include: the stator comprises an arc-shaped connecting piece 31 and a plurality of antennae 32, wherein the antennae 32 are respectively connected with each phase star point outgoing line 24 of the stator winding. Thereby, interference of the arc-shaped connection member 31 with the outermost winding of the weld terminal 23 can be avoided.

Further, the arc-shaped connection piece 31 has a gap between it and the radially outermost winding on the weld end 23 in the radial direction. Thereby, interference of the arc-shaped connection piece 31 with the radially outermost winding on the weld end 23 can be further avoided.

The neutral line 3 may include a plurality of antennas 32 corresponding to the star point outgoing lines 24 one by one, so that each antenna 32 is connected to one star point outgoing line 24. For example, when the machine is 3-phase and each phase winding includes two parallel branches, the winding coil has six star point leads 24, while the neutral 3 for this stator assembly 100 has 6 antennas 32, as shown in fig. 4. When the motor has 3 phases and each phase winding has only one parallel branch, the winding coil has three star point outgoing lines 24, and at this time, three antennas 32 may be provided on the central line for the stator assembly 100, as shown in fig. 5.

Further, as shown in fig. 5, each antenna 32 may include a first connection section 321, a second connection section 322, and a bent section 323, the bent section 323 is connected between the first connection section 321 and the second connection section 322, the first connection section 321 is connected to the arc-shaped connection member 31, and the second connection section 322 is soldered to the wire end of the star point outgoing wire 24.

Advantageously, the first connecting section 321 and the second connecting section 322 are rounded off by a curved section 323.

Alternatively, as shown in fig. 5, the antenna 32 extends from the upper surface of the arc-shaped connection member 31, and both the first connection section 321 and the second connection section 322 extend upward. That is, the first connecting section 321 is connected to the upper surface of the arc connection member 31 and extends upward, the curved section 323 is connected to the upper end of the first connecting section 321, and the lower end of the second connecting section 322 is connected to the curved section 323 and extends upward.

In addition, the first connecting section 321 of the antenna 32 may also extend inward from the radial inner surface of the arc-shaped connecting member 31, and the second connecting section 322 extends upward and is welded to the star point outgoing line 24 extending outward (upward) in the axial direction of the stator core 1. For example, the first connecting section 321 is connected to the inner surface of the arc-shaped connecting member 31 and extends radially inward, the second connecting section 322 extends vertically upward, and the curved section 323 is connected between the horizontal first connecting section 321 and the vertical second connecting section 322, in which case the antenna 32 has an L shape.

Of course, the present invention is not limited to this, and as shown in fig. 6, the antenna 32 may also be formed in a straight line segment shape, and the antenna 32 extends inward from the radially inner surface of the arc-shaped connection member 31, and the antenna 32 is soldered to the end of the star point lead wire 24. Further, the antenna 32 may be soldered to the end of the star point lead 24 bent outward.

Here, it should be noted that when the neutral wire 3 has the antenna 32, at least a part of the antenna 32 extends radially inward, so that by soldering with the antenna 32 extending inward into the wire end of the star point lead-out wire 24, it is advantageous to space the arc-shaped connection member 31 from the outermost winding of the soldering terminal 23 to avoid interference. That is, when the neutral wire 3 has the antenna 32, the avoidance space 5 is formed between the two adjacent corresponding antennas 32, and the avoidance space 5 is adapted to accommodate the outermost winding located between the star point outgoing wires 24 of the two adjacent phases.

In some embodiments of the present invention, the span of the neutral line in the circumferential direction of the stator core is equal to or greater than the maximum span of each of the phase star point outgoing lines in the circumferential direction. So as to ensure that the neutral line has enough length to be connected with the star point outgoing lines of each phase. For example, as shown in fig. 1, the length of the neutral line in the circumferential direction of the stator core is not less than the distance between two star point outgoing lines that are farthest from each other in the circumferential direction of the stator core, that is, the span of the neutral line in the circumferential direction is greater than or equal to the span of the three star point outgoing lines in the circumferential direction, so that the neutral line can be connected to the three star point outgoing lines.

Optionally, the cross-sectional area of the neutral line perpendicular to the length direction thereof is equal to or greater than the cross-sectional area of the star point outgoing line perpendicular to the length direction thereof.

In some embodiments of the invention, the cross-sectional area of the neutral line 3 in the radial direction of the stator core is equal to or greater than the sum of the cross-sectional areas of the star point outgoing lines 24 in each phase. Specifically, when the number of winding parallel branches of the stator winding 2 is 1, the cross-sectional area of the neutral line 3 is greater than or equal to that of the star point outgoing line 24; when the number of parallel winding lines of the stator winding 2 is 2, the cross section area of the neutral wire 3 is larger than or equal to the sum of the cross sections of the two lines. Therefore, the requirement of electrically connecting the neutral wire 3 and the star point leading-out wires 24 can be met, specifically, according to a calculation formula of the resistance, the resistance of the conductor is inversely proportional to the sectional area of the conductor, therefore, the sectional area of the neutral wire 3 is larger than or equal to the sum of the sectional areas of the star point leading-out wires 24 of each path in each phase, which are vertical to the length direction of the star point leading-out wires, the resistance of the neutral wire 3 in unit length is smaller than or equal to the resistance of the star point leading-out wires 24 of each path in each phase, the heat productivity of the neutral wire 3 in unit length is smaller than or equal to the heat productivity of the star point leading-out wires 24 of each path in each phase, and the problem of local overheating of the neutral wire 3 is avoided.

In some embodiments of the invention, the neutral wire 3 may be configured as a flat wire having a rectangular cross section. Further, the cross-sectional areas thereof in the extending direction of the neutral line 3 are the same.

In some embodiments of the invention, the neutral line 3 may be a pressed copper bar. The neutral wire 3 may be a copper wire having a circular cross section. Of course, in some embodiments of the invention, the neutral line 3 may also be a stray line.

Preferably, the material of the neutral wire 3 may be identical to the material of the conductor segments 21 to improve the reliability of the connection between the neutral wire 3 and the star point outgoing wires 24.

In some embodiments of the invention, multiple star point outlets 24 in each phase are combined and connected before being connected to the neutral line 3. Alternatively, the multiple star point outgoing lines 24 in each phase may be directly welded or welded through a connecting strip.

For example, the number of parallel branches of each phase winding is 2, and in the process of connecting the neutral line 3, two star point outgoing lines 24 in the same phase may be welded together first, and then one star point outgoing line 24 is welded with the connecting block 4, and the connecting block 4 is welded with the neutral line 3.

In some embodiments of the present invention, as shown in fig. 1 to 6, the number of winding parallel branches of the stator winding 2 is at least one, and each of the star point outgoing lines 24 of each phase is individually connected to the neutral line 3, for example, the number of winding parallel branches of the stator winding 2 is 2, the stator winding is provided with two neutral lines 3, each of the neutral lines 3 is connected to each of the star point outgoing lines 24 of each phase, and the two neutral lines 3 are arranged in parallel in the axial direction of the stator winding, so that the space in the radial direction of the stator winding can be reduced.

An electric machine according to an embodiment of the second aspect of the invention comprises a stator assembly according to an embodiment of the first aspect of the invention.

The structure and operation of other components of the motor according to the embodiment of the present invention, such as the rotor, etc., are well known to those skilled in the art and will not be described herein.

According to the motor provided by the embodiment of the invention, the stator assembly provided by the embodiment of the first aspect of the invention is arranged, so that the overall performance of the motor is improved.

According to a third aspect of the invention, a vehicle includes the motor according to the embodiment of the second aspect of the invention.

According to the vehicle provided by the embodiment of the invention, the overall performance of the vehicle is improved by arranging the motor according to the embodiment of the second aspect of the invention.

Referring to fig. 7 to 13, a winding method of a stator winding in a stator assembly according to an embodiment of the present invention is described below by taking as an example a stator assembly according to an embodiment of the present invention for an 8-pole 48-slot 3-phase motor: the number of stator slots z is 48, and the number of phases m is 3, wherein three phases comprise a U phase, a V phase and a W phase; the number of poles 2p is 8 (i.e. the number of pole pairs is 4), and each of the three phases includes two.

As shown in fig. 10, in the stator winding 2 of the stator assembly 100, the pitch between the first in-slot portion 202 and the second in-slot portion 203 of the U-shaped conductor segment 20 is y stator slots, where y is an integer and y ═ z/2 p. For an 8-pole 48 slot stator assembly 100, y is 6. That is, there is a 6 stator slot difference between the first in-slot portion 202 and the second in-slot portion 203 of each U-shaped conductor segment 20.

In the following description, the present invention is explained by taking 6 layers as an example in each stator slot 11, the 6 slot layers including a, b, c, d, e, f layers arranged in sequence, and in each stator slot 11, the layer positioned innermost in the radial direction of the stator core 1 is the a layer, and the layer positioned outermost is the f layer.

In the stator assembly shown in fig. 10, the star point outgoing line and the terminal outgoing line of each U phase have a difference of 6 stator slots, and the two phases of each phase have a difference of 1 stator slot in the circumferential direction; the star point outgoing lines corresponding to the U phase, the V phase and the W phase are different by 4 stator slots in the circumferential direction; the terminal leading-out wires corresponding to the U phase, the V phase and the W phase are different by 4 stator slots in the circumferential direction.

More specifically, as shown in fig. 11 and 12, terminal lead U1A of the U-phase 1 and terminal lead U2A of the U-phase 2 differ by 1 stator slot, and terminal lead V1A of the V-phase 1 and terminal lead V2A of the V-phase 2 differ by 1 stator slot; terminal lead wire W1A of W-phase 1 and terminal lead wire W2A of W-phase 2 differ by 1 stator slot.

As shown in fig. 11 and 12, terminal lead U1A of the U-phase 1 path differs by 6 stator slots from star point lead U1B of the U-phase 1 path, and terminal lead U2A of the U-phase 2 path differs by 6 stator slots from star point lead U2B of the U-phase 2 path; similarly, the difference between two terminal outgoing lines V1A and a star point outgoing line V1B, and between two terminal outgoing lines V2A and a star point outgoing line V2B in the V phase is 6 stator slots; two terminal outgoing lines W1A and star point outgoing line W1B, and two terminal outgoing lines W2A and star point outgoing line W2B in the W phase are also different by 6 stator slots.

Further, the U-phase, V-phase, and W-phase star point lead wires are circumferentially separated by 4 stator slots, specifically, taking the first route as an example, the U-phase 1-route star point lead wire U1B, the V-phase 1-route star point lead wire V1B, and the W-phase 1-route star point lead wire W1B are circumferentially separated by 4 slots in this order, for example, as shown in fig. 10, U1B is led from a 07 slot e layer, V1B is led from a 03 slot e layer, and W1B is led from a 47 slot e layer. Similarly, U2B, V2B, and W2B of the second pass exit from the 08 slot e layer, 04 slot e layer, and 48 slot e layer, respectively, sequentially with 4 stator slots therebetween.

Correspondingly, the terminal leading-out wires corresponding to the U phase, the V phase and the W phase are different by 4 stator slots in the circumferential direction. Specifically, taking the first route as an example, the terminal lead U1A of the U-phase 1 route, the terminal lead V1A of the V-phase 1 route, and the terminal lead W1A of the W-phase 1 route are sequentially different by 4 grooves in the circumferential direction, for example, as shown in fig. 10, U1A is drawn from the 01 groove f layer, V1A is drawn from the 45 groove f layer, and W1A is drawn from the 41 groove f layer. Similarly, the U2A, V2A, and W2A of the second pass were introduced from the 02 slot f layer, 46 slot f layer, and 42 slot f layer, respectively, which were sequentially different by 4 stator slots.

The above-mentioned wound coil structure can be wound by the following winding method, as shown in fig. 11 and 12, taking the U-phase first path as an example, the winding route is as follows:

1f→43f→1e→7d→13c→19b→25a→19a→13b→7c→1d→43e→37f→31f→37e→43d→1c→7b→13a→7a→1b→43c→37d→31e→25f→19f→25e→31d→37c→43b→1a→43a→37b→31c→25d→19e→13f→7f→13e→19d→25c→31b→37a→31a→25b→19c→13d→7e，

wherein the phase difference between the winding line of the U-phase second path and the U-phase first path in the circumferential direction is 1 stator slot,

the star point outgoing lines corresponding to the U phase, the V phase and the W phase are different by 4 stator slots in the circumferential direction;

the terminal leading-out wires corresponding to the U phase, the V phase and the W phase are different by 4 stator slots in the circumferential direction.

When the coil is wound by the coil winding method, a plurality of first U-shaped conductor segments, a plurality of second U-shaped conductor segments 2002, a plurality of third U-shaped conductor segments 2003 and a plurality of fourth U-shaped conductor segments 2004 are used, and still taking the U-phase first path as an example, referring to fig. 11 and the winding path, the winding condition is specifically as follows:

the terminal outgoing line U1A is introduced at the soldered end into the radially outermost slot layer 1f of the 1 st slot of the initial slot, connected to the first in-slot portion of the first U-shaped conductor segment 2001, the first U-shaped conductor segment 2001 spanning 6 stator slots in the same layer in the reverse direction to 43 f; wherein, the positive direction is the direction of the motor rotor rotation, and the negative direction is the negative direction of the motor rotor rotation.

Crossing in the forward direction and being connected in series by a plurality of second U-shaped conductor segments 2002, each second U-shaped conductor segment 2002 crossing 6 stator slots, the slot layer in which the second in-slot part of each second U-shaped conductor segment 2002 is located being radially one layer inward of the slot layer in which the first in-slot part is located, until the second in-slot part is located in the radially innermost slot layer, i.e. crossing from 43f to 1e by one second U-shaped conductor segment 2002, crossing from 1e to 7d by the next second U-shaped conductor segment 2002, and so on, until reaching the radially innermost layer 25a of the 25 th slot;

6 stator slots are spanned in the opposite direction in the same layer by a third U-shaped conductor segment 2003 to 19 a;

crossing in the opposite direction and connected in series by a plurality of fourth U-shaped conductor segments 2004, each fourth U-shaped conductor segment 2004 crossing 6 stator slots, the second in-slot portion of each fourth U-shaped conductor segment 2004 lying one layer radially outward of the layer in which the first in-slot portion lies, until the second in-slot portion lies in the radially outermost slot layer, i.e. 19a to 13b by one fourth U-shaped conductor segment 2004, 13b to 7c by the next fourth U-shaped conductor segment 2004, and so on, until reaching the radially outermost layer 37f of the 37 th slot;

the above arrangement is repeated again using the first U-shaped conductor segment 2001, the second U-shaped conductor segment 2002, the third U-shaped conductor segment 2003 and the fourth U-shaped conductor segment 2004 until the second in-slot portion of a certain fourth U-shaped conductor segment 2004 reaches the adjacent layer (i.e., the second outermost slot layer 7e) of the radially outermost slot layer of the 7 th slot of the termination slot and connects the star point lead-out line U1B of that phase, wherein the 7 th slot of the termination slot is 6 stator slots from the initial slot in the forward direction.

In some embodiments, for a stator assembly suitable for an 8-pole 48-slot 3-phase electric machine, the stator assembly may be selectively processed into a two-way scheme or a one-way scheme based on its initial stator assembly 100.

When the user selects a two-way scheme, the U, V, W three-phase first star point lead wires U1B, V1B and W1B and the second star point lead wires U2B, V2B and W2B are respectively bent outwards and connected by welding through the central line 3, as shown in fig. 12, and finally the U, V, W three-phase first terminal lead wires U1A, V1A and W1A and the second terminal lead wires U2A, V2A and W2A are connected with the external controller interface after being fixed by welding through welding terminals.

When a user selects a route scheme, after the U, V, W three-phase second route terminal lead wires U2A, V2A and W2A are lengthened and bent, the U, V, W three-phase second route terminal lead wires U1B, V1B and W1B are respectively welded and fixed with the U, V, W three-phase first route star point lead wires U1B, V1B and W1B, and the second route star point lead wires U2B, V2B and W2B are respectively bent outwards and connected through the neutral wire 3 in a welding mode. And finally, connecting the U, V, W three-phase first path terminal leading-out wires U1A, V1A and W1A with an external controller interface after being welded and fixed through welding terminals.

Of course, when the number of stator slots, the number of poles and the number of phases are different, the winding structure of each path of each phase is also different.

For example, when the number of stator slots is 72, the number of poles is 8, the number of phases is 3, and the stator comprises U-phase, V-phase and W-phase, each phase comprises three phases (not shown in the figure), wherein the star point outgoing line and the terminal outgoing line of each U-phase are separated by 9 stator slots 11, and the three phases of the U-phase are separated by 1 stator slot 11 in the circumferential direction; every two of the three V-phase circuits are circumferentially different by 1 stator slot 11, every two of the three W-phase circuits are circumferentially different by 1 stator slot 11, the star point outgoing lines corresponding to the U-phase, the V-phase and the W-phase are circumferentially different by 6 stator slots 11, and the terminal outgoing lines corresponding to the U-phase, the V-phase and the W-phase are circumferentially different by 6 stator slots 11.

It should be noted that, in some preferred embodiments, on the welding end II of the coil winding, the star point outgoing line of each path of any phase is located on the radially outermost layer, and the terminal outgoing line of each path of any phase is located on the radially second outer layer, so that the leading-in of the terminal outgoing line and the leading-out of the star point outgoing line are facilitated, and the whole coil winding is simple in structure.

In summary, the stator assembly 100 according to the embodiment of the present invention, which adopts the above winding method, has only a welding point on the welding end, and has no welding terminal on the hairpin end, so that the welding process is simple and convenient; the coil type required by winding is less, the required equipment is less, and the batch production is easy to realize. In addition, by adopting the winding method, the voltage difference of the flat wires between the adjacent groove layers in the same groove is smaller than that of the conventional scheme, the insulation breakdown risk of the motor can be effectively reduced, and the reliability is high; in addition, the number of winding paths can be easily adjusted.

In the description herein, references to the description of the term "one embodiment," "some embodiments," "an illustrative embodiment," "an example," "a specific example," or "some examples" or the like mean that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the invention. In this specification, the schematic representations of the terms used above do not necessarily refer to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.

While embodiments of the invention have been shown and described, it will be understood by those of ordinary skill in the art that: various changes, modifications, substitutions and alterations can be made to the embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.

Claims

1. A stator assembly, comprising:

a cylindrical stator core having a plurality of stator slots arranged at intervals in a circumferential direction of the stator core;

a stator winding including a plurality of conductor segments, each of the conductor segments including an in-slot portion disposed in a stator slot, a first end and a second end disposed outside the stator core, the in-slot portion being connected between the first end and the second end, the second ends of the plurality of conductor segments forming a weld end, a star point outgoing line of each phase of the stator winding being located on the weld end;

the neutral line circumferentially surrounds the welding end of the stator winding and is directly connected with the star point outgoing line of each phase;

the cross-sectional areas of the neutral lines are the same in the extending direction of the neutral lines;

the cross section area of the neutral line along the radial direction of the stator core is larger than or equal to the sum of the cross sections of the star point outgoing lines of each phase.

2. The stator assembly of claim 1, wherein the conductor segments are rectangular in cross-section.

3. The stator assembly of claim 2 wherein the conductor segments are U-shaped conductor segments, the U-shaped conductor segments including first and second in-slot portions disposed in stator slots, the first end being a U-bend connecting the first and second in-slot portions, the U-bends in the U-shaped conductor segments forming a hairpin end of the stator winding and the second ends of the first and second in-slot portions forming a weld end of the stator winding.

4. The stator assembly of claim 1, wherein each phase star point lead-out wire of the stator winding is in surface contact with the neutral wire and is fixed by welding.

5. The stator assembly according to claim 1, wherein the wire ends of the star point outgoing wires of each phase of the stator winding extend outwards along the axial direction of the stator core and form axial protrusions, and the neutral wires are respectively connected with the axial protrusions.

6. The stator assembly of claim 5 wherein the axial projection exceeds the end of the weld end by a predetermined distance, the predetermined distance being greater than or equal to a dimension of the neutral wire in an axial direction of the stator core.

7. The stator assembly according to claim 1, wherein the wire ends of the star point outgoing wires of each phase of the stator winding extend outwards along the radial direction of the stator core and are bent by a preset angle to form radial protrusions, and the neutral wires are respectively connected with the radial protrusions.

8. The stator assembly of claim 7 wherein the radial protrusion exceeds the outermost winding layer of the weld end by a predetermined distance greater than or equal to a dimension of the neutral wire in a radial direction of the stator core.

9. The stator assembly of any of claims 1-8, wherein the neutral line includes an arcuate connector and a plurality of tentacles that are respectively connected to respective phase star point lead-outs of the stator windings.

10. The stator assembly of claim 9 wherein the arcuate connection has a gap radially between it and the radially outermost winding on the weld end.

11. An electrical machine comprising a stator assembly according to any of claims 1-10.

12. A vehicle characterized by comprising an electric machine according to claim 11.