CN110971040B

CN110971040B - Stator assembly and motor with same

Info

Publication number: CN110971040B
Application number: CN201811141645.1A
Authority: CN
Inventors: 齐文明; 游斌; 田凯丽; 陈园辉
Original assignee: BYD Co Ltd
Current assignee: BYD Co Ltd
Priority date: 2018-09-28
Filing date: 2018-09-28
Publication date: 2021-09-03
Anticipated expiration: 2038-09-28
Also published as: CN110971040A

Abstract

The invention discloses a stator assembly and a motor with the same. The stator assembly includes a stator core and a stator winding. The stator core has a plurality of stator slots, and the stator winding is constructed from a plurality of U-shaped conductor segments including a first type of conductor segment and a second type of conductor segment. The stator winding comprises an A-phase first winding and an A-phase second winding, the A-phase first winding comprises an A-phase first sub-circuit and an A-phase second sub-circuit, the A-phase first sub-circuit and the A-phase second sub-circuit are wound in a parallel mode, the A-phase second winding comprises an A-phase third sub-circuit and an A-phase fourth sub-circuit, and the A-phase third sub-circuit and the A-phase fourth sub-circuit are wound in a parallel mode. At the corresponding welding ends of the second sub-winding segment of the first route winding of the phase A and the seventh sub-winding segment of the second route winding of the phase A, the welding ends span (y-1) stator slots, so that the distance at the welding ends can be reduced, the welding connection is easy to realize, the conductor area is reduced, and the skin effect can be effectively reduced.

Description

Stator assembly and motor with same

Technical Field

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

Background

The Chinese patent application publication No. 200780022091.7 entitled "electrodes and connections between multiple sets of segmented hairpins" adopts two winding sets, wherein the 1, 2 layers and the 3, 4 layers are different winding sets, the 1 st layer and the 2 nd layer are first winding sets, and the 3 rd layer and the 4 th layer are second winding sets.

In the patent, 4 layers of windings, namely 1 layer and 2 layers, and 3 layers and 4 layers are respectively wound, two winding sleeves are adopted, the structure is complex, the types of coils are relatively more, and the process is more complex; the outgoing line and the star point line are both arranged at the inserting side, namely the forming end, so that the occupied space is large; the distribution of the three-phase star point lines and the outgoing lines is more dispersed, and the three-phase star point lines and the outgoing lines are not easy to connect. From the analysis of the electrical connection, the voltage difference between different layers in the same groove is high in the winding form, and the layers are easy to break down under high voltage, 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, an object of the present invention is to provide a stator assembly, which has simple manufacturing process of winding and safe and reliable electrical connection.

The invention also provides a motor which is provided with the stator assembly.

The stator assembly provided by the embodiment of the invention is suitable for a z-slot 2 p-stage m-phase motor, the number of slots of each pole and each phase is q-z/m/(2 p), the number of parallel branches is a, and a is less than or equal to q, and 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 constructed of a plurality of U-shaped conductor segments, each of the U-shaped conductor segments including a bend and first and second in-slot portions connected to the bend, respectively, the first in-slot portion of the U-shaped conductor segment passing through one of the slot layers of one of the stator slots and the second in-slot portion passing through one of the other stator slots, the first and second in-slot portions passing through the stator slots with ends thereof exceeding the stator core to form a weld end on which the first and second in-slot portions of the plurality of U-shaped conductor segments located in adjacent layers are welded;

the U-shaped conductor segments comprise first-type conductor segments and second-type conductor segments, the first in-slot portions of the first-type conductor segments being located in the outermost slot layer of the respective stator slot, and the second in-slot portions of the first-type conductor segments being located in the innermost slot layer of the respective stator slot; the first in-slot portions of the second type conductor segments and the second in-slot portions of the second type conductor segments are located in the inner slot layers of the corresponding stator slots, the inner slot layers include sub-outer slot layers and sub-inner slot layers, the first in-slot portions of the second type conductor segments are located in the sub-inner slot layers of the corresponding stator slots, and the second in-slot portions of the second type conductor segments are located in the sub-outer slot layers of the corresponding stator slots;

the stator winding comprises an A-phase first winding and an A-phase second winding, the A-phase first winding comprises an A-phase first sub-circuit and an A-phase second sub-circuit, the A-phase first sub-circuit and the A-phase second sub-circuit are wound in a parallel winding mode, the A-phase first winding comprises a plurality of first sub-winding sections, a second sub-winding section, a plurality of third sub-winding sections and a fourth sub-winding section which are sequentially connected, the initial end of the A-phase first winding is connected with an A-phase first outgoing line, and the terminal end of the fourth sub-winding section is connected with an A-phase first star point line; the initial ends of the A-phase first sub-circuit and the A-phase second sub-circuit are connected with the A-phase first outgoing line, and the terminal ends of the A-phase first sub-circuit and the A-phase second sub-circuit are connected with the first star point line;

the first sub winding section is wound by the following method:

s11, leading out the A-phase first leading-out wire to the radially outermost slot layer of the initial slot of the A-phase first path winding wire to prepare for winding a first sub winding wire segment positioned at the initial end, wherein the A-phase first leading-out wire is connected with the first in-slot part of one first type conductor segment positioned at the radially outermost slot layer on the welding end;

s12, spanning y stator slots in a first direction, wherein y is an integer and y is z/2p, and spanning from an outermost slot layer to an innermost slot layer of initial slots of the a-phase first winding;

s13, crossing along a second direction, wherein the number of layers of each crossing y stator slot layers is changed by one, the number of layers is changed from inside to outside along the radial direction to the radially outermost slot layer, and the second direction is opposite to the first direction;

the other first sub winding segments are connected with the first sub winding segment positioned in front of the first sub winding segments;

the second sub-winding section is wound by the following method:

s21, the winding starts from the outermost slot layer of the corresponding stator slot, spans y stator slots in the first direction, and spans from the outermost slot layer to the innermost slot layer;

s22, spanning along the second direction, wherein the number of layers spanning each y stator slot groove layers is changed by one layer, and the number of layers is changed from inside to outside along the radial direction to the radial secondary outer slot layer;

s23, after the winding crosses y-1 stator slots along the second direction and the number of layers changes towards the radially outermost slot layer, the slot where the winding is located is the slot where the termination end of the second sub-winding section is located, the slot is adjacent to the slot where the first outgoing line of the phase A is located, the outermost slot layer is located on one side, facing the first direction, of the first outgoing line of the phase A, the part, crossing the (y-1) stator slots, of the second sub-winding section is a welding end, and the welding end is formed by welding the first in-slot part of the first conductor section and the second in-slot part of the second conductor section;

the third sub winding section is wound by the following method:

s31, spanning y stator slots along the first direction and spanning from the outermost slot layer to the innermost slot layer;

s32, crossing along a second direction, wherein the number of layers of each crossing y stator slot layers is changed by one, the number of layers is changed from inside to outside along the radial direction to the radially outermost slot layer, and the second direction is opposite to the first direction;

the other third sub-winding segments are connected with the third sub-winding segment positioned in front of the first sub-winding segments;

the fourth sub winding section is wound by the following method:

s41, the winding starts from the outermost slot layer of the corresponding stator slot, spans y stator slots in the first direction, and spans from the outermost slot layer to the innermost slot layer of the initial slots;

s42, crossing along the second direction, wherein the number of layers of every y stator slot layers is changed by one, wherein the number of layers is changed from inside to outside along the radial direction to the radial secondary outer slot layer, the terminal end of the fourth sub winding line segment is positioned in the secondary outer slot layer, and the terminal end of the fourth sub winding line segment is connected with the first star point line of the phase A;

the A-phase second routing wire comprises an A-phase third sub-wire and an A-phase fourth sub-wire, the A-phase third sub-wire and the fourth sub-wire are wound in a parallel mode, the A-phase second routing wire comprises a fifth sub-routing wire section, a plurality of sixth sub-routing wire sections, a seventh sub-routing wire section and a plurality of eighth sub-routing wire sections which are sequentially connected, the initial end of the A-phase second routing wire is connected with an A-phase second outgoing wire, and the terminal end of the A-phase second routing wire is connected with an A-phase second star point wire; the initial ends of the A-phase third sub-circuit and the A-phase fourth sub-circuit are connected with an A-phase second outgoing line, and the terminal ends of the A-phase first sub-circuit and the A-phase second sub-circuit are connected with a second star point line;

the fifth sub winding section is wound by the following method:

p11, a groove where the initial end of the A-phase second path winding is located and a groove where the A-phase first star point line is located are separated by y stator grooves, the initial end of the A-phase second path winding is located in a secondary outer groove layer of the corresponding groove, and the A-phase second outgoing line is welded with the initial end of the A-phase second path winding;

p12, spanning along the first direction, wherein the number of layers per y stator slot layers is changed by one, wherein the number of layers is changed from outer to inner along the radial direction to the radially innermost slot layer;

p13, spanning y stator slots in the second direction, and spanning from an innermost slot layer to an outermost slot layer;

the sixth sub winding section is wound by the following method:

p21, the winding starts from the outermost layer of the corresponding stator slot and crosses along the first direction, the number of layers of each crossing y stator slot layers changes by one, wherein the number of layers changes from outside to inside along the radial direction to the radially innermost slot layer;

p22, spanning y stator slots in the second direction, and spanning from an innermost slot layer to an outermost slot layer;

the other sixth sub-winding segments are connected with the sixth sub-winding segment positioned in front of the sixth sub-winding segments;

the seventh sub winding section is wound by the following method:

p31, the winding spanning y-1 stator slots in the first direction starting from the outermost slot layer of the corresponding stator slot, wherein the number of layers varies by one layer to the radially inner slot layer, and the part of the seventh sub-winding segment spanning the (y-1) stator slots is a welding end welded by the first in-slot part of the first type of conductor segment and the second in-slot part of the second type of conductor segment;

p32, spanning along the first direction, wherein the number of layers per y stator slot layers is changed by one, wherein the number of layers is changed from outer to inner along the radial direction to the radially innermost slot layer;

p33, spanning y stator slots in the second direction, and spanning from an innermost slot layer to an outermost slot layer;

the eighth sub-winding section is wound by the following method:

p41, the winding starts from the outermost layer of the corresponding stator slot and crosses along the first direction, the number of layers of each crossing y stator slot layers changes by one, wherein the number of layers changes from outside to inside along the radial direction to the radially innermost slot layer;

p42, spanning y stator slots in the second direction, and spanning from an innermost slot layer to an outermost slot layer;

the other eighth sub winding segment is connected with the eighth sub winding segment positioned in front of the other eighth sub winding segment;

and the phase A second star point line is led out from the outermost groove layer at the termination end of the eighth sub winding line segment.

According to the stator assembly of the embodiment of the invention, at the corresponding welding ends of the second sub-winding segment of the A-phase first winding and the seventh sub-winding segment of the A-phase second winding, the welding ends span (y-1) stator slots, so that the distance at the welding ends can be reduced, and for the whole winding process of the A-phase, the distance between the A-phase star point line and the outgoing line can be reduced, so that the welding connection is easy. Furthermore, the A-phase first winding is wound by the A-phase first sub-circuit and the A-phase second sub-circuit in a parallel winding mode, and the A-phase second winding is wound by the A-phase third sub-circuit and the A-phase fourth sub-circuit in a parallel winding mode, so that the conductor is divided, the area of a single conductor is reduced, and the skin effect can be effectively reduced. In addition, the winding type wiring mode is adopted, the span of partial welding ends is adjusted, the voltage distribution in the same groove is uniform, the voltage difference of the flat wires between adjacent layers is small, the insulation breakdown risk of the motor can be effectively reduced, the reliability is high, the number of required coil types is small, the structure process is simple, required equipment is few, and batch production is easy to carry out.

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

In some embodiments, the number of slot layers in each stator slot is an even number.

In some embodiments, the a-phase first sub-circuit and the a-phase second sub-circuit are equal in cross-sectional area in the extending direction of the conductor segment.

In some embodiments, the phase-a third sub-circuit and the phase-a fourth sub-circuit have equal cross-sectional areas in the extending direction of the conductor segment.

In some embodiments, the first sub-winding segment is three segments; the third sub winding line segment is three segments; the sixth sub winding line segment is three segments; the eighth sub-winding line segment is three segments.

In some embodiments, the number of slots z of the electric machine to which the stator assembly is applied is 48, the number of pole pairs p is 4, the number of phases is 3, and the pitch y is 6, each of the 48 stator slots has 4 slot layers a, B, C, d, where slot layer a is located at the outermost radial side of the stator core, slot layer d is located at the innermost radial side of the stator core, 3 phases include a phase, B phase and C phase, and the number of parallel branches a of each phase is 2, where the first winding of the a phase of the stator core is routed as follows:

1a->7d->1c->43b->37a->

43d->37c->31b->25a->

31d->25c->19b->13a->

19d->13c->7b->2a->

8d->2c->44b->38a->

44d->38c->32b->26a->

32d->26c->20b->14a->

20d->14c->8b，

the route of the A-phase second winding of the stator core is as follows:

14b->20c->26d->

20a->26b->32c->38d->

32a->38b->44c->2d->

44a->2b->8c->14d->

8a->13b->19c->25d->

19a->25b->31c->37d->

31a->37b->43c->1d->

43a->1b->7c->13d->7a；

wherein, the winding of phase A from 1 st slot a layer to 13 th slot a layer comprises a plurality of repeatedly wound first sub winding segments, and in the winding from 1 st slot a layer to 13 th slot a layer, the first conductor segments span 1 st slot a layer and 7 th slot d layer, 37 th slot a layer and 43 th slot d layer, 25 th slot a layer and 31 st slot d layer; the second type conductor segment spans the 1 st and 43 th slot c layers, the 37 th and 31 th slot c layers, and the 25 th and 19 th slot c layers;

the winding of the phase A from the 13 th Slot-a layer to the 2 nd Slot-a layer is the second sub-winding segment, wherein the first conductor segment spans the 13 th Slot-a layer and the 19 th Slot-d layer; the second type conductor segment spans the 13 th slot c layer and the 7 th slot b layer; in the second sub-winding segment, the free end of the second in-slot portion of the second-type conductor segment located in the 7 th slot-b layer is welded to the free end of the first in-slot portion of the first-type conductor segment located in the 2 nd slot-a layer to construct a welded end spanning 5 stator slots;

the winding of the phase A from the 2 nd to the 14 th slot a layers comprises a plurality of repeatedly wound third sub-winding segments, and in the winding from the 2 nd to the 14 th slot a layers, the first conductor segments span the 2 nd and 8 th slot d layers, the 38 th and 44 th slot a layers, the 26 th and 32 th slot a layers; the second type conductor segment spans the 2 nd and 44 th slot-b layers, the 38 th and 32 th slot-b layers, the 26 th and 20 th slot-b layers;

the winding of the phase A from the 14 th slot a layer to the 8 th slot b layer is the fourth sub winding segment, wherein the first conductor segment spans the 14 th slot a layer and the 20 th slot d layer; the second type conductor segment spans the 14 th slot c layer and the 8 th slot b layer;

the winding of the phase A from the 14 th slot-b layer to the 20 th slot-a layer is the fifth sub-winding segment, wherein the first-type conductor segment spans the 26 th slot-d layer and the 20 th slot-a layer; the second type conductor segment spans the 14 th slot b layer and the 20 th slot c layer;

the winding of the phase A from the 20 th slot a layer to the 14 th slot d layer comprises a plurality of repeatedly wound sixth sub-line segments, and in the winding from the 20 th slot a layer to the 14 th slot d layer, the first conductor segment spans the 38 th slot d layer and the 32 th slot a layer, the 2 nd slot d layer and the 44 th slot a layer, and the 14 th slot d layer and the 8 th slot a layer; the second type conductor segment spans the 26 th and 32 th slot b layers, the 38 th and 44 th slot b layers, and the 2 nd and 8 th slot b layers;

the winding of the phase A from the 14 th slot-d layer to the 25 th slot-d layer is the seventh sub-winding segment, wherein the first-type conductor segment spans the 25 th slot-a layer and the 19 th slot-a layer; the second type conductor segment spans the 13 th slot b layer and the 19 th slot c layer; in the seventh sub-winding segment, the free end of the first in-slot portion of the first-type conductor segment located in the 8 th slot-a layer is welded to the free end of the second in-slot portion of the second-type conductor segment located in the 13 th slot-b layer to construct a welded end spanning 5 stator slots;

the winding of the phase A from the 25 th slot d layer to the 7 th slot a layer is a plurality of eighth sub winding segments which are repeatedly wound, and in the winding from the 25 th slot d layer to the 7 th slot a layer, the first conductor segments span the 25 th slot d layer and the 19 th slot a layer, the 37 th slot d layer and the 31 th slot a layer, the 1 st slot d layer and the 43 th slot a layer, and the 13 th slot d layer and the 7 th slot a layer; the second type conductor segment spans the 25 th and 31 th slot b layers, the 37 th and 43 th slot b layers, and the 1 st and 7 th slot b layers.

In some embodiments, the first star point lines for phase a, phase B, and phase C are circumferentially separated by 4 stator slots, and the second star point lines for phase a, phase B, and phase C are circumferentially separated by 4 stator slots.

In some embodiments, the first outgoing lines corresponding to the phases a, B and C are circumferentially different by 4 stator slots, and the second outgoing lines corresponding to the phases a, B and C are circumferentially different by 4 stator slots.

In some embodiments, the stator winding includes a B-phase first winding and a B-phase second winding, the winding method of the B-phase first winding is the same as the winding method of the a-phase first winding, and the winding method of the B-phase second winding is the same as the winding method of the a-phase second winding.

In some embodiments, the stator winding includes a C-phase first winding and a C-phase second winding, the C-phase first winding is wound in the same manner as the a-phase first winding, and the C-phase second winding is wound in the same manner as the a-phase second winding.

In some embodiments, the phase a first sub-path and the phase a second sub-path are arranged side by side in a radial direction of the stator core in an in-slot portion of a stator slot; the phase A third sub-path and the phase A fourth sub-path are arranged in parallel in the slot inner part of the stator slot along the radial direction of the stator core.

In some embodiments, the phase a first sub-path and the phase a second sub-path are arranged side by side in a radial direction of the stator core at a welding end; the phase A third sub-circuit and the phase A fourth sub-circuit are arranged in parallel at the welding end along the radial direction of the stator core.

In some embodiments, the phase a first sub-circuit is disposed in parallel with the phase a second sub-circuit; the phase A third sub-circuit and the phase A fourth sub-circuit are arranged in parallel.

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

According to the motor of the embodiment of the invention, at the respective welding ends of the second sub-winding segment of the a-phase first winding and the seventh sub-winding segment of the a-phase second winding, the welding ends span (y-1) stator slots, whereby the distance at the welding ends can be reduced, and for the entire winding process of the a-phase, the distance between the a-phase star point line and the lead-out wire can be reduced, whereby the welding connection is easy. Furthermore, the A-phase first winding is wound by the A-phase first sub-circuit and the A-phase second sub-circuit in a parallel winding mode, and the A-phase second winding is wound by the A-phase third sub-circuit and the A-phase fourth sub-circuit in a parallel winding mode, so that the conductor can be divided, the area of a single conductor is reduced, and the skin effect can be effectively reduced. In addition, the winding type wiring mode is adopted, the span of partial welding ends is adjusted, the voltage distribution in the same groove is uniform, the voltage difference of the flat wires between adjacent layers is small, the insulation breakdown risk of the motor can be effectively reduced, the reliability is high, the number of required coil types is small, the structure process is simple, required equipment is few, and batch production is easy to carry out.

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 winding diagram of a first phase A winding of a stator assembly according to an embodiment of the present invention;

FIG. 2 is a partial winding schematic of a first phase A winding of a stator assembly according to an embodiment of the present invention;

FIG. 3 is a partial winding schematic of a first phase A winding of a stator assembly according to an embodiment of the present invention;

FIG. 4 is a partial winding schematic of a first phase A winding of a stator assembly according to an embodiment of the present invention;

FIG. 5 is a winding diagram of a phase A second winding of a stator assembly according to an embodiment of the present invention;

FIG. 6 is a partial winding schematic of the A-phase second winding of the stator assembly according to an embodiment of the present invention;

FIG. 7 is a partial winding schematic of the A-phase second winding of the stator assembly according to an embodiment of the present invention;

FIG. 8 is a partial winding schematic of the A-phase second windings of the stator assembly according to an embodiment of the present invention;

FIG. 9 is a wiring schematic of the A-phase first routing of the stator assembly according to an embodiment of the present invention;

FIG. 10 is a wiring schematic of the A-phase second routing of the stator assembly according to an embodiment of the present invention;

FIG. 11 is a wiring schematic of the A, B, and C phase windings of the stator assembly according to an embodiment of the present invention;

FIG. 12 is a structural schematic diagram of a stator assembly according to an embodiment of the present invention;

FIG. 13 is a schematic structural view of a stator assembly according to an embodiment of the present invention;

FIG. 14 is an enlarged partial schematic view at A of FIG. 13;

FIG. 15 is an enlarged partial schematic view at B of FIG. 13;

FIG. 16 is a top view schematic diagram of a stator assembly according to an embodiment of the present invention;

FIG. 17 is an enlarged partial schematic view at C of FIG. 16;

FIG. 18 is a structural schematic diagram of a stator assembly according to an embodiment of the present invention;

FIG. 19 is a partial schematic structural view of a stator assembly according to an embodiment of the present invention;

FIG. 20 is a schematic view of the mating of a first type of conductor segment and a second type of conductor segment of a stator assembly according to an embodiment of the present invention;

FIG. 21 is a schematic structural view of a U-shaped conductor segment of a stator assembly according to an embodiment of the present invention;

FIG. 22 is a schematic structural view of a U-shaped conductor segment of a stator assembly according to an embodiment of the present invention;

FIG. 23 is a schematic structural view of a U-shaped conductor segment of a stator assembly according to an embodiment of the present invention;

FIG. 24 is a schematic structural view of a U-shaped conductor segment of a stator assembly according to an embodiment of the present invention;

FIG. 25 is a schematic structural view of a U-shaped conductor segment of a stator assembly according to an embodiment of the present invention;

FIG. 26 is a schematic diagram of the mating of a first type of conductor segments and a second type of conductor segments of a stator assembly, wherein the first type of conductor segments are arranged side by two sub-paths of a respective phase and the second type of conductor segments are arranged side by two sub-paths of a respective phase, in accordance with an embodiment of the present invention;

FIG. 27 is an exploded view of the first and second conductor segments of FIG. 26;

FIG. 28 is a schematic view of a stator assembly having first and second conductor segments of a stator assembly in accordance with an embodiment of the present invention, wherein the first conductor segments are arranged side-by-side by two sub-paths of a respective phase and the second conductor segments are arranged side-by-side by two sub-paths of a respective phase;

FIG. 29 is an exploded view of the first type conductor segment and the second type conductor segment of FIG. 28;

FIG. 30 is a schematic diagram of a stator assembly having first type conductor segments and second type conductor segments mated together, wherein the first type conductor segments are positioned side-by-side by two sub-paths of a respective phase and the second type conductor segments are positioned side-by-side by two sub-paths of a respective phase, in accordance with an embodiment of the present invention;

fig. 31 is an exploded view of the first type conductor segment and the second type conductor segment of fig. 30.

Reference numerals:

stator assembly 1000, stator core 100, stator slots 101,

a stator winding 200, a U-shaped conductor segment 201, a first type of conductor segment 203, a second type of conductor segment 204,

a bending portion 210, a first connecting portion 211, a second connecting portion 212, an intermediate connecting portion 213,

first in-slot portion 214, second in-slot portion 215, weld end 220' spanning y-1 stator slots,

the phase a first sub-circuit 201A, the phase a second sub-circuit 202A,

a first sub-winding portion 231, a second sub-winding portion 232, a third sub-winding portion 233, a fourth sub-winding portion 234,

a fifth sub-winding wire section 235, a sixth sub-winding wire section 236, a seventh sub-winding wire section 237, an eighth sub-winding wire section 238,

a phase a first lead line 251a1, a phase a first star point line 252a1, a phase a second lead line 251a2, and a phase a second star point line 252a 2; a B-phase first lead line 251B1, a B-phase first star point line 252B1, a B-phase second lead line 251B2, a B-phase second star point line 252B2, a C-phase first lead line 251W1, a C-phase first star point line 252W1, a C-phase second lead line 251W2, and a C-phase second star point line 252W 2.

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.

A stator assembly 1000 according to an embodiment of the present invention is described below with reference to fig. 1-31.

As shown in fig. 1 to 12, a stator assembly 1000 according to an embodiment of the present invention is applied 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: a cylindrical stator core 100 and a stator winding 200.

The stator core 100 has a plurality of stator slots 101 arranged at intervals along a circumferential direction of the stator core 100. The stator winding 200 is constructed by a plurality of U-shaped conductor segments 201, each of the U-shaped conductor segments 201 includes a bent portion 210 and a first in-slot portion 214 and a second in-slot portion 215 connected to the bent portion 210, respectively, the first in-slot portion 214 of the U-shaped conductor segment 201 passes through one of the slot layers of one of the stator slots 101, the second in-slot portion 215 passes through one of the slot layers of the other stator slot 101, the first in-slot portion 214 and the second in-slot portion 215 pass through the stator slot 101 and then end portions thereof protrude beyond the stator core 100 to form a weld end 220, and the first in-slot portion 214 and the second in-slot portion 215 of the plurality of U-shaped conductor segments 201 located in adjacent layers are welded and connected on the weld end 220.

The bent portions 210 of the U-shaped conductor segments 201 are located at one side of the stator core 100 to form a hairpin end, the hairpin end can select different coil structures according to the process and actual requirements, and the welding end 220 is located at the other side of the stator core 100. For example, the U-shaped conductor segment 201 may be a flat coil, i.e., a coil with a large length-width ratio (e.g., the intermediate connection portion 213 of the bent portion 210 is configured to be an open annular structure, i.e., the middle portion of the bent portion 210 forms a nose structure, as shown in fig. 21-23), and the U-shaped conductor segment 201 may also be a stamped coil (e.g., the intermediate connection portion 213 of the bent portion 210 is configured to be a straight structure, i.e., the middle portion of the bent portion 210 forms a flat head structure, as shown in fig. 24 and 25).

The U-shaped conductor segments 201 comprise conductor segments of a first type 203 and conductor segments of a second type 204, the first in-slot portions 214 of the conductor segments of the first type 203 being located in the outermost slot layer of the respective stator slot 101 and the second in-slot portions 215 of the conductor segments of the first type 203 being located in the innermost slot layer of the respective stator slot 101; the first in-slot portions 214 of the conductor segments 204 of the second type and the second in-slot portions 215 of the conductor segments 204 of the second type are located in the inner slot layers of the corresponding stator slots 101, the inner slot layers comprising a sub-outer slot layer (e.g. slot layer b as shown in fig. 1-2) and a sub-inner slot layer (e.g. slot layer c as shown in fig. 1-2), the first in-slot portions 214 of the conductor segments 204 of the second type being located in the sub-inner slot layer of the corresponding stator slot 101, and the second in-slot portions 215 of the conductor segments 204 of the second type being located in the sub-outer slot layer of the corresponding stator slot.

It will be appreciated that the U-shaped conductor segments 201 may be classified into two categories depending on where the first in-slot portions 214, the second in-slot portions 215 are located, wherein the first in-slot portions 214 of the first type conductor segments 203 are located in the outermost slot layer of the respective stator slot 101 and the second in-slot portions 215 are located in the innermost slot layer of the respective stator slot 101; the first in-slot portion 214 and the second in-slot portion 215 of the second type of conductor segment 204 are each located in an inner slot layer, e.g. a sub-inner layer or a sub-outer layer, of the respective stator slot 101.

The stator winding 200 includes a first a-phase winding and a second a-phase winding, the first a-phase winding includes a plurality of first sub-winding sections 231, a second sub-winding section 232, a plurality of third sub-winding sections 233, and a fourth sub-winding section 234, which are connected in sequence, an initial end of the first a-phase winding is connected to a first a-phase outgoing line 251a1, and a terminal end of the fourth sub-winding section 234 is connected to a first a-phase star point 252a 1.

It should be noted that "phase a" herein may designate any phase in the subassembly, and is taken as an example for convenience of description.

As shown in fig. 1, the plurality of first sub-winding segments 231 are sequentially connected, the first sub-winding segment 231 located at the head end is directly connected to the a-phase first outgoing line 251a1, and the first sub-winding segment 231 located at the tail end is directly connected to the second sub-winding segment 232. The plurality of third sub-winding segments 233 are sequentially connected, the third sub-winding segment 233 positioned at the head end is directly connected to the second sub-winding segment 232, and the third sub-winding segment 233 positioned at the tail end is directly connected to the fourth sub-winding segment 234.

The phase A first winding line comprises a phase A first sub-circuit 201A and a phase A second sub-circuit 202A, the phase A first sub-circuit 201A and the phase A second sub-circuit 202A are wound in a parallel mode, the initial end of the phase A first winding line is connected with a phase A first outgoing line 251A1, and the terminal end of the fourth sub-winding line is connected with a phase A first star point line 252A 1; the initial ends of the a-phase first sub-circuit 201A and the a-phase second sub-circuit 202A are connected to the a-phase first outgoing line 251A1, and the terminal ends of the a-phase first sub-circuit 201A and the a-phase second sub-circuit 202A are connected to the first star point line 252A 1.

As shown in fig. 1 and 4, the first sub-winding segment 231 is wound by the following method:

s11, leading out the a-phase first lead-out wire 251a1 to the radially outermost slot layer of the initial slot of the a-phase first winding, which is the stator slot 101 inserted for the first time when the a-phase first lead-out wire 251a1 starts to be prepared for winding, so as to prepare for winding the first sub-winding segment 231 located at the initial end, and connecting the a-phase first lead-out wire 251a1 at the welding end 220 with the first in-slot portion 214 of one first-type conductor segment 203 located at the radially outermost slot layer. For example, as shown in fig. 1, the a-phase first lead-out line 251a1 is led out from the outermost a-layer of the 1 st groove, which is the initial groove;

s12, spanning y stator slots 101 in a first direction (the direction shown in fig. 1), wherein y is an integer and y is z/2p, and spanning from the outermost slot layer to the innermost slot layer of the initial slots of the a-phase first winding;

s13, crossing in a second direction (the direction shown in fig. 1) opposite to the first direction, wherein the number of layers varies from inside to outside in the radial direction to the radially outermost slot layer for every y slot layers 101; the remaining first sub-winding segments 231 are connected to the first sub-winding segment 231 located in front thereof;

as shown in fig. 1 and 2, the second sub-winding segment 232 is wound by the following method:

s21, the winding starts from the outermost slot layer of the corresponding stator slots 101, spans y stator slots 101 in the first direction, and spans from the outermost slot layer to the innermost slot layer;

s22, spanning along the second direction, wherein the number of layers of the slot layers of the y stator slots 101 is changed by one layer every time the slot layers are spanned, and the number of layers is changed from inside to outside along the radial direction to the radial secondary outer slot layer;

s23, after the winding crosses y-1 stator slots 101 along the second direction and the number of layers changes towards the radial outermost slot layer, the slot where the winding is located is the slot where the termination end of the second sub-winding section 232 is located, the groove is adjacent to the groove where the phase a first lead-out wire 251a1 is located, and the outermost groove layer is located on the side of the phase a first lead-out wire 251a1 facing the first direction, the portion of the second sub-winding segment 232 that spans the (y-1) stator slots 101 is a weld end 220, the welding tip 220 is formed by welding the first in-slot portion 214 of the first-type conductor segment 203 and the second in-slot portion 215 of the second-type conductor segment 204, for example, in the example shown in fig. 2, the weld end 220' spanning (y-1) stator slots is formed by welding the free end of the second in-slot portion 215 located at the 7 th slot b layer with the first in-slot portion 214 located at the 2 nd slot a layer;

as shown in fig. 1 and 4, the third sub-winding segment 233 is wound by the following method:

s31, spanning y stator slots 101 in the first direction, and spanning from the outermost slot layer to the innermost slot layer;

s32, crossing along a second direction, wherein the number of layers of the slot layers of every y stator slots 101 is changed by one, the number of layers is changed from inside to outside along the radial direction to the radially outermost slot layer, and the second direction is opposite to the first direction;

the remaining third sub-winding segments 233 are connected to the third sub-winding segment 233 located in front thereof;

as shown in fig. 1 and 3, the fourth sub-winding segment 234 is wound by the following method:

s41, the winding starts from the outermost slot layer of the corresponding stator slot 101, spans y stator slots 101 in the first direction, and spans from the outermost slot layer to the innermost slot layer of the initial slots;

s42, crossing along the second direction, changing the number of layers of each y stator slot 101 slot layers, wherein the number of layers changes from inside to outside along the radial direction to the next outer slot layer along the radial direction, the terminal end of the fourth sub-winding segment 234 is located in the next outer slot layer, and the terminal end of the fourth sub-winding segment 234 is connected with the a-phase first star point line 252a 1;

the A-phase second routing wire comprises an A-phase third sub-circuit and an A-phase fourth sub-circuit, the A-phase third sub-circuit and the fourth sub-circuit are wound in a parallel mode, the initial end of the A-phase second routing wire is connected with an A-phase second outgoing wire 251A2, and the terminal end of the A-phase second routing wire is connected with an A-phase second star point wire 252A 2; the initial ends of the phase A third sub-circuit and the phase A fourth sub-circuit are connected with a phase A second outgoing line 251A2, and the terminal ends of the phase A first sub-circuit and the phase A second sub-circuit are connected with a second star point line 252A 2.

The a-phase second routing wire includes a fifth sub-winding wire segment 235, a plurality of sixth sub-winding wire segments 236, a seventh sub-winding wire segment 237, and a plurality of eighth sub-winding wire segments 238, which are connected in sequence, an initial end of the a-phase second routing wire is connected to the a-phase second outgoing wire 251a2, and a terminal end of the a-phase second routing wire is connected to the a-phase second star point wire 252a 2.

As shown in fig. 1, the plurality of sixth sub-winding segments 236 are sequentially connected, the sixth sub-winding segment 236 positioned at the head end is directly connected to the fifth sub-winding segment 235, and the sixth sub-winding segment 236 positioned at the tail end is directly connected to the seventh sub-winding segment 237. The eighth sub-winding segments 238 are sequentially connected, the eighth sub-winding segment 238 positioned at the head end is directly connected to the seventh sub-winding segment 237, and the eighth sub-winding segment 238 positioned at the tail end is directly connected to the a-phase star point line.

As shown in fig. 5 and 7, the fifth sub-winding segment 235 is wound by the following method:

the P11, the slot (for example, the 14 th slot, the b layer) where the initial end of the A phase second routing wire is located and the slot where the A phase first star point line 252A1 is located are separated by y stator slots, the initial end of the A phase second routing wire is located in the secondary outer slot layer of the corresponding slot, and the A phase second outgoing wire 251A2 is welded with the initial end of the A phase second routing wire. It is understood that the initial slot of the phase a second winding line is the stator slot into which the phase a second outgoing line 251a2 is first inserted when it is ready to be wound;

p13, spanning y stator slots 101 in the second direction, and spanning from the innermost slot layer to the outermost slot layer;

as shown in fig. 5 and 8, the sixth sub-winding segment 236 is wound by the following method:

p21, the winding starts from the outermost layer of the corresponding stator slot 101 and crosses along the first direction, the number of layers of slot layers changes by one layer every y stator slots 101, wherein the number of layers changes from outer to inner along the radial direction to the radially innermost slot layer;

p22, spanning y stator slots 101 in the second direction, and spanning from the innermost slot layer to the outermost slot layer; the remaining sixth sub-winding segment 236 is connected to the sixth sub-winding segment 236 located in front thereof;

as shown in fig. 5 and 6, the seventh sub-winding segment 237 is wound by the following method:

p31, the winding starting from the outermost slot layer of the respective stator slot 101, spanning y-1 stator slots 101 in the first direction, wherein the number of layers varies by one to the radially inner slot layer, the part of the seventh sub-winding segment 237 spanning the (y-1) stator slots 101 being a welding terminal 220, which welding terminal 220 is formed by welding the first in-slot portions 214 of the conductor segments of the first type 203 and the second in-slot portions 215 of the conductor segments of the second type 204, e.g. in the example shown in fig. 6, the welding terminal 220' spanning the (y-1) stator slots is formed by welding the free end of the first in-slot portion 214 at the 8 th slot-a layer with the second in-slot portion 215 at the 13 th slot-b layer;

p32, spanning along the first direction, wherein the number of layers per y stator slot 101 slot layers is changed by one, wherein the number of layers is changed from outer to inner along the radial direction to the radially innermost slot layer;

p33, spanning y stator slots 101 in the second direction, and spanning from the innermost slot layer to the outermost slot layer;

as shown in fig. 5, the eighth sub-winding segment 238 is wound by the following method:

p41, the winding starts from the outermost layer of the corresponding stator slot 101 and crosses along the first direction, the number of layers of slot layers changes by one layer every y stator slots 101, wherein the number of layers changes from outer to inner along the radial direction to the radially innermost slot layer;

p42, spanning y stator slots 101 in the second direction, and spanning from the innermost slot layer to the outermost slot layer from which the a-phase second dotted line 252a2 is drawn, e.g., in the example shown in fig. 8, the a-phase second dotted line 252a2 is drawn from the 7 th slot a layer; the remaining eighth sub-winding segment 238 is connected to the eighth sub-winding segment 238 located in front thereof.

According to the stator assembly 1000 of the embodiment of the present invention, at the respective welding ends 220 ' of the second sub-winding segment 232 of the a-phase first winding and the seventh sub-winding segment 237 of the a-phase second winding, the welding ends 220 ' span (y-1) stator slots 101, whereby the distance at the welding ends 220 ' can be reduced, and for the entire winding process of the a-phase, the distance between the a-phase star point line and the outgoing line can be reduced, whereby the welding connection is easy.

Furthermore, the a-phase first winding is wound by the a-phase first sub-circuit 201A and the a-phase second sub-circuit 202A in a parallel winding manner, and the a-phase second winding is wound by the a-phase third sub-circuit and the a-phase fourth sub-circuit in a parallel winding manner, so that the conductor is divided, the area of a single conductor is reduced, and the skin effect can be effectively reduced.

In addition, by adopting a wave winding type wiring mode and combining with the adjustment of the span of part of the welding end 220, the voltage distribution in the same groove is uniform, the voltage difference of the flat wires between adjacent layers is small, the insulation breakdown risk of the motor can be effectively reduced, the reliability is high, the types of required coils are few, the structure and the process are simple, required equipment is few, and batch production is easy to carry out.

In addition, it should be further noted that the winding manner of other phases of the stator assembly 1000 may be the same as that of the phase a, so that the distance between the corresponding phase star point line and the corresponding phase outgoing line may be reduced on the whole, and the performance of the motor may be further optimized, so that the voltage distribution in the same slot is more uniform, the voltage difference between the flat lines between adjacent layers is reduced, the risk of insulation breakdown of the motor is reduced, and the reliability of the motor is improved.

In some embodiments, the U-shaped conductor segments 201 are equal in cross-sectional area in the direction of extension of the conductor segments. In some embodiments, the number of slot layers in each stator slot 101 is an even number. Therefore, the performance of the motor can be further optimized, and the operation reliability of the motor is improved.

In some embodiments, the first sub-winding segment 231 is three segments; the third sub winding section 233 is three sections; the sixth sub-winding section 236 is three sections; the eighth sub-winding segment 238 has three segments.

According to some embodiments of the present invention, as shown in fig. 1 to 12, the stator assembly 1000 is adapted to 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, each of the 48 stator slots 101 has 4 slot layers a, B, C, and d, wherein the slot layer a is located at the outermost radial side of the stator core 100, the slot layer d is located at the innermost radial side of the stator core 100, the 3 phases include an a phase, a B phase, and a C phase, and the number a of parallel branches of each phase is 2, wherein the a phase first winding of the stator core is routed as follows:

1a->7d->1c->43b->37a->

43d->37c->31b->25a->

31d->25c->19b->13a->

19d->13c->7b->2a->

8d->2c->44b->38a->

44d->38c->32b->26a->

32d->26c->20b->14a->

20d->14c->8b；

the route of the A-phase second winding of the stator core is as follows:

14b->20c->26d->

20a->26b->32c->38d->

32a->38b->44c->2d->

44a->2b->8c->14d->

8a->13b->19c->25d->

19a->25b->31c->37d->

31a->37b->43c->1d->

43a->1b->7c->13d->7a；

wherein the winding of the a phase from the 1 st moat a layer to the 13 th moat a layer includes a plurality of the first sub-winding segments 231 repeatedly wound, and in the winding from the 1 st moat a layer to the 13 th moat a layer, the first-type conductor segments 203 span the 1 st moat a layer and the 7 th moat d layer, the 37 th moat a layer and the 43 th moat d layer, the 25 th moat a layer and the 31 th moat d layer; the second type conductor segment 204 spans the 1 st and 43 th slot c layers, the 37 th and 31 th slot c layers, and the 25 th and 19 th slot c layers;

a winding of the a-phase from the 13 th moat-a layer to the 2 nd moat-a layer is the second sub-winding segment 232, wherein the first-type conductor segment 203 spans the 13 th moat-a layer and the 19 th moat-d layer; the second type conductor segment 204 spans the 13 th slot c layer and the 7 th slot b layer; in the second sub-winding segment 232, the free end of the second in-slot portion 215 of the second-type conductor segment 204 located in the 7 th slot-b layer is welded to the free end of the first in-slot portion 214 of the first-type conductor segment 203 located in the 2 nd slot-a layer to construct a welding end 220' spanning 5 stator slots 101;

the winding of the a phase from the 2 nd to 14 th slot-a layers includes a plurality of repeatedly wound third sub-winding segments 233, and in the winding from the 2 nd to 14 th slot-a layers, the first-type conductor segments 203 span the 2 nd and 8 th slot-d layers, the 38 th and 44 th slot-a layers, the 26 th and 32 th slot-a layers; the second type of conductor segment 204 spans the 2 nd and 44 th, 38 th and 32 th, 26 th and 20 th slot c layers;

a winding of the a-phase from the 14 th slot-a layer to the 8 th slot-b layer is the fourth sub-winding segment 234, wherein the first-type conductor segment 203 spans the 14 th slot-a layer and the 20 th slot-d layer; the second type conductor segment 204 spans the 14 th slot c layer and the 8 th slot b layer;

a winding of the a-phase from the 14 th slot-b layer to the 20 th slot-a layer is the fifth sub-winding segment 235, wherein the first-type conductor segment 203 spans the 26 th slot-d layer and the 20 th slot-a layer; the second type conductor segment 204 spans the 14 th slot b layer and the 20 th slot c layer;

the winding of the phase a from the 20 th slot a layer to the 14 th slot d layer comprises a plurality of repeatedly wound sixth sub-line segments 236, and in the winding from the 20 th slot a layer to the 14 th slot d layer, the first-type conductor segments 203 span the 38 th and 32 th slot a layers, the 2 nd and 44 th slot a layers, the 14 th and 8 th slot a layers; the second type conductor segment 204 spans the 26 th and 32 th slot b layers, the 38 th and 44 th slot b layers, the 2 nd and 8 th slot b layers;

a winding of the a phase from the 14 th slot-d layer to the 25 th slot-d layer is the seventh sub-winding segment 237, wherein the first-type conductor segment 203 spans the 25 th slot-a layer and the 19 th slot-a layer; the second type conductor segment 204 spans the 13 th slot b layer and the 19 th slot c layer; in the seventh sub-winding segment, the free ends of the first in-slot portions 214 of the first-type conductor segments 203 located in the 8 th slot-a layer are welded to the free ends of the second in-slot portions 215 of the second-type conductor segments 204 located in the 13 th slot-b layer to construct welding ends 220' spanning 5 stator slots;

the winding of the a phase from the 25 th slot-d layer to the 7 th slot-a layer is a plurality of eighth sub-winding segments 238 repeatedly wound, and in the winding from the 25 th slot-d layer to the 7 th slot-a layer, the first-type conductor segment 203 spans the 25 th slot-d layer and the 19 th slot-a layer, the 37 th slot-d layer and the 31 th slot-a layer, the 1 st slot-d layer and the 43 th slot-a layer, the 13 th slot-d layer and the 7 th slot-a layer; the second type of conductor segment 204 spans the 25 th and 31 th slot b layers, the 37 th and 43 th slot b layers, and the 1 st and 7 th slot b layers.

In some embodiments, the corresponding star point lines of phase a, phase B, and phase C are circumferentially separated by 4 stator slots 101, and the second star point lines of phase a, phase B, and phase C are circumferentially separated by 4 stator slots. In some embodiments, the first outgoing lines corresponding to phases a, B, and C are circumferentially different by 4 stator slots 101, and the second outgoing lines corresponding to phases a, B, and C are circumferentially different by 4 stator slots.

In some embodiments, the winding method of the phase B winding is the same as the winding method of the phase A winding. In some embodiments, the winding method of the phase C winding is the same as the winding method of the phase A winding. Therefore, the distance between the corresponding star point line and the corresponding leading-out line can be reduced on the whole, the performance of the motor can be further optimized, the voltage distribution in the same groove is more uniform, the voltage difference of flat wires between adjacent layers is reduced, the insulation breakdown risk of the motor is reduced, and the reliability of the motor is improved.

In some embodiments, the phase B winding includes a phase B first winding and a phase B second winding, the winding method of the phase B first winding is the same as the winding method of the phase a first winding, the initial end of the phase B first winding is connected to the phase B first outgoing line 251B1, the terminal end of the phase B first winding is connected to the phase B first star point line 252B1, the winding method of the phase B second winding is the same as the winding method of the phase a second winding, the initial end of the phase B second winding is connected to the phase B second outgoing line 251B2, and the terminal end of the phase B first winding is connected to the phase B second star point line 252B 2.

In some embodiments, the C-phase windings include a C-phase first winding and a C-phase second winding, the winding method of the C-phase first winding is the same as that of the a-phase first winding, the initial end of the C-phase first winding is connected to the C-phase first outgoing line 251W1, and the terminal end of the C-phase first winding is connected to the C-phase first star point line 252W 1; the winding method of the C-phase second winding is the same as that of the A-phase second winding, the initial end of the C-phase second winding is connected with a C-phase second outgoing line 251W2, and the terminal end of the C-phase first winding is connected with a C-phase second star point line 252W 2.

In some embodiments, the bending portion 210 includes a first connection portion 211, a second connection portion 212, and an intermediate connection portion 213, the first connection portion 211 is connected to the first in-slot portion 214, one end of the intermediate connection portion 213 is connected to the first connection portion 211, the other end of the intermediate connection portion 213 is connected to the second connection portion 212, and the second connection portion 212 is connected to the second in-slot portion 215. As shown in fig. 18 to 23, the intermediate connection part 213 has an annular structure having an opening, and one end of the intermediate connection part 213 is twisted with respect to the other end of the intermediate connection part 213 in a radial direction of the stator core 100. It will be appreciated that the intermediate connection 213 is configured in a nose configuration.

According to some embodiments of the present invention, as shown in fig. 18, the intermediate connection portions 213 of the first-type conductor segments 203 are the same shape as the intermediate connection portions 213 of the second-type conductor segments 204. Further, as shown in fig. 21-23, the intermediate connection portions 213 of the first-type conductor segments 203 are sleeved on the intermediate connection portions 213 of the second-type conductor segments 204. In some embodiments, the intermediate connection 213 of the second-type conductor segments 204 is located directly below the intermediate connection 213 of the first-type conductor segments 203. It should be noted that "directly below" here may mean that the intermediate connection portion 213 of the conductor segment 204 of the second type is located below the intermediate connection portion 213 of the conductor segment 203 of the first type, and an orthogonal projection of the intermediate connection portion 213 of the conductor segment 203 of the first type on a horizontal plane covers an orthogonal projection of the intermediate connection portion 213 of the conductor segment 204 of the second type on a horizontal plane, in other words, an orthogonal projection of the intermediate connection portion 213 of the conductor segment 204 of the second type on a horizontal plane overlaps an orthogonal projection of the intermediate connection portion 213 of the conductor segment 203 of the first type on a horizontal plane.

According to some embodiments of the present invention, as shown in fig. 28, the bent portion 210 includes a first connection portion 211, a second connection portion 212, and an intermediate connection portion 213, the first connection portion 211 is connected to the first in-slot portion 214, one end of the intermediate connection portion 213 is connected to the first connection portion 211, the other end of the intermediate connection portion 213 is connected to the second connection portion 212, the second connection portion 212 is connected to the second in-slot portion 215, and one end of the intermediate connection portion 213 is twisted with respect to the other end of the intermediate connection portion 213 in a radial direction of the stator core 100. The intermediate connection portion 213 of the first-type conductor segment 203 has an open ring structure, and the intermediate connection portion 213 of the second-type conductor segment 204 has a linear structure. It will be appreciated that the intermediate connection portions 213 of the first type of conductor segments 203 are configured in a nose end configuration and the intermediate connection portions 213 of the second type of conductor segments 204 are configured in a flat head configuration, whereby the nose end configuration can give way to the flat head configuration and the design of the flat head configuration is also effective in reducing the height of the coil.

In some embodiments, as shown in fig. 28, the intermediate connection 213 of the second-type conductor segment 204 is located directly below the intermediate connection 213 of the first-type conductor segment 203. Thus, the intermediate connection portions 213 of the first-type conductor segments 203 can avoid the intermediate connection portions 213 of the second-type conductor segments 204, and the intermediate connection portions 213 of the second-type conductor segments 204 can be designed to effectively reduce the height of the coil.

According to some embodiments of the present invention, as shown in fig. 24, 25, 30-31, the bent portion 210 includes a first connection portion 211, a second connection portion 212, and an intermediate connection portion 213, the first connection portion 211 is connected to the first in-slot portion 214, one end of the intermediate connection portion 213 is connected to the first connection portion 211, the other end of the intermediate connection portion 213 is connected to the second connection portion 212, the second connection portion 212 is connected to the second in-slot portion 215, the intermediate connection portion 213 has a linear structure, and one end of the intermediate connection portion 213 is twisted with respect to the other end of the intermediate connection portion 213 in a radial direction of the stator core 100. It is understood that the intermediate connection portion 213 has a long bar-shaped structure, and in order to make the cylindrical stator core 100 have a certain curvature of the intermediate connection portion 213, and in order to facilitate winding, both ends of the intermediate connection portion 213 are twisted at a certain angle along the radial direction of the stator core 100, that is, the intermediate connection portion 213 has a flat head structure, so that the height of the coil can be reduced.

In some embodiments, as shown in fig. 30, the length of the intermediate connection 213 of the first-type conductor segments 203 is greater than the length of the intermediate connection 213 of the second-type conductor segments 204. In some embodiments, the twist angle of the intermediate connection 213 of the first-type conductor segment 203 is the same as the twist angle of the intermediate connection 213 of the second-type conductor segment 204. In order to improve the regularity of the winding and reduce the volume of space occupied by the bent portions, in some embodiments, such as shown in fig. 30, the intermediate connection portion 213 of the second-type conductor segment 204 is located directly below the intermediate connection portion 213 of the first-type conductor segment 203.

According to some embodiments of the present invention, as shown in fig. 13 to 17, the phase a first winding line includes a phase a first sub-circuit 201A and a phase a second sub-circuit 202A, and the phase a first sub-circuit 201A is wound around the phase a second sub-circuit 202A. It is to be appreciated that in some embodiments, the phase a first sub-circuit 201A is disposed in parallel with the phase a second sub-circuit 202A. The phase A second routing line comprises a phase A third sub-path and a phase A fourth sub-path, and the phase A third sub-path and the phase A fourth sub-path are in parallel routing. It will be appreciated that in some embodiments, the phase a third sub-circuit is arranged in parallel with the phase a fourth sub-circuit.

According to the winding mode of the embodiment, 8 conductor sections are arranged in each stator slot, which is equivalent to 8 layers of coils, and compared with the arrangement of 4 conductor sections in each stator slot, the winding mode has the advantages of low skin effect, low copper consumption and high efficiency. It is understood that, as shown in fig. 26 to 31, each U-shaped conductor segment 201 is composed of two wires, and since each U-shaped conductor segment 201 is composed of two wires, the copper wires are relatively flat, and a cast coil can be used, so that paint film damage during coil forming can be avoided.

Taking a motor with four slot layers in each slot as an example, each phase of the stator winding 200 is formed by winding two windings in parallel, so that 8 conductors are arranged in each stator slot 101, which is equivalent to 8 layers of coils, and compared with the stator winding 200 with 4 conductors in each slot, the skin effect can be effectively reduced and reduced due to the fact that the conductor area is small. In addition, under the condition of the wave winding type wiring mode, 8 layers of coils can be realized by utilizing the forming process of 4 layers of coils, and compared with the existing 8 layers of formed coil structure, the structure is easy to realize and the process is simpler. Also, in this embodiment, there are fewer pads at the bond tip 220, and there are only 2 pads for 8 conductors per slot.

In some embodiments, the a-phase first sub-path 201A and the a-phase second sub-path 202A are side by side in a radial direction of the stator core 100. Further, the a-phase first sub-path 201A and the a-phase second sub-path 202A are arranged side by side in the radial direction of the stator core 100 in the in-slot portion of the stator slot 101. In some embodiments, the phase a third sub-path and the phase a fourth sub-path are side by side in a radial direction of the stator core 100. Further, the phase a third sub-path and the phase a fourth sub-path are arranged side by side in the slot inner portion of the stator slot 101 along the radial direction of the stator core. In some embodiments, the dotted lines and the lead-out lines of each phase of the stator winding 200 are located on the same side of the stator core 100. In some embodiments, the a-phase first sub-circuit 201A and the a-phase second sub-circuit 202A are equal in cross-sectional area in the extending direction of the conductor segment. In some embodiments, the phase-a third sub-circuit and the phase-a fourth sub-circuit are equal in cross-sectional area in the extending direction of the conductor segment.

In some embodiments, the phase a first sub-path 201A and the phase a second sub-path 202A are arranged side by side in a radial direction of the stator core 100 at the welding end 220; the phase a third sub-path and the phase a fourth sub-path are arranged side by side at the welding end 220 along the radial direction of the stator core 100.

An electric machine according to an embodiment of the invention comprises a stator assembly 1000 as described above.

According to the motor of the embodiment of the present invention, at the respective welding terminals 220 ' of the second sub-winding segment 232 of the a-phase first winding wire and the seventh sub-winding segment 237 of the a-phase second winding wire, the welding terminals 220 ' span (y-1) stator slots 101, whereby the distance at the welding terminals 220 ' can be reduced, and for the entire winding process of the a-phase, the distance between the a-phase star point line and the lead-out wire can be reduced, whereby the welding connection is easy. In addition, by adopting a wave winding type wiring mode and combining with the adjustment of the span of part of the welding end 220, the voltage distribution in the same groove is uniform, the voltage difference of the flat wires between adjacent layers is small, the insulation breakdown risk of the motor can be effectively reduced, the reliability is high, the types of required coils are few, the structure and the process are simple, required equipment is few, and batch production is easy to carry out.

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

the U-shaped conductor segments include first-type conductor segments, the first in-slot portions of which are located at the outermost slot layers of the respective stator slots, and second-type conductor segments, the second in-slot portions of which are located at the innermost slot layers of the respective stator 15 slots; the first in-slot portions of the second type conductor segments and the second in-slot portions of the second type conductor segments are located in the inner slot layers of the corresponding stator slots, the inner slot layers include sub-outer slot layers and sub-inner slot layers, the first in-slot portions of the second type conductor segments are located in the sub-inner slot layers of the corresponding stator slots, and the second in-slot portions of the second type conductor segments are located in the sub-outer slot layers of the corresponding stator slots;

the first sub winding section is wound by the following method:

the second sub-winding section is wound by the following method:

s23, after the winding crosses y-1 stator slots along the second direction and the number of layers changes towards the radially outermost slot layer, the slot where the winding is located is the slot where the termination end of the second sub-winding section is located, the slot is adjacent to the slot where the A-phase first outgoing line is located, the outermost slot layer is located on one side, facing the first direction, of the A-phase first outgoing line, the part of the second sub-winding section crossing (y-1) stator slots is a welding end, and the welding end is formed by welding the first in-slot part of the first conductor section and the second in-slot part of the second conductor section;

the third sub winding section is wound by the following method:

the fourth sub winding section is wound by the following method:

the fifth sub winding section is wound by the following method:

the sixth sub winding section is wound by the following method:

p21, the windings cross in said first direction starting from the outermost layer of the corresponding stator slot, every y stators cross

The number of 35-slot groove layers is changed by one, wherein the number of layers is changed from outside to inside along the radial direction

Until the radially innermost groove layer; p22 stator spanning y stators in the second direction

A trench spanning from the innermost trench layer to the outermost trench layer; the other sixth sub-winding segments and the

The sixth sub winding section positioned in front of the first sub winding section is connected with the first sub winding section; the seventh sub-winding section is formed by

The following method is used for winding:

p31, the winding spanning y-1 stator slots in said first direction starting from the outermost slot layer of the corresponding stator slot, wherein the number of layers varies by one layer to the radially inner slot layer, the portion of said seventh sub-winding segment spanning said (y-1) stator slots being a weld end welded from the first in-slot portion of said first conductor segment type and the second in-slot portion of said second conductor segment type;

the eighth sub-winding section is wound by the following method:

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

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

4. The stator assembly of claim 1, wherein the a-phase first sub-path and the a-phase second sub-path are equal in cross-sectional area in a direction of extension of the conductor segments.

5. The stator assembly of claim 1, wherein the a-phase third sub-path and the a-phase fourth sub-path are equal in cross-sectional area in an extending direction of the conductor segment.

6. The stator assembly of claim 1 wherein the first sub-winding segment is three segments; the third sub winding line segment is three segments;

the sixth sub winding line segment is three segments; the eighth sub-winding line segment is three segments.

7. The stator assembly according to any of claims 1-6, wherein the stator assembly is adapted to 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 4 slot layers a, B, C, d, wherein the slot layer a is located at the radially outermost side of the stator core, the slot layer d is located at the radially innermost side of the stator core, the 3 phases include an a phase, a B phase, and a C phase, and the number a of parallel branches of each phase is 2, wherein the a phase first winding of the stator core is routed as follows:

1a->7d->1c->43b->37a->

43d->37c->31b->25a->

31d->25c->19b->13a->

19d->13c->7b->2a->

8d->2c->44b->38a->

44d->38c->32b->26a->

32d->26c->20b->14a->

20d->14c->8b，

the route of the A-phase second winding of the stator core is as follows:

14b->20c->26d->

20a->26b->32c->38d->

32a->38b->44c->2d->

44a->2b->8c->14d->

8a->13b->19c->25d->

19a->25b->31c->37d->

31a->37b->43c->1d->

43a->1b->7c->13d->7a；

8. The stator assembly of claim 7, wherein first dotted star lines for phase A, phase B, and phase C are circumferentially separated by 4 stator slots, and wherein second dotted star lines for phase A, phase B, and phase C are circumferentially separated by 4 stator slots.

9. The stator assembly of claim 7, wherein the first outgoing lines corresponding to the phases A, B and C are circumferentially separated by 4 stator slots, and the second outgoing lines corresponding to the phases A, B and C are circumferentially separated by 4 stator slots.

10. The stator assembly according to claim 7, wherein the stator winding comprises a first route of winding of B phase and a second route of winding of B phase, the winding method of the first route of winding of B phase is the same as the winding method of the first route of winding of A phase, and the winding method of the second route of winding of B phase is the same as the winding method of the second route of winding of A phase.

11. The stator assembly according to claim 7, wherein the stator winding comprises a C-phase first winding and a C-phase second winding, the C-phase first winding is wound in the same manner as the a-phase first winding, and the C-phase second winding is wound in the same manner as the a-phase second winding.

12. The stator assembly of claim 1, wherein the phase a first sub-path and the phase a second sub-path are arranged side by side in a radial direction of the stator core in an in-slot portion of a stator slot; the phase A third sub-path and the phase A fourth sub-path are arranged in parallel in the slot inner part of the stator slot along the radial direction of the stator core.

13. The stator assembly of claim 1, wherein the phase a first sub-path and the phase a second sub-path are arranged side by side at a weld end in a radial direction of the stator core; the phase A third sub-circuit and the phase A fourth sub-circuit are arranged in parallel at the welding end along the radial direction of the stator core.

14. The stator assembly of claim 1, wherein the phase a first sub-circuit is disposed in parallel with the phase a second sub-circuit; the phase A third sub-circuit and the phase A fourth sub-circuit are arranged in parallel.

15. An electrical machine comprising a stator assembly according to any of claims 1-14.