CN109586462B

CN109586462B - Stator module and motor with same

Info

Publication number: CN109586462B
Application number: CN201710912477.0A
Authority: CN
Inventors: 林焕炜; 舒圣浪; 游斌
Original assignee: BYD Co Ltd
Current assignee: BYD Co Ltd; Nanjing BYD Automobile Co Ltd
Priority date: 2017-09-29
Filing date: 2017-09-29
Publication date: 2020-11-20
Anticipated expiration: 2037-09-29
Also published as: CN109586462A

Abstract

The invention discloses a stator assembly suitable for a z-slot 2 p-stage m-phase motor and a motor with the stator assembly. Stator module includes stator core and stator winding, and stator winding is made by the flat line and includes first U-shaped conductor section, second U-shaped conductor section, third U-shaped conductor section and fourth U-shaped conductor section to realize forward coiling partial stator slot, reverse coiling again, then reverse again after another partial stator slot of forward coiling again, with this circulation, through this kind of wave winding mode, make the flat line voltage difference between the adjacent groove layer in the same inslot less than current scheme, can effectively reduce motor insulation breakdown risk, and the reliability is high.

Description

Stator module and motor with same

Technical Field

The present invention relates to the field of motors, and more particularly, to a stator assembly of a driving motor for a vehicle and a motor having the same.

Background

The chinese patent application publication No. 201180004987.9 entitled "armature for rotating electrical machine" discloses a rotating electrical machine armature connection method in which the armature is wound in a wave manner from the outermost layer to the innermost layer, and then in a reverse wave manner to the outermost layer, as shown in fig. 15.

The inventor of the application finds that, in the armature connection and implementation manner in the prior art, from the aspect of the manufacturing process, the types of flat wire armatures to be manufactured are multiple, and both axial ends of the flat wire armatures need to be welded, so that a plurality of welding spots are caused; in addition, in the wave winding mode, the flat wire is difficult to accurately fix after being taken off, the production cost is high, and the manufacturing process difficulty is high. In view of electrical connection, the wave winding form in the prior art is adopted, the voltage difference between different layers in the same slot is high, and the layers are easy to break down under the high voltage condition, so that short circuit is caused, and the motor fails.

Disclosure of Invention

The present invention is directed to solving at least one of the problems of the prior art. Therefore, the stator assembly provided by the invention has the advantages that the manufacturing process of the stator assembly winding is simple, and the electrical connection is safe and reliable.

According to an embodiment of the first aspect of the present invention, a stator assembly is adapted to a z-slot 2 p-stage m-phase motor, where the number of slots per phase per pole is q ═ z/m/(2p), the number of parallel branches is a, and a ≦ q, and includes:

the stator core is provided with a plurality of stator slots which are arranged at intervals along the circumferential direction of the stator core, and each stator slot is provided with a plurality of slot layers;

a stator winding including a plurality of U-shaped conductor segments, each of the U-shaped conductor segments including a bent portion and first and second in-slot portions connected to the bent portion, respectively, an end of the first in-slot portion being connected to a first welding portion, an end of the second in-slot portion being connected to a second welding portion, and free ends of the first and second welding portions each having a chamfered portion,

the pitch between the first in-slot portions and the second in-slot portions is y stator slots, wherein y is an integer and y is z/2p, the first in-slot portions of the U-shaped conductor segments penetrate one slot layer of one of the stator slots, the second in-slot portions penetrate one slot layer of the other stator slot, the first in-slot portions and the second in-slot portions penetrate the stator slots and then the ends of the first in-slot portions and the second in-slot portions exceed the stator core to form welding ends, and the first in-slot portions and the second in-slot portions of the U-shaped conductor segments located in the adjacent layers are welded and connected at the welding ends;

the U-shaped conductor section comprises a first U-shaped conductor section, a second U-shaped conductor section, a third U-shaped conductor section and a fourth U-shaped conductor section, when the winding is wound, in each phase,

the terminal outgoing line is connected with a first in-slot part of a first U-shaped conductor section located on the radially outermost slot layer at the welding end, and the first U-shaped conductor section spans y stator slots on the same layer along a first direction;

a plurality of second U-shaped conductor segments cross and are sequentially connected along a second direction, each second U-shaped conductor segment crosses y stator slots, and a slot layer in which a second in-slot part of each second U-shaped conductor segment is located is radially inward by one layer than a slot layer in which a first in-slot part is located until the second in-slot part is located at the radially innermost slot layer;

a third U-shaped conductor segment spans y stator slots in a same layer along the first direction;

a plurality of fourth U-shaped conductor segments cross and are sequentially connected along the first direction, each fourth U-shaped conductor segment crosses y stator slots, and a second in-slot portion of each fourth U-shaped conductor segment is located in a slot layer which is radially outward one layer than a first in-slot portion until the second in-slot portion is located in a radially outermost slot layer;

repeating the arrangement by adopting the first U-shaped conductor section, the second U-shaped conductor section, the third U-shaped conductor section and the fourth U-shaped conductor section until a second in-slot part of a certain fourth U-shaped conductor section reaches an adjacent layer of a radially outermost slot layer of a termination slot and is connected with a star point outgoing line of the path, wherein the termination slot is y stator slots away from the initial slot in the second direction;

wherein the first direction and the second direction are opposite directions along the circumference of the stator core.

According to some embodiments of the invention, the number of layers of the slot layer in each of the stator slots is an even number.

According to some embodiments of the invention, the terminal lead-out wires of the same phase are circumferentially separated by 1 stator slot by two.

According to some embodiments of the invention, the star point lines of each path in phase are circumferentially separated by 2q stator slots by two, and the terminal outgoing lines of each path in phase are circumferentially separated by 2q stator slots by two.

According to the stator assembly provided by the embodiment of the invention, the terminal outgoing line and the star point outgoing line are both arranged on the welding end I, and compared with the traditional coil in which welding points are arranged at the welding end and the hairpin end, the welding process is simple; in addition, the stator assembly of the embodiment of the invention adopts the winding method, and is different from the mode that the stator assembly is wound from the outmost layer to the innermost layer and then reversely wound to the outmost layer in the prior art, but part of stator slots are wound in the forward direction, then reversely wound, and then the other part of stator slots are wound in the forward direction and then reversely wound, so that the circulation is realized, the voltage difference of the flat wires between the adjacent slot layers in the same slot is smaller than that of the prior scheme through the wave winding mode, the insulation breakdown risk of the motor can be effectively reduced, and the reliability is high.

According to some embodiments of the invention, an end of either one of the first and second in-slot portions of the U-shaped conductor section is connected with a connection portion and a weld portion, the connection portion being bent with respect to the in-slot portion in which it is located.

According to some embodiments of the invention, the bending directions of the connecting portions of the first in-slot portion and the second in-slot portion in the first U-shaped conductor section are the same; the bending directions of the connecting parts of the first in-groove part and the second in-groove part in the fourth U-shaped conductor section are consistent; the first U-shaped conductor segment and the fourth U-shaped conductor segment are basically consistent in shape and the bending directions of the connecting parts are opposite.

According to some embodiments of the invention, the connection portions of the first and second in-slot portions of the second U-shaped conductor segment are bent in opposite directions, and the second and third U-shaped conductor segments are substantially identical in shape.

According to some embodiments of the invention, the first in-slot portion and the second in-slot portion of the second U-shaped conductor segment are located on different surfaces.

According to some embodiments of the present invention, the stator assembly is suitable for an electric machine having a slot number z of 48, a pole pair number p of 4, a phase number of 3, and a pitch y of 6, wherein each of the 48 stator slots has 6 slot layers a, b, c, d, e, f, and 3 phases including a U phase, a V phase, and a W phase, and the number a of each phase is 2, wherein the winding route of the first U phase of the stator 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，

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.

According to some embodiments of the invention, the U-shaped conductor segments have equal cross-sectional areas in the direction of extension of the U-shaped conductor segments.

According to some embodiments of the invention, the outer surface of the chamfered portion is beveled and forms an angle β with the horizontal plane, wherein the angle β is greater than or equal to 45 degrees.

According to some embodiments of the invention, the included angle β is in the range of 45-60 degrees.

According to some embodiments of the invention, the chamfer is provided on an outer surface of the rectangular shape.

According to some embodiments of the present invention, the chamfered portion is formed in an inverted conical shape at an end of the second welding portion and the first welding portion.

According to some embodiments of the invention, the height h of the chamfered portion satisfies: tan β ═ h/0.5b, where b is the length of the long side of the rectangular shape.

According to some embodiments of the invention, the conductor segment further comprises: a first connection portion connected between the first in-slot portion and the first weld portion, the first connection portion being bent relative to the first in-slot portion, the first weld portion being bent relative to the first connection portion and being parallel to the first connection portion; a second connection portion connected between the second in-slot portion and the second weld portion, the second connection portion being bent relative to the second in-slot portion, the second weld portion being bent relative to the second connection portion and being parallel to the second connection portion.

According to some embodiments of the invention, the angle γ 1 between the first connection portion and the first in-groove portion and the angle γ 2 between the second connection portion and the second in-groove portion are obtuse angles.

According to some embodiments of the invention, γ 1, γ 2 satisfies: gamma 1 is more than or equal to 100 degrees and less than or equal to 160 degrees; gamma 2 is more than or equal to 100 degrees and less than or equal to 160 degrees.

According to some embodiments of the invention, the first connection portion is connected to the first in-groove portion and the first weld portion by a fillet.

According to some embodiments of the invention, any cross-section of the conductor segments is rectangular in shape, the short sides of the rectangle being perpendicular to the stator slot bottom wall.

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

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 core in a stator assembly according to an embodiment of the present invention;

FIG. 2 is a schematic view of a U-shaped conductor segment of a stator assembly according to an embodiment of the present invention;

FIGS. 3 a-3 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;

figure 4 is a schematic view of a stator assembly according to an embodiment of the first aspect of the present invention as an initial setup, illustrated with an 8-pole 48 slot 3 phase as an example;

FIG. 5 is a winding pattern diagram of the stator assembly of FIG. 4, illustrating a U-phase 1-path by way of example;

FIG. 6 is the final stator assembly of FIG. 4 after the stator assembly has been processed to form a 2-way connection;

FIG. 7 is the final stator assembly of FIG. 4 after the stator assembly has been processed to form a 1-way connection;

FIG. 8a is a schematic illustration of a conductor segment according to an embodiment of the present invention;

FIG. 8b is an enlarged view of the circled portion in FIG. 8 a;

FIG. 9 is a top view of the conductor segment shown in FIG. 8 a;

fig. 10a is a schematic view of the bends of a conductor segment according to a first embodiment of the invention;

FIG. 10b is a schematic view of the twist of the bend shown in FIG. 10 a;

fig. 11a is a schematic view of the bends of a conductor segment according to a second embodiment of the invention;

FIG. 11b is a schematic view of the twist of the bend shown in FIG. 11 a;

figure 12 is a schematic view of a stator assembly according to an embodiment of the present invention showing a stator core and conductor segments as an example.

Fig. 13 a-14 b are schematic views of a conductor segment according to a first embodiment of the invention during different stages of manufacture.

Fig. 15 is a schematic view of a winding structure of a stator assembly in the related art.

Reference numerals:

stator assembly 100, stator core 1, stator slots 11,

the coil winding 2, the U-shaped conductor section 20,

bend 201, first layer segment 2011, second layer segment 2012, link segment 2013,

a first in-slot portion 202, a second in-slot portion 203,

a first connecting portion 2041, a second connecting portion 2042,

a first weld 2051, a second weld 2052,

a first U-shaped conductor segment 2001; a second U-shaped conductor segment 2002; a third U-shaped conductor segment 2003; a fourth U-shaped conductor segment 2004;

a neutral line 3, a hairpin end I and a welding end II;

three phases: u phase, V phase, W phase

A U-phase 1 lead line U1A; a U-phase 2-path lead line U2A;

u-phase 1 way star point line U1A; u-phase 2-way star point line U2B;

a V-phase 1 lead line V1A; a V-phase 2-lead line V2A;

v-phase 1 way star point line V1A; v-phase 2 way star point line V2B;

a W-phase 1-lead line W1A; a W-phase 2-lead line W2A;

w-phase 1-way star point line W1A; w-phase 2-way star point line W2B

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 "central," "upper," "lower," "vertical," "horizontal," "top," "bottom," "inner," "outer," "axial," "radial," "circumferential," and the like are used in the positional or orientational relationships indicated in the drawings to facilitate the description of the invention and to simplify the description, and are not intended to indicate or imply that the referenced device or element must have a particular orientation, be constructed and operated in a particular orientation, and are not to be construed as limiting the 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 according to an embodiment of the first aspect of the present invention will be described with reference to fig. 1 to 4, and the stator assembly can be used as an initial stator assembly and processed according to the customer's requirements to obtain final stator assemblies with different paths in final forms.

A stator assembly 100 according to one embodiment of the present invention includes: stator core 1 and stator winding 2.

As shown in fig. 1, a plurality of stator slots 11 are formed in a stator core 1, 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 peripheral 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. Each stator slot 11 has a plurality of slot layers therein and the stator winding 2 comprises a plurality of U-shaped conductor segments 20. As shown in fig. 2, each U-shaped conductor segment 20 comprises a bend 201 and a first in-slot portion 202 and a second in-slot portion 203 connected to the bend 201, respectively, the first in-slot portion 202 passing through one of the slot layers in one of the stator slots 11, the second in-slot portion 203 passing through one of the slot layers in the other stator slot 11, the first in-slot portion 202 and the second in-slot portion 203 passing through the stator slot 11 with their ends extending beyond the stator core 1.

Any cross section of the U-shaped conductor section 20 perpendicular to its extension is non-circular, and as an example is rectangular. Alternatively, any cross section of the U-shaped conductor section 20 is rectangular in shape, the short sides of the rectangle being perpendicular to the bottom wall of the stator slot 11. Further, the cross-sectional areas of the U-shaped conductor segments 20 are equal in the extending direction of the U-shaped conductor segments 20.

As shown in fig. 8a, the end of the first in-slot portion 202 is connected with a first weld 2051 and the end of the second in-slot portion 203 is connected with a second weld 2052, wherein the free ends of the first weld 2051 and the second weld 2052 each have a chamfered portion 2060. According to the conductor segment provided by the embodiment of the invention, the chamfer part 2060 is arranged at the welding end, so that the stator core 1 is convenient to be inserted, the risk of scratching the paint skin of the adjacent copper wire during inserting can be reduced, and the reliability of the motor is improved. In addition, the welding end is provided with a chamfer, so that the welding is convenient.

As shown in fig. 4, one end of the U-shaped conductor segment 20 where the bent portion 201 is located is a hairpin end I of the stator winding 2, and one end of the first in-slot portion 202 and the second in-slot portion 203 where the end is located is referred to as a welding end II of the stator winding 2, and as shown in fig. 4, the welding end II is formed by sequentially welding the first in-slot portions 202 of the plurality of U-shaped conductor segments 20 and the second in-slot portions 203 of the U-shaped conductor segments 20 adjacent thereto.

On the welding end II, the star point outgoing line and the terminal outgoing line of each path of any phase are circumferentially different by 3q stator slots 11, and the multiple paths of any phase are circumferentially different by 1 stator slot 11 in pairs;

the corresponding star point outgoing lines among the multiple phases are different by 2q stator slots 11 in the circumferential direction;

the corresponding terminal lead-out wires between the phases differ by 2q in the circumferential direction of the stator slot 11,

wherein the number of grooves of each phase of each pole is q ═ z/m/(2p), the number of parallel branches is g, and g is less than or equal to q;

wherein z is the number of stator slots, m is the number of phases, and 2p is the number of poles.

The stator assembly 100 is suitable for a z-slot 2 p-stage m-phase motor, the number of slots z can be 24, 48, 72, etc., the number of phases m can be three-phase, two-phase or single-phase, the number of pole pairs p can be 8 poles, 4 poles, etc., and the setting can be carried out according to the specific motor.

It should be noted that "difference" refers to the difference between two numbers of slots, for example, if the initial slot is 1, then the 7 th slot is after 6 slots are different.

The winding structure can be wound by the following winding method:

s1, providing a plurality of U-shaped conductor segments 20, where each U-shaped conductor segment 20 includes a bent portion and a first in-slot portion 202 and a second in-slot portion 203 connected to the bent portion, respectively, and the pitch between the first in-slot portion 202 and the second in-slot portion 203 is y stator slots 11, where y is an integer and y is z/2p, and any cross section of the U-shaped conductor segment 20 perpendicular to the extending direction thereof is rectangular;

s2, passing the first in-slot portion 202 of the U-shaped conductor segment 20 through one of the slot layers of one of the stator slots 11, passing the second in-slot portion 203 through one of the slot layers of the other stator slot 11, the first in-slot portion 202 and the second in-slot portion 203 passing through the stator slots 11 with their ends extending beyond the stator core to form welded ends;

s3, welding the first in-slot portions 202 and the second in-slot portions 203 of the plurality of U-shaped conductor segments 20 at the welding ends in multiple layers such that the winding direction of the coil is configured such that in each phase:

s31, leading the terminal lead-out wire out to the radially outermost slot layer of the initial slot, wherein the initial slot is the stator slot 11 which is inserted for the first time when the terminal lead-out wire starts to prepare for winding;

s32, crossing y stator slots 11 along the reverse same layer;

s33, crossing along the positive direction, wherein the number of layers of the slot layer of each y stator slots 11 is changed by one layer, and the number of layers is changed from outside to inside along the radial direction to the radially innermost slot layer;

s34, crossing y stator slots 11 along the reverse same layer;

s35, crossing in the reverse direction, wherein the number of layers of the slot layers of each y stator slots 11 is changed by one layer, and the number of layers is changed from inside to outside along the radial direction to the radially outermost slot layer;

s36, repeating S32-S35 until the winding reaches the adjacent layer of the radially outermost slot layer of the termination slot, and then leading out the star point lead-out wire of the phase on the way, wherein the termination slot is y stator slots 11 away from the initial slot in the forward direction, wherein the term "termination slot" herein refers to the last stator slot that is passed after the winding of the coil is completed.

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.

According to the stator assembly provided by the embodiment of the invention, the terminal outgoing line and the star point outgoing line are both arranged on the welding end I, and compared with the traditional coil in which welding points are arranged at the welding end and the hairpin end, the welding process is simple; in addition, the stator assembly of the embodiment of the invention adopts the winding method, and is different from the mode that the stator assembly is wound from the outmost layer to the innermost layer and then reversely wound to the outmost layer in the prior art, but part of stator slots are wound in the forward direction and then reversely wound, and then the other part of stator slots are wound in the forward direction and then reversely wound, so that the circulation is realized, the winding voltage difference between the adjacent slot layers in the same slot is smaller than that in the prior art through the wave winding mode, the insulation breakdown risk of a motor can be effectively reduced, and the reliability is high.

According to some embodiments of the present invention, as shown in FIG. 8b, the outer surface of the chamfered portion 2060 is inclined and forms an angle β with the horizontal plane, wherein the angle β is greater than or equal to 45 degrees. Considering that if the included angle β is too large, the height of the chamfered portion 2060 is too high, so that the height of the welding end is too high, and the axial size is affected, and on the other hand, the thickness of the chamfered portion 2060 is too small, which is not favorable for offline and is easy to bend; when the angle of the included angle beta is too small, the effects of guiding and easy line unloading cannot be achieved. Thus, in some preferred embodiments of the present invention, included angle β is in the range of 45-60 degrees.

As shown in fig. 8b, the outer surface of the chamfer 2060 is sloped parallel to the short side of the rectangular shape of the conductor segment cross-section to facilitate forming the chamfer. In some embodiments, the chamfered portion 2060 is formed in a reverse tapered shape at the end of each of the second welding portion 2052 and the first welding portion 2051, so that the wire can be fed more conveniently and the adjacent copper wire enamel can be less damaged.

In some alternative embodiments, as shown in fig. 8b, the height h of the chamfer 2060 may satisfy: tan β ═ h/0.5b, where b is the length of the long side of the rectangular shape. By satisfying the above formula between the height h and the long side dimension of the cross section of the conductor segment, and the angle β, the height of the chamfer portion 2060 can be within the normal range, i.e., the axial dimension is not affected, the guiding is easy, and the offline effect is not affected. Further, in some specific examples, the height h of the chamfered portion 2060 is ≦ 4 mm. Further, the height h of the chamfered portion 2060 is 2mm or less, thereby facilitating welding.

As shown in fig. 8a, in some embodiments of the invention, the conductor segment further comprises: first connecting portion 2041 and second connecting portion 2042, first connecting portion 2041 is connected between first in-groove portion 202 and first welding portion 2051, first connecting portion 2041 is bent relative to first in-groove portion 202, and first welding portion 2051 is bent relative to first connecting portion 2041 and is parallel to first connecting portion 2041. The second connecting portion 2042 is connected between the second in-slot portion 203 and the second welding portion 2052, the second connecting portion 2042 is bent with respect to the second in-slot portion 203, and the second welding portion 2052 is bent with respect to the second connecting portion 2042 and is parallel to the second connecting portion 2042. Alternatively, as shown in fig. 8a, the first connection 2041 is connected to the first in-slot portion 202 and the first weld 2051 by rounded corners, and correspondingly, the second connection 2042 is connected to the second in-slot portion 203 and the second weld 2052 by rounded corners.

In an alternative embodiment, the included angle γ 1 between the first connecting portion 2041 and the first in-slot portion 202 and the included angle γ 2 between the second connecting portion 2042 and the second in-slot portion 203 are all obtuse angles. Further, γ 1, γ 2 satisfy: gamma 1 is more than or equal to 100 degrees and less than or equal to 160 degrees; gamma 2 is more than or equal to 100 degrees and less than or equal to 160 degrees.

According to the conductor segment of the embodiment of the invention, the parts of the first in-slot portion 202 and the second in-slot portion 203 exceeding the stator core are bent to form the first connecting portion 2041 and the second connecting portion 2042, and the first welding portion 2051 and the second welding portion 2052 are formed at the end portions of the first connecting portion 2041 and the second connecting portion 2042, so that the offline is more reliable and the welding is more convenient.

The use of conductor segments for layer crossing (i.e., same layer conductor segments) will be described in detail below with reference to fig. 8 a-14 b.

According to some embodiments of the present invention, the bending part 201 further comprises a connecting section 2013 connected between the first layer section 2011 and the second layer section 2012, and at least one of the first layer section 2011 and the second layer section 2012 is twisted radially so that the first layer section 2011 and the second layer section 2012 are not on the same concentric circle of the stator core 1.

In some of these embodiments, as shown in fig. 11a and 11b, first layer segment 2011 and second layer segment 2012 are twisted in opposite radial directions relative to connecting segment 2013, respectively, such that first layer segment 2011 and second layer segment 2012 do not lie on the same line or concentric circle. Optionally, the first layer segment 2011 and the second layer segment 2012 are both arc line segments, while the first layer segment 2011 and the second layer segment 2012 are not located on the same circle or concentric circle. Preferably, the arc segments in which first layer segment 2011 and second layer segment 2012 reside are non-concentric. Or alternatively, the arc lengths of first layer segment 2011 and second layer segment 2012 are not equal.

Specifically, the connecting section 2013 is inclined with respect to the radial direction of the stator, the first layer section 2011 is twisted with respect to the connecting section 2013 toward the radially outward direction, and the second layer section 2012 is twisted with respect to the connecting section 2013 toward the radially inward direction. As shown in fig. 11a and 11b, an arc o1 is a part of a base circle of the bending portion 201, where the base circle refers to a circle where the bending portion 201 is located before being bent; arc o2 is a portion of the circle in which second interval 2012 was twisted; and the arc o3 is a portion of the circle that the first layer segment 2011 twists around.

As shown in fig. 11a, the distance d in the radial direction of the free ends of the first layer segment 2011 and the second layer segment 2012 is larger than the radial width of the first in-slot portion 202 or the second in-slot portion 203. Thus, when the plurality of conductor segments 20 are simultaneously inserted into the stator slots 11 of the stator core 1, interference between adjacent conductor segments is more effectively prevented.

Of course, the present invention is not limited thereto. In other examples of the invention, first layer segment 2011 and second layer segment 2012 may both be straight segments (not shown). In this case, the connecting section 2013 is inclined with respect to the radial direction of the stator, and the included angle α 1 between the first layer section 2011 and the connecting section 2013, and the included angle α 2 between the second layer section 2012 and the connecting section 2013 are all obtuse angles. Preferably, α 1 is not equal to α 2, so that a good interference prevention effect can be ensured.

In other embodiments, as shown in fig. 10a and 10b, one of the first layer segment 2011 and the second layer segment 2012 is radially twisted with respect to the connecting segment 2013, while the other is left untreated, such that the first layer segment 2011 and the second layer segment 2012 are not located on the same line or concentric circle. Optionally, the first layer section 2011 and the second layer section 2012 are both arc line sections, and preferably, the arc line sections where the first layer section 2011 and the second layer section 2012 are located are not concentric, that is, the first layer section 2011 and the second layer section 2012 are not located on the same concentric circle. Further, one of the first layer segment 2011 and the second layer segment 2012 is located in an arc segment concentric with the stator core 1, and the other is not concentric with the stator core 1. Or alternatively, the arc lengths of first layer segment 2011 and second layer segment 2012 are not equal.

In one specific example, the connecting section 2013 is inclined with respect to the radial direction of the stator, the first layer 2011 is twisted with respect to the connecting section 2013 in a radially outward direction, as shown in fig. 10a and 10b, an arc o1 is a part of a base circle of the bending portion 201, and the base circle refers to a circle where the bending portion 201 is located before being bent; the arc o2 is a portion of the circle that the first layer segment 2011 twists around. In another specific embodiment, where the connecting segments 2013 are angled with respect to the radial direction of the stator, the second layer segments 2012 may be twisted in a radially inward direction with respect to the connecting segments 2013.

As shown in fig. 10a, the distance d in the radial direction of the free ends of the first layer segment 2011 and the second layer segment 2012 is larger than the radial width of the first in-slot portion 202 or the second in-slot portion 203. Thus, when the plurality of conductor segments 20 are simultaneously inserted into the stator slots 11 of the stator core 1, interference between adjacent conductor segments is more effectively prevented.

Of course, the present invention is not limited thereto. In other embodiments of the present invention, first layer segment 2011 and second layer segment 2012 may both be straight segments (not shown). In this case, the connecting section 2013 is inclined with respect to the radial direction of the stator, and the included angle α 1 between the first layer section 2011 and the connecting section 2013, and the included angle α 2 between the second layer section 2012 and the connecting section 2013 are all obtuse angles. Preferably, α 1 is not equal to α 2, so that a good interference prevention effect can be ensured.

According to some embodiments of the invention, as shown in fig. 9, the first in-slot portions 202 and the first layer segments 2011 are located within the first plane Y1, and the second in-slot portions 203 and the second layer segments 2012 are located within the second plane Y2. Optionally, the first face Y1 is an arc face or a plane, and the second face Y2 is an arc face or a plane. That is, when the first layer segment 2011 and the second layer segment 2012 are both arc segments, as shown in fig. 2, the first plane Y1 and the second plane Y2 are both arc surfaces. And when first layer segment 2011 and second layer segment 2012 are both straight segments, first face Y1 and second face Y2 are both planar (not shown). Therefore, the compact structure degree of the stator winding can be ensured.

In some embodiments of the present invention, any cross-section of the conductor segment 20 perpendicular to its direction of extension is rectangular in shape. Alternatively, any cross-section of the conductor segments is rectangular in shape, the shorter sides of the rectangle being perpendicular to the bottom wall of the stator slot 11. Further optionally, the conductor segments have the same cross-section in the direction of extension of the conductor segments. In one particular embodiment, the conductor segment 20 is made of flat copper wire.

By using the conductor segments 20 with rectangular cross section, when inserted into the stator slots, on the one hand the structure between the first or second in-slot portions of adjacent slot layers can be made compact, and on the other hand the integrity of the surface insulating varnish can be ensured, thus ensuring excellent insulating properties.

Conductor segments according to two specific embodiments of the invention are described below with reference to fig. 8 a-12.

In the first embodiment, the first step is,

as shown in fig. 8a, the conductor segment 20 according to this embodiment comprises a bend 201, a first in-slot portion 202 and a second in-slot portion 203. In the present embodiment, as shown in fig. 1 and 2, the conductor segment 20 is made of flat copper wire.

As shown in fig. 9 and 10a, the bending portion 201 includes a first layer 2011, a second layer 2012, and a connecting section 2013 connected between the first layer 2011 and the second layer 2012, and both the first layer 2011 and the second layer 2012 are arc-shaped. The first in-slot portion 202 is connected at the end of the first layer section 2011 remote from the link section 2013 and the second in-slot portion 203 is connected at the end of the second layer section 2012 remote from the link section 2013.

The conductor segment 20 further comprises: the first and

second connection portions

2041 and 2042, and the first and

second welding portions

2051 and 2052, respectively, the first connection portion 2041 is connected between the first in-groove portion 202 and the first welding portion 2051, the first connection portion 2041 is bent relative to the first in-groove portion 202, and the first welding portion 2051 is bent relative to the first connection portion 2041 and is parallel to the first connection portion 2041. The second connecting portion 2042 is connected between the second in-slot portion 203 and the second welding portion 2052, the second connecting portion 2042 is bent with respect to the second in-slot portion 203, and the second welding portion 2052 is bent with respect to the second connecting portion 2042 and is parallel to the second connecting portion 2042. Wherein the free ends of the first weld 2051 and the second weld 2052 each have a chamfered portion 2060.

As shown in fig. 8b, the outer surface of the chamfered portion 2060 is inclined and forms an angle β with the horizontal plane, the angle β is not less than 45 degrees, and the chamfered portion 2060 is formed in a reverse tapered shape at both the second welding portion 2052 and the end of the first welding portion 2051. Further, the height h of the chamfered portion 2060 is less than or equal to 2mm for facilitating welding.

As shown in fig. 10a and 10b, the connecting section 2013 is inclined with respect to the radial direction of the stator, the first layer section 2011 is twisted with respect to the connecting section 2013 in a radially outward direction, as shown by the arc o3, and the second layer section 2012 is twisted with respect to the connecting section 2013 in a radially inward direction, as shown by the arc o 2.

Wherein the distance d in the radial direction of the free ends of the first layer section 2011 and the second layer section 2012 is larger than the radial width of the first in-slot portion 202 or the second in-slot portion 203.

Meanwhile, the first in-slot portion 202 and the first layer segment 2011 are located in the first plane Y1, and the second in-slot portion 203 and the second layer segment 2012 are located in the second plane Y2, where both the first plane Y1 and the second plane Y2 are cambered surfaces, as shown in fig. 9.

In addition, the method for manufacturing the conductor segment according to the first embodiment is as follows:

when making into U type coil, compress tightly "U" style of calligraphy rectangular copper line both sides through cambered surface frock or equipment, the arc surface control on two straight line limits differs, and the rotatory skew of inlayer border straight line portion toward the notch direction, outer border straight line portion toward the reverse rotation skew, the schematic diagram is shown as figure 4, and the straight line limit is in basic circle o1 department, and the inlayer limit circular arc is as o3, and the outer limit circular arc is as o 2. Cutting two ends of a U-shaped flat copper wire with cambered surface characteristics into sharp angles, inserting the wire into an iron core, twisting and forming a welding end, and finally forming the coil as shown in figures 8 a-12.

According to the conductor segment of the embodiment of the invention, the whole stator winding formed after the stator core is inserted has a compact structure, and meanwhile, good insulation performance can be ensured.

In the second embodiment, the first embodiment of the method,

as shown in fig. 8a, the conductor segment 20 according to this embodiment comprises a bend 201, a first in-slot portion 202 and a second in-slot portion 203. In the present embodiment, as shown in fig. 8a and 9, the conductor segment 20 is made of flat copper wire.

The conductor segment 20 further comprises: the first and

second connection portions

2041 and 2042, and the first and

second welding portions

As shown in fig. 10a and 10b, the connecting section 2013 is inclined with respect to the radial direction of the stator, and the first layer section 2011 is twisted toward the radially outward direction with respect to the connecting section 2013 on the basis of the arc o1, such as the arc o 2.

Meanwhile, the first in-slot portion 202 and the first layer segment 2011 are located in the first plane Y1, and the second in-slot portion 203 and the second layer segment 2012 are located in the second plane Y2, where both the first plane Y1 and the second plane Y2 are cambered surfaces, as shown in fig. 2.

Besides, the manufacturing method of the conductor segment according to the above embodiment is as follows:

when a U-shaped coil is manufactured, two sides of a U-shaped flat copper wire are pressed through an arc surface tool or equipment, arc surfaces of two straight line sides are controlled differently, an inner layer side rotates and deviates in the direction of a notch along a straight line part, an outer layer side is concentric with an inner circle iron core of a stator iron core, and does not need to rotate and deviate, a principle diagram is shown in figures 10 a-11 b, a connecting piece of the straight line side and the outer layer side is arranged at a basic circle o1 (concentric with an inner circle of the stator iron core 1), and an arc of the inner layer side is as o 2. Cutting two ends of a U-shaped flat copper wire with cambered surface characteristics into sharp angles, inserting the wire into an iron core, twisting and forming a welding end, and finally forming the coil as shown in figure 12.

A method of forming a conductor segment according to the first embodiment will be described below by taking fig. 13a to 14b as an example.

The molding method comprises the following steps:

s1, bending the straight flat copper wire 20' into a "Z" shape to form a top and bottom side dislocation feature, wherein the two

sides

21 and 22 of the flat copper wire are located on different planes, as shown in fig. 13a and 13 b;

s2, folding the flat copper wire with the Z-shaped bending feature into a V-shape by a tool or equipment, fixing the middle part of the flat copper wire with the V-shaped bending feature by the tool or equipment, and bending the two sides of the flat copper wire to form a U-shape, as shown in fig. 14a, thereby initially forming the conductor segment 20 including the bending portion 201, the first in-slot portion 202 and the second in-slot portion 203, and the plan view thereof is shown in fig. 14 b.

S3, the first layer 2011 and the second layer 2012 of the bending portion 201 of the "U" shaped conductor segment 20 in fig. 14b are compacted by a cambered tooling or a device, so as to obtain the connecting segment 2013 inclined with respect to the radial direction of the stator, and at the same time, the first layer 2011 is twisted with respect to the connecting segment 2013 in the radial outward direction, as shown by the arc o3 in fig. 11a and 11b, and the second layer 2012 is twisted with respect to the connecting segment 2013 in the radial inward direction, as shown by the arc o2 in fig. 11a and 11 b.

S4, bending the lower end of the first in-groove portion 202 to form a first connection portion 2041, further bending the end of the first connection portion 2041 to form a first welding portion 2051, and forming a chamfered portion 2060 at the end of the first welding portion 2051; similarly, the lower end of the second in-slot portion 203 is bent to form a second connection portion 2042, the end of the second connection portion 2042 is further bent to form a second soldering portion 2052, and the end of the second soldering portion 2052 is chamfered to form a chamfered portion 2060, thereby forming the conductor segment 20 according to the first embodiment.

After the conductor segment 20 is formed, it is inserted into the stator core 1, and the straight line portion is twisted and formed by a tooling fixture, and finally the stator winding is formed as shown in fig. 12.

According to the conductor segment of the embodiment of the invention, the first layer segment 2011 and/or the second layer segment 2012 of the bending part 201 are/is twisted in the radial direction, and the first in-slot part 202 and the second in-slot part 203 are/is not processed, so that compared with the conductor segment with a bending step characteristic in the related art, the height of the conductor segment cannot be influenced in the axial direction, the height of the whole stator winding cannot be influenced, and the formed stator winding has a compact structure. In addition, due to radial torsion, compared with the bending step characteristic in the related art, the bending step characteristic can effectively reduce the damage risk of an insulating layer caused by bending, can protect the flat copper wire surface paint coat, and ensures good insulating property. In addition, the stator winding formed after the conductor sections is adopted has the advantages of less copper amount, less copper consumption and higher motor efficiency, and the chamfer part 2060 is arranged at the welding end, so that the stator core 1 is convenient to get off the line when being inserted, the risk of scratching the paint skin of the adjacent copper wire during the off-line process can be reduced, and the reliability of the motor is improved. In addition, the welding end is provided with a chamfer, so that the welding is convenient.

According to one embodiment of the invention, the U-shaped conductor segment 20 comprises at least: a plurality of first U-shaped conductor segments 2001, 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, the first U-shaped conductor segments 2001 being used for the same-layer crossing in step S32, the second U-shaped conductor segments 20 being used for the radial crossing from the radially outer layer inward by one layer when the winding is crossing in the forward direction in step S33, the third U-shaped conductor segments 20 being used for the radial crossing from the radially inner layer outward by one layer when the winding is crossing in the reverse direction in step S35, and the fourth U-shaped conductor segments 20 being used for the same-layer crossing in step S34. In other words, the first U-shaped conductor segment 2001 is for a peer-to-peer crossing between the radially outermost layers, and the fourth U-shaped conductor segment 2004 is for a peer-to-peer crossing between the radially innermost layers; the second U-shaped conductor segment 2002 is used to span one layer inward and outward, i.e., forward, and the third U-shaped conductor segment 2003 is used to span one layer inward and outward, i.e., reverse.

More specifically, in coil winding, in each phase, the terminal lead-out wire is connected at the weld end to the first in-slot portion of one first U-shaped conductor segment 2001 located at the radially outermost slot layer, the first U-shaped conductor segment 2001 crossing y stator slots on the same layer in the reverse direction; a plurality of second U-shaped conductor segments 2002 span in the forward direction and are connected in sequence, each second U-shaped conductor segment 2002 spans y stator slots, and a slot layer in which a second in-slot portion of each second U-shaped conductor segment 2002 is located is radially inward by one layer than a slot layer in which a first in-slot portion is located until the second in-slot portion is located in a radially innermost slot layer; a third U-shaped conductor segment 2003 spans y stator slots in opposite directions on the same layer; a plurality of fourth U-shaped conductor segments 2004 span in opposite directions and are connected in sequence, each fourth U-shaped conductor segment 2004 spans y stator slots, and a second in-slot portion of each fourth U-shaped conductor segment 2004 is located one layer radially outward of a slot layer in which the first in-slot portion is located until the second in-slot portion is located at a radially outermost slot layer; the above arrangement is repeated again with 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 of the radially outermost slot layer of the termination slot and connects the star point outgoing line of that phase, wherein the termination slot is y stator slots away from the initial slot in the forward direction.

As shown in fig. 2 to 3d, the end of each of the first in-slot portion 202 and the second in-slot portion 203 of the U-shaped conductor segment 20 is connected with a connection portion and a soldering portion, and the connection portion is bent with respect to the in-slot portion. Specifically, as shown in fig. 3a and 3d, the bending directions of the connection portions 204 of the first in-slot portion 202 and the second in-slot portion 203 in the first U-shaped conductor segment 20 are the same, the bending directions of the connection portions 204 of the first in-slot portion 202 and the second in-slot portion 203 in the fourth U-shaped conductor segment 20 are the same, the shapes of the first U-shaped conductor segment 20 and the fourth U-shaped conductor segment 20 are substantially the same, and the bending directions of the connection portions 204 are opposite, but due to the difference in width between the stator slots at different radial positions, the spanning dimensions of the first U-shaped conductor segment 2001 and the fourth U-shaped conductor segment 2004 are different, that is, the distance L1 between the two in-

slot portions

202 and 203 of the first U-shaped conductor segment 2001 and the distance L4 between the two in-

slot portions

202 and 203 of the fourth U-shaped conductor segment 2004 are different, more specifically, L1 > L4.

As shown in fig. 3b and 3c, the connection portions 204 of the first in-slot portion 202 and the second in-slot portion 203 of the second U-shaped conductor segment 2002 are bent in opposite directions, and the second U-shaped conductor segment 2002 and the third U-shaped conductor segment 2003 have substantially the same shape and span (6 stator slots). It should be readily understood by those skilled in the art that the dimensions between the two in-slot portions of the forward-spanning second U-shaped conductor segment 2002 and the reverse-spanning third U-shaped conductor segment 2003 between the adjacent two slot layers should be identical, for example, the distance L2 between the two in-

slot portions

202, 203 of the second U-shaped conductor segment 2002 when spanning from the radially outer second layer to the third layer, and the distance L3 between the two in-

slot portions

202, 203 of the third U-shaped conductor segment 2003 when spanning from the third layer to the second layer, are equal. Of course, it is also to be understood that due to the different widths between the stator slots at different radial positions, the distance L2 between the two in-

slot portions

202, 203 of the plurality of second U-shaped conductor segments 2002 that are positively spanned between different slot layers should also be different, e.g. the distance L2 between the two in-

slot portions

202, 203 of the second U-shaped conductor segment 2002 when spanning from the radially outer second layer to the third layer and the distance L2 'between the two in-

slot portions

202, 203 of the second U-shaped conductor segment 2002 when spanning from the third layer to the fourth layer are different, more precisely L2' is smaller than L2.

Optionally, the first in-slot portion 202 and the second in-slot portion 203 of the second U-shaped conductor segment 20 are located on different surfaces, and likewise, the first in-slot portion 202 and the second in-slot portion 203 of the third U-shaped conductor segment 2003 are also located on different surfaces. Here, "surface" refers to a cylindrical surface concentric with the stator core, and the first in-slot portion 202 and the second in-slot portion 203 are located on different surfaces, meaning that they are not on the same cylindrical surface of the stator core.

According to the winding method provided by the embodiment of the invention, the types of the U-shaped conductor sections required by winding are few, so that the equipment for manufacturing the U-shaped conductor sections is few, and the mass production is easy to realize.

In addition, according to the winding method provided by the embodiment of the invention, the distance between the terminal outgoing line and the star point outgoing line is minimum, the terminal outgoing line and the star point outgoing line can be used as the structure of an initial stator assembly, for example, the terminal outgoing line and the star point outgoing line are structurally arranged in a factory, and the number of the parallel branch circuits of the winding can be respectively adjusted according to the requirements of customers. Therefore, on the basis of the stator assembly, if a user needs 1-path access, the stator assembly provided by the embodiment of the invention can be processed to be adjusted into the stator assembly with 1-path parallel branches, and then the stator assembly is assembled with components such as a rotor and the like to obtain a path of access motor; correspondingly, when 2 paths of access are needed, the stator assembly provided by the embodiment of the invention is processed to be adjusted into the stator assembly with 2 paths of parallel branches.

The processing method of the stator assembly 100 according to the different paths required by the user will be described in detail below.

The processing method comprises the following steps:

s1, selecting the number g of paths, wherein g is a natural number more than or equal to 1

Where q is odd, g has 2 choices: q-way and 1-way;

when q is an even number, g has q/2+1 choices, q, q/2, q/4, … …, 1;

s2, when the number g of the selected paths is q, bending the star point outgoing lines of each path in the m phases outwards, and connecting the star point outgoing lines through a neutral line 3; and the terminal lead-out wire of each path in the m phases is connected with an interface of an external controller after being welded and fixed. Alternatively, the material in the neutral wire 3 here may correspond to the material of the U-shaped conductor section 20.

S3, when the number g of the selected paths is 1, extending and bending the terminal lead wire of the kth path in each phase outwards, and then sequentially welding and fixing the terminal lead wire of the kth path with the star point lead wire of the kth-1 path in the corresponding phase, wherein k is a natural number from 2 to q; welding and fixing the 1 st path of terminal lead-out wire in each phase and then connecting the terminal lead-out wires with an external controller interface; the star point lead-out wires of the paths except the 1 st path in each phase are bent outwards and connected through a neutral line 3.

At this time, for clarity of description, taking the U-phase winding of 4 paths as an example, if it is to be changed into one path, it can be done in the following way: leading-out wires of the U-phase 4 th path are connected with star point lines of the U-phase 3 path after being elongated and bent, leading-out wires of the U-phase 3 path are connected with star point lines of the U-phase 2 path after being elongated and bent, leading-out wires of the U-phase 2 path are connected with star point lines of the U-phase 1 path after being elongated and bent, and leading-out wires of the U-phase 1 path are connected with an external controller after being welded and fixed; in addition, the star point lines of the U-phase 4-way are connected through a first neutral line 3; star points of the U-phase 3 path are connected through a second neutral line 3; the star point lines of the U-phase 2-way are connected through a third neutral line 3.

And when the number of the S4 and q is even, q paths in each phase are divided into q/2 groups, one path of terminal outgoing line in at least one group of the q/2 groups is fixed with the other path of star point outgoing line in a welding manner after being elongated and bent, wherein one path of star point outgoing line is bent outwards and connected with the neutral line 3, and the other path of terminal outgoing line is connected with an external controller interface after being fixed in a welding manner.

For clarity of description, the U phase in 4 paths is still taken as an example, and if it is to be changed into two paths, the following steps are performed: 4 ways in the U phase are divided into 2 groups, the 1 st way and the 2 nd way are the first group, the 3 rd way and the 4 th way are the second group, wherein, the outgoing line of the 2 nd way is welded and fixed with the star point line of the 1 st way, the star point line of the 2 nd way is connected with the neutral line 3, and the 1 st way is connected with the external controller. And the leading-out wire of the 4 th path is welded and fixed with the star point line of the 3 rd path, the star point line of the 4 th path is connected with the neutral line 3, and the 3 rd path is connected with the external controller. Thus, 2 paths are formed finally.

According to the processing method provided by the embodiment of the invention, the number of winding paths of the stator assembly can be adjusted, and the adjusting mode is simple and quick; and can match the whole car demand of different motor voltage grades, also can match the whole car demand of different high-efficient districts. In addition, the number of paths can be adjusted to be different, so that the voltage difference between adjacent layers in each stator slot is different, the requirements on a layer insulation system are different, and different path schemes can be selected according to actual risks and cost control.

The stator assembly, the winding method and the processing method for adjusting the number of paths will be described by taking the stator assembly according to the embodiment of the invention as an example for a motor with 8 poles, 48 slots and 3 phases: 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. 4, in the 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 is 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. 4, the difference between the star point outgoing line and the terminal outgoing line of each U phase is 6 stator slots 11, and the difference between two U phases is 1 stator slot 11 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 11 in the circumferential direction; the terminal lead wires corresponding to the U phase, the V phase and the W phase are different by 4 stator slots 11 in the circumferential direction.

More specifically, as shown in fig. 5 and 6, 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. 5 and 6, 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, U1B for U-phase 1 route, V1B for V-phase 1 route, and W1B for W-phase 1 route are circumferentially separated by 4 slots in this order, for example, as shown in fig. 2, 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.

Accordingly, the terminal lead wires corresponding to the U-phase, the V-phase, and the W-phase are circumferentially different by 4 stator slots 11. 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. 2, 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 stator winding structure may be wound by the following winding method, as shown in fig. 5 and 6, 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,

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. 5 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;

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 through the neutral wire 3 by welding, as shown in fig. 7, 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 through welding terminals by welding.

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, according to the stator assembly 100 of the embodiment of the present invention, only the welding point is located at the welding end, and the welding terminal is not located at 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.

An electric machine according to an embodiment of another aspect of the invention comprises a stator assembly according to the description in the above embodiment.

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 module is suitable for a z-slot 2 p-level m-phase motor, the number of slots of each pole and each phase is q ═ z/m/(2p), the number of parallel branches is a, a is less than or equal to q, and the stator module is characterized by comprising the following components:

the pitch between the first in-slot portion and the second in-slot portion is y stator slots, wherein y is an integer and y is z/2p, the first in-slot portion of the U-shaped conductor segments passes through one slot layer of one of the stator slots, the second in-slot portion passes through one slot layer of the other stator slot, the first in-slot portion and the second in-slot portion pass through the stator slots and then the ends of the first in-slot portion and the second in-slot portion exceed the stator core to form a weld end, and the first in-slot portion and the second in-slot portion of the plurality of U-shaped conductor segments located in the adjacent slot layers are welded and connected at the weld end;

2. The stator assembly of claim 1 wherein the number of slot layers in each of said stator slots is an even number.

3. The stator assembly of claim 1 wherein the terminal lead wires of each of the in-phase paths are circumferentially separated by 1 stator slot by two.

4. The stator assembly of claim 1, wherein the star point lines of each path in phase are circumferentially separated by 2q stator slots by two, and the terminal lead lines of each path in phase are circumferentially separated by 2q stator slots by two.

5. The stator assembly of claim 1, wherein an end of either of the first and second in-slot portions of the U-shaped conductor segment has a connection portion and a weld portion connected thereto, the connection portion being bent with respect to the in-slot portion in which it is located.

6. The stator assembly according to claim 5, characterized in that the bending directions of the connecting portions of the first in-slot portion and the second in-slot portion in the first U-shaped conductor section are uniform;

the bending directions of the connecting parts of the first in-groove part and the second in-groove part in the fourth U-shaped conductor section are consistent;

the bending directions of the connecting parts of the first U-shaped conductor section and the fourth U-shaped conductor section are opposite.

7. The stator assembly according to claim 5, characterized in that the bending directions of the connecting portions of the first in-slot portions and the second in-slot portions of the second U-shaped conductor segments are opposite, and the second U-shaped conductor segments and the third U-shaped conductor segments are identical in shape.

8. The stator assembly of claim 6, wherein the first in-slot portion and the second in-slot portion of the second U-shaped conductor segment are located on different planes.

9. The stator assembly according to any of claims 1-8, wherein the stator assembly is suitable for an electric machine having a slot number z of 48, a pole pair number p of 4, a phase number 3, and a pitch y of 6, wherein each of the 48 stator slots has 6 slot layers a, b, c, d, e, f, and 3 phases including a U phase, a V phase, and a W phase, and each phase number a is 2, and wherein the winding route of the first U phase of the stator is as follows:

10. The stator assembly of claim 1, characterized in that the U-shaped conductor segments are equal in cross-sectional area in the direction of extension of the U-shaped conductor segments.

11. The stator assembly of claim 1, wherein the outer surface of the chamfer is beveled and forms an included angle β with a horizontal plane, the included angle β being greater than or equal to 45 degrees.

12. The stator assembly of claim 11 wherein the included angle β is in the range of 45-60 degrees.

13. The stator assembly according to claim 11, characterized in that any cross section of the U-shaped conductor segments perpendicular to its extension direction is rectangular in shape, and the chamfer has an outer surface with a slope parallel to a short side of the rectangular shape.

14. The stator assembly of claim 11, wherein the chamfered portion is formed in a reverse taper shape at an end of the second weld and the first weld.

15. The stator assembly according to claim 14, characterized in that any cross section of the U-shaped conductor segments perpendicular to the extension direction thereof is rectangular in shape, and the height h of the chamfer satisfies: tan β ═ h/0.5b, where b is the length of the long side of the rectangular shape.

16. The stator assembly of claim 1, wherein the conductor segments further comprise:

a first connection portion connected between the first in-slot portion and the first weld portion, the first connection portion being bent relative to the first in-slot portion, the first weld portion being bent relative to the first connection portion and being parallel to the first connection portion;

a second connection portion connected between the second in-slot portion and the second weld portion, the second connection portion being bent relative to the second in-slot portion, the second weld portion being bent relative to the second connection portion and being parallel to the second connection portion.

17. The stator assembly of claim 16, wherein an angle γ 1 between the first connection and the first in-slot portion and an angle γ 2 between the second connection and the second in-slot portion are obtuse angles.

18. The stator assembly of claim 17, wherein γ 1, γ 2 satisfies:

gamma 1 is more than or equal to 100 degrees and less than or equal to 160 degrees; gamma 2 is more than or equal to 100 degrees and less than or equal to 160 degrees.

19. The stator assembly of claim 18, wherein the first connection is connected to the first in-slot portion and the first weld by a fillet.

20. The stator assembly of claim 1 wherein any cross section of the conductor segments is rectangular in shape, the shorter sides of the rectangle being perpendicular to the stator slot bottom walls.

21. An electrical machine comprising a stator assembly according to any of claims 1-20.