CN110971042B

CN110971042B - Stator assembly and motor with same

Info

Publication number: CN110971042B
Application number: CN201811141698.3A
Authority: CN
Inventors: 齐文明; 游斌; 林焕炜; 陈晓平
Original assignee: BYD Co Ltd
Current assignee: BYD Co Ltd
Priority date: 2018-09-28
Filing date: 2018-09-28
Publication date: 2022-04-15
Anticipated expiration: 2038-09-28
Also published as: CN110971042A

Abstract

The invention discloses a stator assembly and a motor with the stator assembly, the stator assembly comprises a stator core and a stator winding, a plurality of stator slots are arranged on the stator core, the stator winding comprises an A-phase winding, the A-phase 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 way, the A-phase winding comprises a plurality of first sub-winding sections to an eighth sub-winding section and a bridging line which are connected in sequence, the initial end of the A-phase winding is connected with an A-phase leading-out line, the terminal end of the eighth sub-winding section is connected with an A-phase star point line, the welding ends cross (y-1) stator slots at the corresponding welding ends of the second sub-winding section and the seventh sub-winding section of the A-phase winding, therefore, 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 A-phase leading-out line can be reduced, thereby facilitating the solder connection.

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: the stator core is cylindrical, and a plurality of stator slots are arranged on the stator core at intervals along the 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 in 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 protruding beyond the stator core to form a weld terminal 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 winding, the A-phase 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 winding comprises a plurality of first sub-winding sections, a second sub-winding section, a plurality of third sub-winding sections, a fourth sub-winding section, a bridging line, a fifth sub-winding section, a plurality of sixth sub-winding sections, a seventh sub-winding section and a plurality of eighth sub-winding sections which are sequentially connected, the initial end of the A-phase winding is connected with an A-phase leading-out line, and the terminal end of the eighth sub-winding section is connected with an A-phase star point line;

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

s11, leading out an A-phase leading-out wire to a radially outermost slot layer of an initial slot of the A-phase winding wire to prepare for winding a first sub-winding wire segment positioned at the initial end, wherein the A-phase leading-out wire is connected with a first in-slot part of a first type conductor segment positioned at the radially outermost slot layer on a 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 the initial slots of the a-phase 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, enabling the winding to cross over y-1 stator slots along the second direction, enabling the number of layers to change towards the radially outermost slot layer, enabling the slot where the winding is located to be the slot where the termination end of the second sub-winding section is located, enabling the slot to be adjacent to the slot where the A-phase leading-out wire is located, enabling the outermost slot layer to be located on one side, facing the first direction, of the A-phase leading-out wire, enabling the part, crossing over the (y-1) stator slots, of the second sub-winding section to be a welding end, and enabling the welding end to be formed by welding a first in-slot part of the first conductor section and a 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, and the terminal end of the fourth sub-winding line segment is positioned in the secondary outer slot layer;

s43, welding one end of the bridging line with the terminal end of the fourth sub-winding line segment, wherein the bridging line spans y stator slots on the same layer along the first direction;

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

p11, welding the other end of the bridging line with the initial end of a fifth winding line segment to prepare for winding a fifth sub winding line segment, wherein the winding line crosses from the other end of the bridging line along the first direction, and the number of layers of the y stator slot layers is changed by one layer every time the winding line crosses, wherein the number of layers is changed from outside to inside along the radial direction to the innermost slot layer along the radial direction;

p12, 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 the innermost slot layer to the outermost slot layer from which the a phase dotted line is drawn.

According to the stator assembly provided by the embodiment of the invention, the A-phase winding is constructed by utilizing the parallel winding of the A-phase first sub-circuit and the A-phase second sub-circuit, and the welding ends of the second sub-winding segment and the seventh sub-winding segment of the A-phase winding span (y-1) stator slots, so that the distance at the welding ends can be reduced, and the distance between the A-phase star point line and the A-phase lead line can be reduced for the whole winding process of the A-phase, so that 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 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 stator assembly is suitable for an electric machine having a slot number z of 48, a pole pair number p of 4, a phase number of 3, and a pitch y of 6, wherein each of the 48 stator slots has 4 slot layers a, B, C, d, wherein the slot layer a is located at the outermost radial side of the stator core, the slot layer d is located at the innermost radial side of the stator core, and the 3 phases include an a phase, a B phase, and a C phase, and wherein the 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->

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 bridge line spans from the 8 th groove b layer to the 14 th groove 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 corresponding star point lines of phase a, phase B, and phase C are circumferentially separated by 4 stator slots.

In some embodiments, the outgoing lines corresponding to the 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 phase B winding includes a phase B first sub-path and a phase B second sub-path, and the phase B first sub-path and the phase B second sub-path are wound around a winding.

In some embodiments, the B-phase first sub-path and the B-phase second sub-path are juxtaposed in a radial direction of the stator core.

In some embodiments, the C-phase winding is wound in the same manner as the a-phase winding.

In some embodiments, the C-phase winding includes a C-phase first sub-path and a C-phase second sub-path, and the C-phase first sub-path is wound around the winding with the C-phase second sub-path.

In some embodiments, the C-phase first sub-path and the C-phase second sub-path are juxtaposed in a 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 in an in-slot portion of a stator slot.

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 the welding end.

In some embodiments, the phase a first sub-circuit is disposed in parallel with the phase a second sub-circuit.

In some embodiments, the bridge wire is located at one side of the weld end of the stator core.

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

According to the motor provided by the embodiment of the invention, the A-phase winding is constructed by winding the A-phase first sub-circuit and the A-phase second sub-circuit in parallel, and the welding ends of the second sub-winding segment and the seventh sub-winding segment of the A-phase winding span (y-1) stator slots, so that the distance between the welding ends can be reduced, and the distance between the A-phase star point line and the A-phase lead line can be reduced for the whole winding process of the A-phase, so that 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.

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 the A-phase windings of a stator assembly according to an embodiment of the present invention;

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

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

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

FIG. 5 is a partial winding schematic of the A-phase windings of the stator assembly according to an embodiment of the present invention;

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

FIG. 7 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. 8 is a schematic structural view of a stator assembly according to an embodiment of the present invention;

FIG. 9 is an enlarged partial schematic view at A of FIG. 8;

FIG. 10 is a schematic diagram of the neutral line of FIG. 8;

FIG. 11 is a schematic diagram of the bridge threads of FIG. 8;

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

FIG. 13 is an enlarged partial schematic view at B of FIG. 12;

FIG. 14 is a schematic diagram of the bridge threads of FIG. 12;

FIG. 15 is a schematic structural view of a U-shaped conductor segment of a stator assembly according to an embodiment of the present invention;

FIG. 16 is a schematic structural view of a U-shaped conductor segment of a stator assembly according to an embodiment of the present invention;

FIG. 17 is a schematic structural view of a U-shaped conductor segment of a stator assembly according to an embodiment of the present invention;

FIG. 18 is a schematic structural view of a U-shaped conductor segment of a stator assembly according to an embodiment of the present invention;

FIG. 19 is a schematic structural view of a U-shaped conductor segment of a stator assembly according to an embodiment of the present invention;

FIG. 20 is a partial schematic structural view of a stator assembly according to an embodiment of the present invention;

FIG. 21 is a partial schematic structural view of a stator assembly according to an embodiment of the present invention;

FIG. 22 is a partial schematic structural view of a stator assembly according to an embodiment of the present invention;

FIG. 23 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. 24 is a partial schematic structural view of a stator assembly according to an embodiment of the present invention;

FIG. 25 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. 26 is a partial schematic structural view of a stator assembly according to an embodiment of the present invention;

FIG. 27 is a partial schematic structural view of a stator assembly according to an embodiment of the present invention;

FIG. 28 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. 29 is a partial schematic structural view of a stator assembly according to an embodiment of the present invention;

FIG. 30 is an enlarged partial schematic view at C of FIG. 29;

FIG. 31 is an enlarged partial schematic view at D of FIG. 29;

FIG. 32 is a top view schematic diagram of a stator assembly according to an embodiment of the present invention;

FIG. 33 is an enlarged partial schematic view at E of FIG. 32;

FIG. 34 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. 35 is an exploded view of the first type conductor segments and the second type conductor segments of FIG. 34;

FIG. 36 is a schematic view 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. 37 is an exploded view of the first type conductor segments and the second type conductor segments of FIG. 36;

FIG. 38 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. 39 is an exploded view of the first type conductor segment and the second type conductor segment of fig. 38.

Reference numerals:

the stator assembly 1000 is shown in a schematic view,

the stator core 100, the stator slots 101,

the stator winding 200 is wound on a stator,

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,

a first in-slot portion 214, a second in-slot portion 215,

a weld end 220, a weld end 220' spanning y-1 stator slots,

the phase a winding 230A is wound on the core,

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,

the bridge threads 240, connecting segments 241, first segments 242, second segments 243, curved segments 244,

the side wall 2421 of the first section located radially inward of the stator core,

the side wall 2431 of the second segment located radially inward of the stator core,

bridge line 240A for phase a, bridge line 240B for phase B, bridge line 240W for phase C,

the length of the first sidewall 245, the second sidewall 246,

the third side wall 247 is provided with a third side wall,

the length of the fourth sidewall 248, the fifth sidewall 249,

phase a outgoing line 251A, phase a star point line 252A,

phase B outgoing line 251B, phase B star point line 252B,

phase C outgoing line 251W, phase C star point line 252W,

a neutral line 260, a main body segment 261, a first boss 262, a second boss 263, a third boss 264,

a side wall 2621 of the first protrusion in the circumferential direction of the stator core,

a side wall 252a1 of the phase star point line in the circumferential direction of the stator core,

a side wall 2631 of the second convex portion in the circumferential direction of the stator core,

a side wall 252W1 of the C-phase star point line in the stator core circumferential direction,

a side wall 2641 of the third convex portion in the radial direction of the stator core,

the B-phase star point line is along the sidewall 252B1 in the radial direction of the stator core,

the main body segment is a sidewall 2611 in the axial direction of the stator core.

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 in accordance with an embodiment of the present invention is described below with reference to fig. 1-38.

As shown in fig. 1 to 8, a stator assembly 1000 according to an embodiment of the present invention is suitable for 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. 15 and 16), 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. 18 and 19).

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.

Stator winding 200 includes a-phase winding 230A, and a-phase winding 230A includes a-phase first sub-circuit 201A and a-phase second sub-circuit 202A, and the a-phase first sub-circuit 201A is wound in parallel with the a-phase second sub-circuit 202A.

The a-phase winding 230A includes a plurality of first sub-winding segments 231, a second sub-winding segment 232, a plurality of third sub-winding segments 233, a fourth sub-winding segment 234, a bridge line 240, a fifth sub-winding segment 235, a plurality of sixth sub-winding segments 236, a seventh sub-winding segment 237, and a plurality of eighth sub-winding segments 238, which are connected in sequence, an initial end of the a-phase winding 230A is connected to the a-phase lead-out line 251A, and a terminal end of the eighth sub-winding segment 238 is connected to the a-phase star point line 252A. 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 outgoing line 251A, 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. 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. 1 and 2, the first sub-winding segment 231 is wound by the following method:

s11, leading out the a-phase lead-out wire 251A to a radially outermost slot layer of an initial slot of the a-phase winding wire 230A, where the initial slot of the a-phase winding wire 230A is the stator slot 101 into which the a-phase lead-out wire 251A is first inserted when starting to prepare for winding, so as to prepare for winding the first sub-winding wire segment 231 located at the initial end, and the a-phase lead-out wire 251A is connected to the first in-slot portion 214 of one first type conductor segment 203 located at the radially outermost slot layer at the welding end 220. For example, as shown in fig. 1, the a-phase lead line 251A is led out from the outermost layer a 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 an outermost slot layer to an innermost slot layer of an initial slot of the a-phase winding 230A;

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 5, 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 a-phase outgoing line 251A is located, and the outermost groove layer is located on one side of the a-phase outgoing line 251A 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 terminals 220 are formed by welding the first in-slot portions 214 of the first-type conductor segments 203 and the second in-slot portions 215 of the second-type conductor segments 204, for example, in the example shown in fig. 5, 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, the third sub-winding segment 233 is wound by:

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, where the number of layers per y stator slot 101 slot layers changes by one, where the number of layers changes from inside to outside along the radial direction to the next outer slot layer along the radial direction, and the terminal end of the fourth sub-winding segment 234 is located in the next outer slot layer;

s43, welding one end of the bridge wire 240 to the terminal end of the fourth sub-winding wire segment 234, and crossing the y stator slots 101 on the same layer along the first direction with the bridge wire 240, as shown in fig. 3;

as shown in fig. 1 and 3, the fifth sub-winding segment 235 is wound by the following method:

p11, the other end of the bridge wire 240 being welded to the beginning of the fifth wire segment 235 in preparation for winding a fifth sub-winding segment 235, the winding crossing in the first direction from the other end of the bridge wire 240, the number of layers per layer crossing y stator slots 101 slot layers varying by one, wherein the number of layers varies radially from the outside to the inside up to the radially innermost slot layer;

p12, 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. 1, 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. 1 and 4, 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. 5, 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. 1 and 2, 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 dotted line 252A leads, the remaining eighth sub-winding segment 238 being connected to the eighth sub-winding segment 238 located in front thereof; for example, in the example shown in fig. 2, the a-phase star point line 252A is drawn from the 7 th slot a layer.

According to the stator assembly 1000 of the embodiment of the present invention, the a-phase winding 230A is configured by winding the a-phase first sub-circuit 201A and the a-phase second sub-circuit 202A in parallel, and the welding end 220 ' spans (y-1) stator slots 101 at the welding ends 220 ' of the second sub-winding segment 232 and the seventh sub-winding segment 237 of the a-phase winding 230A, so that the distance at the welding end 220 ' can be reduced, and for the entire winding process of the a-phase, the distance between the a-phase star point line 252A and the a-phase lead-out line 251A can be reduced, thereby facilitating the welding connection.

Furthermore, the A-phase winding is wound by the A-phase first sub-circuit 201A and the A-phase second sub-circuit 202A 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, 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 7, 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 3, and a pitch y of 6, wherein each of the 48 stator slots 101 has 4 slot layers a, B, C, 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, and the 3 phases include an a phase, a B phase, and a C phase, wherein the a-phase winding 230A of the stator core has the following route:

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->

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;

the bridge threads 240 span from the 8 th slot b layer to the 14 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. In some embodiments, the outgoing lines for phase a, phase B, and phase C are circumferentially separated by 4 stator slots 101.

In some embodiments, as shown in fig. 8, 12, 20, 21, 26 and 29, the bridge wire 240 is located at one side of the welding end 220 of the stator core 100. In some embodiments, as shown in fig. 8, 12, 20, 21, 26, and 29, the outgoing line and the star point line of the corresponding phase are located on one side of the welding end 220 of the stator core 100. Therefore, the height of the welding end 220 can be fully utilized, the space is saved, and the height of the motor is reduced.

In some embodiments, the phase B winding is wound in the same manner as the phase a winding 230A. In some embodiments, the C-phase winding is wound in the same manner as the a-phase winding 230A. 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 stator winding 200 includes a phase a winding 230A, B and a phase C winding, the phase B winding is wound in the same manner as the phase a winding, the initial end of the phase B winding is connected to a phase B outgoing line 251B, and the terminal end of the phase B winding is connected to a phase B star point line 252B; the winding method of the C-phase winding is the same as that of the A-phase winding, the initial end of the C-phase winding is connected with a C-phase outgoing line 251W, and the terminal end of the C-phase winding is connected with a C-phase star point line 252W; the star point lines corresponding to the phase A, the phase B and the phase C are different by 4 stator slots 101 in the circumferential direction.

As shown in fig. 8 to 10, the stator winding 200 further includes a neutral wire 260, the neutral wire 260 includes a main body segment 261 and a first protrusion 262, the main body segment 261 extends in the circumferential direction of the stator core 100, the first protrusion 262 is located at one end of the main body segment 261, and a side wall 2621 of the first protrusion 262 in the circumferential direction of the stator core 100 is welded to a side wall 252A1 of the a-phase star point line 252A in the circumferential direction of the stator core 100.

According to some embodiments of the present invention, as shown in fig. 8 to 10, the neutral line 260 further includes a second protruding portion 263, the second protruding portion 263 is located at the other end of the main body segment 261, and a side wall 2631 of the second protruding portion 263 in the circumferential direction of the stator core 100 is welded to a side wall 252W1 of the C-phase star point line 252W in the circumferential direction of the stator core 100.

According to some embodiments of the present invention, as shown in fig. 10, the neutral line 260 further includes a third protruding portion 264, the third protruding portion 264 is located between the first protruding portion 262 and the second protruding portion 263, and a sidewall 2641 of the third protruding portion 264 in the radial direction of the stator core 100 is welded to a sidewall 252B1 of the B phase star point line 252B in the radial direction of the stator core 100. As shown in fig. 10, the main body segment 261 is provided with at least one of the first protrusion 262, the second protrusion 263, and the third protrusion 264 on a sidewall 2611 in the axial direction of the stator core 100. In some embodiments, the neutral line 260 may adopt a sheet metal structure, which not only saves space, but also has the advantages of good manufacturability and low cost.

As shown in fig. 8-11, in some embodiments, the bridge threads 240 include a connecting segment 241, a first segment 242, and a second segment 243. Specifically, the connecting section 241 extends in the circumferential direction of the stator core 100, the first section 242 extends in the axial direction of the stator core 100, the first section 242 is connected to one end of the connecting section 241, the side wall 2421 of the first section 242 located radially inside the stator core 100 is welded to the welding end 220 of the corresponding U-shaped conductor segment 201, the second section 243 extends in the axial direction of the stator core 100, the second section 243 is connected to the other end of the connecting section 241, and the side wall 2431 of the second section 243 located radially inside the stator core 100 is welded to the welding end 220 of the corresponding U-shaped conductor segment 201.

Further, as shown in fig. 8, an end surface of one end of the first segment 242 is welded to the connecting segment 241, and an end surface of one end of the second segment 243 is welded to the connecting segment 241. Thereby saving space. For convenience of processing and production cost saving, in some embodiments, the bridge connector 240 is an integrally formed piece. According to some embodiments of the present invention, as shown in fig. 8, the first segment 242 and the second segment 243 are located on the same side of the connecting segment 241. To facilitate welding of the bridge wires 240 with the corresponding welding terminals 220, in the example shown in fig. 8, the ends of the connection segments 241 are each bent radially inward of the stator core 100 to form bent segments 244, and the connection segments 241 are U-shaped. Therefore, the connecting section 241 of the U-shaped structure has an avoidance space, and can avoid the outer coil. In addition, the bridge lines 240 are mainly arranged in the radial direction of the stator core 100, occupying no axial space thereof, and the axial height of the stator core 100 can be reduced. In some embodiments, each phase bridge wire 240 of the stator winding 200 may be machined by using sheet metal parts, which is relatively low in cost.

As shown in fig. 12 to 14, according to some embodiments of the present invention, the opposite sidewalls of the bridge wire 240 in the radial direction of the stator core 100 are a first sidewall 245, a second sidewall 246, and one of the first sidewall 245 and the second sidewall 246 is welded with the corresponding welding terminal 220. For example, in the example shown in fig. 14, the bridge wire 240 has a long shape and a curvature in the circumferential direction of the stator core 100, so that the structure of the bridge wire 240 can be simplified to facilitate the manufacturing process and save the manufacturing cost.

As shown in fig. 12 and 13, in some embodiments, the bridge wire 240 is provided on an end surface of the welding end 220 in the axial direction of the stator core 100, and a side wall of the connecting segment 241 facing the welding end 220 is a third side wall 247, and the third side wall 247 is welded to the corresponding welding end 220. Further, the opposite side walls of the bridge wire 240 in the circumferential direction of the stator core 100 are a fourth side wall 248 and a fifth side wall 249, and the fourth side wall 248 and the fifth side wall 249 are respectively welded to the corresponding welding ends 220.

In some embodiments, the bridge threads 240 of one portion of the stator winding 200 may be bridge threads 240 as shown in fig. 11, and the bridge threads 240 of another portion may be bridge threads 240 as shown in fig. 14. For example, in the example shown in fig. 12, the stator winding 200 includes a phase winding 230A, B and a phase winding C, the winding method of the phase winding B is the same as the winding method of the phase winding 230A, and the winding method of the phase winding C is the same as the winding method of the phase winding 230A, where as shown in fig. 6 and 7, the bridge of the phase winding a 230A is a phase bridge 240A, the bridge of the phase winding B is a phase bridge 240B, and the bridge of the phase winding C is a phase bridge 240W, where any one of the phase bridge 240B and the phase bridge 240W may be the bridge 240 as shown in fig. 14, or the bridge 240 as shown in fig. 11.

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. 15 to 17, 21 to 25, and 34 to 37, the intermediate connection part 213 has an annular structure with 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. 21-23, 34-35, 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 and 34-35, 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. 18, 19, 25, 28, 36 to 39, 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. 25, 36, 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. 26 to 28 and 38 to 39, 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. 28, 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. 28, 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. 29 to 39, the a-phase winding line 230A includes an a-phase first sub-circuit 201A and an a-phase second sub-circuit 202A, and the a-phase first sub-circuit 201A is wound around the a-phase second sub-circuit 202A. In some embodiments, the phase a first sub-circuit 201A is disposed in parallel with the phase a second sub-circuit 202A. It can be understood that each U-shaped conductor section 201 consists of two wires, and each U-shaped conductor section 201 consists of two wires, so that the copper wires are relatively flat, and a coil can be formed by drawing, so that a paint film can be prevented from being damaged in the coil forming process.

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.

According to some embodiments of the present invention, as shown in fig. 29 to 33, the a-phase first sub-path 201A and the a-phase second sub-path 202A are juxtaposed in the 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 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. 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.

According to some embodiments of the present invention, the stator winding 200 includes an a-phase winding 230A, B-phase winding and a C-phase winding. The winding method of the phase B winding is the same as that of the phase a winding, the phase B winding includes a phase B first sub-path and a phase B second sub-path, the phase B first sub-path and the phase B second sub-path are wound in parallel, and the phase B first sub-path and the phase B second sub-path are parallel to each other in the radial direction of the stator core 100.

The winding method of the C-phase winding is the same as that of the a-phase winding, the C-phase winding includes a C-phase first sub-path and a C-phase second sub-path, wherein the C-phase first sub-path and the C-phase second sub-path are wound in parallel, and the C-phase first sub-path and the C-phase second sub-path are juxtaposed in the radial direction of the stator core 100.

The winding method of the C-phase winding is the same as that of the A-phase winding, the initial end of the C-phase winding is connected with a C-phase outgoing line 251W, and the terminal end of the C-phase winding is connected with a C-phase star point line 252W; the star point lines corresponding to the phase A, the phase B and the phase C are different by 4 stator slots 101 in the circumferential direction.

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 and seventh

sub-winding segments

232 and 237 of the a-phase winding wire 230A, 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 wire 252A and the a-phase lead-out wire 251A 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. The utility model provides a stator module, is applicable to in the m motor of level 2p looks in the z groove, and its every utmost point is every looks groove number q ═ z/m/(2p), and the branch number that connects in parallel is g, and g is ≤ q, its characterized in that includes:

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 first sub winding section is wound by the following method:

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

s23, enabling the winding to cross over y-1 stator slots along the second direction, enabling the number of layers to change towards the radially outermost slot layer, enabling the slot where the winding is located to be the slot where the termination end of the second sub-winding section is located, enabling the slot to be adjacent to the slot where the A-phase leading-out wire is located, enabling the outermost slot layer to be located on one side, facing the first direction, of the A-phase leading-out wire, enabling the part, crossing over y-1 stator slots, of the second sub-winding section to be a welding end, and enabling the welding end to be formed by welding a first in-slot part of the first conductor section and a 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:

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 in the radial direction towards the inner slot layer, and the part of the seventh sub-winding segment spanning 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;

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

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;

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

2. The stator assembly of claim 1, characterized in that the U-shaped conductor segments are equal in cross-sectional area in the direction of extension of the 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. A stator assembly according to any of claims 1-3, characterized in that the stator assembly is adapted for use in an electrical machine having a number of slots, z, p, 3, and a pitch, y, 6, wherein each of the 48 stator slots has 4 slot layers, a, B, C, d, wherein slot layer a is located at the radially outermost side of the stator core and slot layer d is located at the radially innermost side of the stator core, and wherein 3 phases comprise a, B and C phases, wherein the 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->

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；

the bridge line spans from the 8 th groove b layer to the 14 th groove b layer;

5. The stator assembly of claim 4, wherein the corresponding star points of phases A, B, C differ by 4 stator slots in the circumferential direction.

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

7. The stator assembly of claim 4 wherein the winding of the B-phase winding is the same as the A-phase winding.

8. The stator assembly of claim 7, wherein the B-phase windings comprise a B-phase first sub-path and a B-phase second sub-path, the B-phase first sub-path and the B-phase second sub-path being wound around a winding.

9. The stator assembly of claim 8 wherein the B-phase first sub-path and the B-phase second sub-path are juxtaposed in a radial direction of the stator core.

10. The stator assembly of claim 4 wherein the C-phase winding is wound in the same manner as the A-phase winding.

11. The stator assembly of claim 10 wherein the C-phase windings comprise a C-phase first sub-path and a C-phase second sub-path, the C-phase first sub-path and the C-phase second sub-path being wound around a winding.

12. The stator assembly of claim 11 wherein the C-phase first sub-path and the C-phase second sub-path are juxtaposed in a radial direction of the stator core.

13. The stator assembly of claim 1, wherein the a-phase first sub-path and the a-phase second sub-path are arranged side-by-side in a radial direction of the stator core within a slot portion of a stator slot.

14. 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 along a radial direction of the stator core.

15. The stator assembly of claim 1, wherein the phase a first sub-circuit is disposed in parallel with the phase a second sub-circuit.

16. The stator assembly of claim 1 wherein the bridge wires are located at the weld end of the stator core.

17. An electrical machine comprising a stator assembly according to any of claims 1-16.