CN109586465B

CN109586465B - Stator assembly and motor and vehicle with same

Info

Publication number: CN109586465B
Application number: CN201710912483.6A
Authority: CN
Inventors: 田凯丽; 游斌; 齐文明
Original assignee: BYD Co Ltd
Current assignee: BYD Co Ltd
Priority date: 2017-09-29
Filing date: 2017-09-29
Publication date: 2021-09-03
Anticipated expiration: 2037-09-29
Also published as: WO2019062921A1; CN109586465A

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 conductor segment comprises an in-slot part arranged in a stator slot of the stator core, a first end and a second end, wherein the first end and the second end are arranged outside the stator core; a neutral wire circumferentially surrounding a weld end of the stator winding; and the plurality of connecting blocks are provided with accommodating spaces in each connecting block, and the neutral wires penetrate through and are welded in the accommodating spaces to be connected to the phase star point lead-out wires of the stator winding. According to the stator assembly disclosed by the invention, the occupied space can be 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 of a stator core, 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 welding end, a star point outgoing line of each phase of the stator winding being located on the welding end; a neutral wire circumferentially surrounding the weld end of the stator winding; and each connecting block is internally provided with a containing space, and the neutral wire penetrates through and is welded in the containing space to be connected to each phase star point lead-out wire of the stator winding.

According to the stator assembly, the neutral line is arranged, and the star point outgoing lines are respectively connected with the neutral line through the connecting blocks, so that the neutral line is formed by connecting every two connecting parts of three star point outgoing lines through two line U-shaped lines in the prior art, the connecting structure of the star point outgoing lines and the neutral line can be simplified, welding parts 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 segment is a U-shaped conductor segment comprising a first in-slot portion and a second in-slot portion disposed in a stator slot, the first end is a U-shaped bend connecting the first in-slot portion and the second in-slot portion; u-shaped bends in the plurality of U-shaped conductor segments form a hairpin end of the stator winding, and second ends of the first and second in-slot portions form a weld end of the stator winding.

In some embodiments of the present invention, the cross-section of the receiving space is formed in an arc shape, a U shape, or a polygonal shape.

In some embodiments of the invention, the wire ends of the star point outgoing wires extend axially along the stator core; the connecting block is configured in a U-shape and includes radially spaced inner and outer legs, the inner leg being soldered to a wire end of the star point outgoing wire, and the neutral wire being soldered between the inner and outer legs.

Further, the neutral wire is welded to a radially inner surface of the outer leg and is spaced from a U-shaped bottom wall connecting the bottom of the outer leg and the inner leg.

Further, the neutral wire is welded to a U-shaped bottom wall connecting the bottom of the outer leg and the bottom of the inner leg.

In some embodiments of the present invention, the top of the receiving space is open, and the top surface of the neutral line is flush with the top surface of the connection block.

Further, star point outgoing lines of all phases of the stator winding are located on the last radial outer layer of the stator winding.

In some embodiments of the present invention, the neutral line is an arc-shaped line segment having a rectangular cross section and is concentric with the stator core, and a width thereof in a radial direction is smaller than a height thereof in an axial direction.

In some embodiments of the present invention, a span of the neutral line in a circumferential direction of the stator core is equal to or greater than a maximum span of the star point outgoing lines in the circumferential direction of each phase.

In some embodiments of the invention, the cross-sectional area of the neutral line is equal to or greater than the cross-sectional area of the star point outgoing line for each phase.

In some embodiments of the invention, the neutral is a press formed copper bar or a copper bar having a circular cross section and the material of the neutral is the same as the material of the conductor segment.

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, wherein the neutral and star point outgoing lines are connected by a U-shaped connection block;

FIG. 2 is an enlarged view of the star point outlet, connection block and neutral connection shown in FIG. 1;

FIG. 3 is a schematic view of a stator assembly according to an embodiment of the present invention, wherein the neutral and star point outgoing lines are connected by a block-shaped connection block;

FIG. 4 is a schematic diagram of a stator assembly according to an embodiment of the present invention, wherein two star point outgoing lines in each phase are merged and then connected to a neutral line through a connection block;

FIG. 5 is an enlarged view of the star point outlet, connection block and neutral connection shown in FIG. 4;

FIG. 6 is a schematic view of a stator core in a stator assembly according to an embodiment of the present invention;

FIG. 7 is a schematic view of a U-shaped conductor segment of a stator assembly according to an embodiment of the present invention;

FIGS. 8 a-8 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. 9 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. 10 is a winding schematic of the stator assembly of FIG. 9, illustrating a U-phase 1-path by way of example;

FIG. 11 is the final stator assembly of FIG. 9 after the stator assembly has been machined to form a 2-way connection;

fig. 12 is a final stator assembly of fig. 9 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,

stator winding 2, conductor segments 21, hairpin terminals 22, weld terminals 23, star point terminals 24, terminal terminals 25,

the neutral line 3 is a line which is,

the connecting block 4, the accommodation space 401, the inner leg 41, the outer leg 42, the U-shaped bottom wall 43,

avoiding the 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. 1-5. 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, a connection block 4, 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 and a second in-slot portion described below) that is provided in the stator slot, and a bend that connects the in-slot portions, which pass through the stator slot with their ends (e.g., the upper ends of the in-slot portions shown in fig. 1) beyond the stator core 1, and the end at which the ends of the in-slot portions are located (e.g., the upper ends of the in-slot portions shown in fig. 1) form a 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.

In some examples, as shown in fig. 1 and 2, the connection block includes a plurality of connection blocks 4, and the plurality of connection blocks 4 are connected between the star point outgoing line 24 and the neutral line 3 in one-to-one correspondence. Through setting up connecting block 4 indirect connection, can reduce the size of single welding point, be applicable to all the way or multichannel (the parallelly connected counts in every phase winding) and stable in structure, in addition, can also conveniently change connecting block 4. When each phase comprises a plurality of star point outgoing lines, the connecting blocks can comprise a plurality of star point outgoing lines which are in one-to-one correspondence with the multiphase windings, and the plurality of connecting blocks are connected with the star point outgoing lines which are combined and connected in each phase in a one-to-one correspondence mode.

In addition, the connecting block can also comprise a plurality of star point outgoing lines which are respectively connected with each path of star point outgoing line in a one-to-one correspondence mode.

The connection block 4 may have a receiving space 401 therein, and the neutral wire 3 passes through and is received in the receiving space 401 to be connected to each of the phase star point outgoing lines of the stator winding. From this, occupation space can be reduced to, at the motor operation in-process, the vibrations of different degrees can appear, and this vibrations cause the welding position of neutral conductor and star point lead-out wire to appear droing easily, and for this reason, neutral conductor 3 passes and holds in accommodation space 401, makes neutral conductor and accommodation space's connection more stable, is difficult for causing droing of neutral conductor. Wherein, alternatively, the cross section of the receiving space 401 in the radial direction of the stator core 1 may be formed in an arc shape, a U shape, or a polygon shape.

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

As shown in fig. 1, 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, the six outgoing lines 25 of the three-phase winding are respectively: a U-phase one-path outgoing line, a U-phase two-path outgoing line, a V-phase one-path outgoing line, a V-phase two-path outgoing line, a W-phase one-path outgoing line and a W-phase two-path outgoing line. Six star point outgoing lines 24 of the three-phase winding are respectively as follows: the star point line comprises a U-phase one-star point line a, a U-phase two-star point line b, a V-phase one-star point line c, a V-phase two-star point line d, a W-phase one-star point line e and a W-phase two-star point line 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 neutral line is formed by connecting the connection parts of three star point outgoing lines two by two through two U-shaped lines in the prior art, the connection structure of the star point outgoing lines 24 and the neutral line 3 can be simplified, the welding parts are reduced, the axial and radial spaces of the stator assembly 100 occupied by the welding parts 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, the conductor segments 21 are non-circular in cross-section perpendicular to their length. 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 comprises a U-shaped bending part, a first in-slot part and a second in-slot part, wherein the first in-slot part and the second in-slot part are arranged in a stator slot, the first in-slot part and the second in-slot part are respectively connected with the U-shaped bending part, and the end parts of the first in-slot part and the second in-slot part exceed the stator core 1 after the first in-slot part and the second in-slot part penetrate through a stator slot. For example, the lower end of the first in-slot portion and the lower end of the second in-slot portion are both connected to the U-shaped bent portion, and the upper end of the first in-slot portion and the upper end of the second in-slot portion both pass through the stator slot and extend 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 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 and the second in-slot portion are located is a hairpin end 22 of the stator winding 2, and the end where the ends of the first in-slot portion and the second in-slot portion are located is a welding end 23 of the stator winding 2.

Preferably, the distance of the connecting pieces 4 is equal to or less than the distance of the neutral line 3 in the axial direction of the stator core 1 (e.g., the up-down direction shown in fig. 3). Here, the distance of the connecting block in the axial direction of the stator core means the height or size of the connecting block in the axial direction of the stator core, and the distance of the neutral line means the height or size of the neutral line in the axial direction of the stator core. For example, both ends of the connecting block 4 in the axial direction of the stator core 1 do not exceed both ends of the neutral line 3 in the axial direction of the stator core 1.

As shown in fig. 3, the connection block 4 is formed in a rectangular parallelepiped shape, the cross section of the neutral wire 3 and the cross section of the end of the star point outgoing wire 24 are both square, and the radially inner surface and the radially outer surface of the connection block 4 are respectively attached to and welded to the star point outgoing wire 24 and the neutral wire 3, wherein the upper surface of the connection block 4 is flush with the upper surface of the end of the star point outgoing wire 24 and the upper surface of the neutral wire 3, and the lower surface of the connection block 4 is flush with the lower surface of the neutral wire 3.

Preferably, in the radial direction of the stator core 1, the cross-sectional area of the connecting block 4 to which the star point outgoing lines of the respective paths in each phase are connected is greater than or equal to the sum of the cross-sectional areas of the star point outgoing lines 24 of the respective paths in each phase. For example, when there is only one path in one phase winding, the cross-sectional area of the connection block 4 in the radial direction is not smaller than the cross-sectional area of the star point outgoing line 24 of the path; when a phase winding is provided with two parallel branches, the radial sectional area of the connecting block 4 is not less than the sum of the sectional areas of the two star point outgoing lines 24 in the phase; when three paths of parallel branches are arranged in one phase winding, the cross section area of the connecting block 4 in the radial direction is not smaller than the sum of the cross section areas of the three star point outgoing lines 24 in the phase. So as to meet the requirement of electric connection between the connecting block and the star point outgoing line.

Specifically, according to a calculation formula of the resistance, the resistance of the conductor is inversely proportional to the sectional area of the conductor, so that the sectional area of the connecting block 4 is larger than or equal to the sum of the sectional areas, perpendicular to the length direction, of the star point outgoing lines 24 of each path in each phase, the resistance of the connecting block 4 in unit length is smaller than or equal to the resistance of the star point outgoing lines 24 of each path in each phase in unit length, the heating value of the connecting block 4 in unit length is smaller than or equal to the heating value of the star point outgoing lines 24 of each path in each phase in unit length, and the problem of local overheating of the connecting block 4 is avoided.

Further, as shown in fig. 2, the wire ends of the star point outgoing wires 24 extend in the axial direction of the stator core (for example, the up-down direction shown in fig. 2); the connection block 4 is configured in a U-shape, and the connection block 4 may include: an inner leg 41 and an outer leg 42, the inner leg 41 and the outer leg 42 being spaced apart in a radial direction of the stator core 1, the inner leg 41 being welded to a terminal end of the star point lead wire 24, the neutral wire 3 being welded between the inner leg 41 and the outer leg 42.

As shown in fig. 5, when multiple star point outgoing lines are included in each phase, the inner leg may be soldered to a line end of any one of the multiple star point outgoing lines merged in each phase, and the neutral line is soldered between the inner leg and the outer leg.

In addition, the inner supporting leg can be welded with the line end of each phase of star point outgoing line, and the neutral line is welded between the inner supporting leg and the outer supporting leg.

Alternatively, the neutral wire 3 may be welded to the radially inner surface of the outer leg 42 with the neutral wire 3 spaced from the U-shaped bottom wall 43 connecting the bottom of the outer leg 42 and the inner leg 41. Of course, the invention is not limited thereto, and the neutral wire 3 may also be welded to a U-shaped bottom wall 43 connected to the bottom of the outer leg 42 and the inner leg 41, that is, the neutral wire 3 may also be welded to the U-shaped bottom wall 43, wherein the U-shaped bottom wall 43 is connected to the bottom of the outer leg 42 and the inner leg 41.

Further, as shown in fig. 2, the top of the accommodating space 401 is open, so that the neutral wire 3 can be inserted into the accommodating space 401 from top to bottom, facilitating assembly. Preferably, the top surface of the neutral wire 3 is flush with the top surface of the connection block 4 to reduce the occupied space.

In some examples, the neutral line 3 is an arc-shaped line segment having a rectangular cross section, and the neutral line 3 of the arc-shaped line segment is concentric with the stator core 1, so that the distances between the neutral line 3 and the plurality of star point outgoing lines 24 spaced in the circumferential direction in the radial direction can be made uniform, so that the neutral line 3 is connected to each star point outgoing line 24.

Further, the width of the neutral line 3 in the radial direction of the stator core 1 is smaller than the height of the neutral line 3 in the axial direction of the stator core 1, so that the occupied space in the radial direction can be reduced, and the connection is convenient.

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 star point outgoing lines in the three phases.

Optionally, the cross-sectional area of the neutral line is greater than or equal to the cross-sectional area of the star point outgoing line of each phase.

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

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 with the star point outgoing wire 24 can be met. Specifically, according to the calculation formula of the resistance, the resistance of the conductor is inversely proportional to the sectional area of the conductor, so that the sectional area of the neutral line 3 is larger than or equal to the sum of the sectional areas of the star point outgoing lines 24 of each path in each phase, which are perpendicular to the length direction of the star point outgoing lines, the resistance of the neutral line 3 per unit length is smaller than or equal to the resistance of the star point outgoing lines 24 of each path in each phase, the heating value of the neutral line 3 per unit length is smaller than or equal to the heating value of the star point outgoing lines 24 of each path in each phase, and the problem of local overheating of the neutral line 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, as shown in fig. 5, multiple star point outlets 24 in each phase are merged 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, as shown in fig. 5, 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 to the connection block 4, and the connection block 4 is welded to the neutral line 3.

In some embodiments of the present invention, as shown in fig. 1 to 3, 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 wires 3, each neutral wire 3 is connected with each star point outgoing wire 24 of each phase, and the two neutral wires 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. 6 to 12, a winding method of a stator winding in a stator assembly according to an embodiment of the present invention will be 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.

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 segments 21 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, the first in-slot portion 202 and the second in-slot portion 203 of each U-shaped conductor segment 21 differ by 6 stator slots.

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. 9, 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. 10 and 11, 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. 10 and 11, 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. 9, 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. 9, 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. 10 and 11, 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. 10 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 comprising a plurality of conductor segments; each conductor segment comprises an in-slot portion arranged in a stator slot of a stator core, a first end and a second end arranged outside the stator core, the in-slot portion is connected between the first end and the second end, the second ends of the plurality of conductor segments form a welding end, 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 the stator slot, and the first end is a U-shaped bent portion connecting the first in-slot portion and the second in-slot portion; u-shaped bent parts in the U-shaped conductor sections form a hairpin end of the stator winding, second ends of the first in-slot part and the second in-slot part form a welding end of the stator winding, and star point outgoing lines of all phases of the stator winding are located on the welding end;

a neutral wire circumferentially surrounding the weld end of the stator winding;

a plurality of connection blocks each having an accommodation space therein, the neutral wire passing through and being welded in the accommodation space to be connected to each of the phase star point outgoing lines of the stator winding;

the connecting block is configured in a U-shape and includes radially spaced apart inner and outer legs, with the neutral wire welded between the inner and outer legs.

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

3. The stator assembly of claim 1, wherein the receiving space is formed in an arc shape, a U shape, or a polygonal shape in cross-section.

4. The stator assembly of claim 1, wherein the wire ends of the star point lead-out wires extend axially along the stator core;

and the inner supporting leg is welded with the line end of the star point outgoing line.

5. The stator assembly of claim 4 wherein the neutral line is welded to a radially inner surface of the outer leg and spaced from a U-shaped bottom wall connected to a bottom of the outer leg and the inner leg.

6. The stator assembly of claim 5 wherein the neutral wire is welded to a U-shaped bottom wall connected to the bottom of the outer leg and the inner leg.

7. The stator assembly of claim 1, wherein the top of the receiving space is open and the top surface of the neutral line is flush with the top surface of the connecting block.

8. The stator assembly of claim 1 wherein the star point lead-out wires of each phase of the stator winding are located on the radially last outer layer of the stator winding.

9. The stator assembly of any of claims 1-8, wherein the neutral line is an arcuate line segment having a rectangular cross-section and is concentric with the stator core, and has a width in a radial direction that is less than a height in an axial direction.

10. The stator assembly according to claim 1, wherein a span of the neutral line in a circumferential direction of the stator core is equal to or greater than a maximum span of the star point outgoing lines of each phase in the circumferential direction.

11. The stator assembly according to any of claims 1-8, characterized in that a cross-sectional area of the neutral line is equal to or greater than a cross-sectional area of the star point outgoing line of each phase.

12. The stator assembly of claim 1, wherein the neutral wire is a press formed copper bar or a copper bar having a circular cross-section and the material of the neutral wire is consistent with the material of the conductor segment.

13. An electrical machine comprising a stator assembly according to any of claims 1-12.

14. A vehicle characterized by comprising an electric machine according to claim 13.