CN114709955A

CN114709955A - Three-phase and multi-phase motor stator structure and manufacturing method thereof

Info

Publication number: CN114709955A
Application number: CN202210439568.8A
Authority: CN
Inventors: 洪涛; 吴兴国
Original assignee: Hangzhou Volt Power Technology Co ltd
Current assignee: Hangzhou Volt Power Technology Co ltd
Priority date: 2022-04-25
Filing date: 2022-04-25
Publication date: 2022-07-05

Abstract

The invention discloses a three-phase and multi-phase motor stator structure and a manufacturing method thereof, wherein the structure comprises the following components: at least three stator cores; at least three flat wire windings; at least two adapter plates; the outer side face of each stator core is provided with a lead slot, the inner side face of each stator core comprises winding slots, the flat wire winding is installed in the winding slots, a double-spiral winding structure is formed by double-spiral winding, a lead end used for outgoing wires is formed on the inner side of the winding, and each adapter plate is axially and fixedly connected with two adjacent stator cores, so that the two adjacent stator cores form a fixed angle. The structure and the manufacturing method have the advantages that the winding structure of the multilayer flat wire wound in a double-spiral mode is adopted, the diameter of the winding wire can be smaller due to the flat wire winding structure, the slot filling rate of the winding in the motor is higher, and the eddy current loss problem of the transverse flux winding can be effectively reduced.

Description

Three-phase and multi-phase motor stator structure and manufacturing method thereof

Technical Field

The invention relates to the technical field of motors, in particular to a multi-phase motor stator structure and a manufacturing method thereof.

Background

In the prior art, the problem of how to reduce the volume needs to be solved in the transverse flux permanent magnet motor, the stator structure basically adopts the mode of evenly distributing in the circumferential direction, and a larger gap exists between every two stator cores, so that space waste is caused to a certain extent, if the motor is manufactured into an integrated structure, a proper tooth form and wall thickness can be selected through calculation, and then the areas through which magnetic lines of force pass are approximately equal. Although the integrally molded structure can effectively reduce the volume, the integrally molded structure actually has difficulties in processing, manufacturing, and assembling processes, such as precision. And the winding outgoing line of the stator in the prior art occupies the space of the stator, so that the effective electromagnetic volume is reduced, the torque and the power are influenced, and the traditional motor stator winding is specified.

Disclosure of Invention

One of the objectives of the present invention is to provide a stator structure of a three-phase and multi-phase motor and a manufacturing method thereof, in which a winding structure of a multi-layer flat wire wound in a double spiral is used, and the winding in a flat wire shape can make the winding more flat, so that the slot filling rate of the winding in the motor is higher, and the eddy current loss of a transverse flux winding can be effectively reduced.

One of the purposes of the invention is to provide a three-phase and multi-phase motor stator structure and a manufacturing method thereof, the structure and the manufacturing method are wound by double helix, the wire outlet mode at the inner side of a flat wire winding does not need to punch a hole on each phase of motor stator, three-phase and multi-phase lead wires are led out in a concentrated mode through lead wire slots at the outer side of a stator iron core, and the difficulty of lead wire outlet can be effectively reduced.

Another object of the present invention is to provide a stator structure of a three-phase or multi-phase motor and a method for manufacturing the same, in which a lead slot is formed at an outer edge of a stator, and the lead slot can be used for leading out a lead, so that the flat lead wire does not occupy an effective area of the motor, and thus the magnetic flux performance of the motor is not affected.

The invention also aims to provide a stator structure of a three-phase and multi-phase motor and a manufacturing method thereof, wherein the structure and the manufacturing method only have an axial modular overlapping installation mode among the multi-phase stators by arranging the adapter plate and the lead slots, and the adapter plate has a fixing hole and a lead notch, so that the size precision requirements of installation modes in different directions in the installation of the multi-phase stators can be effectively reduced, the tolerance matching is reduced, and the electromagnetic performance of the motor is improved.

The structure and the method are characterized in that a plurality of layers of flat wire windings wound in a double helix are wound towards the inner side of a coil, and axial connection is realized through a lead notch of the adapter plate and a lead slot of a stator of different phases, so that lead tapping in an effective flux space of the stator is avoided, and the influence on the performance of the motor is reduced.

To achieve at least one of the above objects, the present invention further provides a stator structure of three-phase and multi-phase motor, the structure comprising:

at least three stator cores;

at least three flat wire windings;

at least two adapter plates;

each stator core lateral surface has the lead wire groove, the stator core medial surface includes the winding wire groove, the flat line winding install in the winding wire groove, the double helix of flat line winding is encircleed and is formed the duplex winding structure the winding inboard forms the lead wire end that is used for being qualified for the next round of competitions, every keysets axially fixed connection two adjacent stator cores, make two adjacent stator cores form fixed angle.

According to a preferred embodiment of the present invention, the flat wire winding has at least two layers of parallel winding structures, and two outlet ends of the flat wire winding are both located at an inner side of the flat wire winding, and the outlet ends of the flat wire winding respectively have corresponding lead wires, and the lead wires are led out from the inner side of the flat wire winding.

According to another preferred embodiment of the present invention, the adapter plate is a C-shaped structure, the side surface of the adapter plate has a connecting hole, the adjacent side surfaces of two adjacent stator cores have a fixing hole corresponding to the position of the connecting hole of the adapter plate, and a connecting member penetrates through the connecting hole of the adapter plate and the fixing hole of the stator core to fixedly connect the adjacent stator cores.

According to another preferred embodiment of the invention, the C-shaped structure of the adapter plate is provided with a lead notch, the adapter plate is of a sheet structure, and the adapter plate and two adjacent stator cores are axially connected in parallel.

According to another preferred embodiment of the present invention, the lead notches of the adapter plate are disposed on the outer side surfaces of the adjacent stator cores and have lead groove positions, when the adapter plate axially fixes the adjacent stator cores, the lead notches of the adjacent stator cores have gaps, and the stator core leads extend from the lead notches.

According to another preferred embodiment of the invention, the lead wires of the stator core have a transition wire connecting the flat wire windings of different layers.

According to another preferred embodiment of the present invention, the stator core is a double-row stator tooth yoke structure, and the double-row stator tooth yoke structure is staggered by a fixed angle between different rows of teeth in the axial direction, wherein the fixed angle is staggered: α 1=180 °/Z, where α 1 is the stagger angle and Z is the single row tooth count; wherein the staggered fixed angle α 1 needs to satisfy: α 1=180 °/Z +360/Z/β, where β =2P/GCD (Z,2P), Z being the number of teeth of a single row of the stator of the motor, P being the number of pole pairs of the motor, GCD (Z,2P) representing the number of slots and the greatest common divisor of the number of steps 2P.

According to another preferred embodiment of the present invention, the stator core has a two-phase structure, the adapter plate includes a phase connection hole and a two-phase connection hole, the two phases of the corresponding stator core are respectively provided with a corresponding phase fixing hole and a corresponding two-phase fixing hole, and a connecting member passes through the phase connection hole and the phase fixing hole to fix two adjacent stator cores to form a two-phase structure; the connecting piece penetrates through the double-petal connecting hole and the double-petal fixing hole, so that two different petals of the same stator core can be fixed, and the single-phase stator core is formed.

According to another preferred embodiment of the invention, the stator core is provided with a rotor in the middle, the magnetic material and the magnetic conducting blocks on the outer surface of the rotor are formed by connecting a plurality of mutually inverted trapezoidal blocks in series, and the trapezoidal blocks are alternately arranged in a circumferential manner and are used for forming a circular structure of the rotor.

To achieve at least one of the above objects, the present invention further provides a motor stator manufacturing method comprising:

obtaining a flat copper conductor, and weaving the flat copper conductor into a layered flat wire winding in a double-spiral surrounding manner;

a single-layer winding is wound outwards from the inner side of the flat wire winding serving as a start, a transition wire is wound after a preset number of turns are wound, and the other single-layer winding is performed on the winding inwards through the transition wire;

after winding of the multilayer flat wire winding is completed, the flat wire winding is installed and fixed in a winding wire slot on the inner side surface of the stator core;

the C-shaped adapter plate is axially and fixedly connected with stator cores of different phases through a connecting piece, and stator cores of the same phases and different petals are fixed through the connecting piece;

the lead wire at the inner side of the flat wire winding extends out of the stator core through the lead wire groove and the lead wire gap.

Drawings

Fig. 1 is a general schematic view showing a stator structure of a motor according to the present invention.

Fig. 2 is a schematic view showing the structure of a flat wire winding of a stator according to the present invention.

Fig. 3 shows a partially enlarged view of the position of the flat wire winding S of the stator according to the invention.

Fig. 4 is a schematic view showing the winding direction of the flat wire winding of the stator according to the present invention.

Fig. 5 is a schematic diagram showing a double row stator tooth yoke structure according to the present invention.

Fig. 6 shows a schematic view of a single-lobe stator structure according to the present invention.

FIG. 7 is a schematic diagram of an adapter plate according to the present invention.

Figure 8 is a schematic view of a single stator assembly of the present invention.

Fig. 9 is a schematic view showing a structure of connecting two stator assemblies according to the present invention.

Figure 10 shows a schematic of a three-phase stator assembly according to a preferred embodiment of the invention.

Fig. 11 shows a schematic view of a rotor structure associated with a stator according to the present invention.

Fig. 12 is a schematic flow chart of a method for manufacturing a stator of an electric motor according to the present invention.

The stator comprises a stator core-10, a single-lobe stator core-10A, a tooth row-11, teeth-111, lead wire grooves-112, a phase fixing hole-12, a double-lobe fixing hole-13, winding wire grooves-14, flat wire windings-20, first layer flat wire windings-21, second layer flat wire windings-22, a starting end-23, an ending end-24, a transition wire-25, a lead wire-26, an adapter plate-30, a lead wire notch-31, a connecting hole-32, a double-lobe connecting hole-33, a rotor-40, a magnetic material-41 and a magnetic conducting block-42. The stator core assembly comprises an A-A phase stator core assembly, a B-B phase stator core assembly and a C-C phase stator core assembly.

Detailed Description

The following description is presented to disclose the invention so as to enable any person skilled in the art to practice the invention. The preferred embodiments described below are by way of example only, and other obvious variations will occur to those skilled in the art. The underlying principles of the invention, as defined in the following description, may be applied to other embodiments, variations, modifications, equivalents, and other technical solutions without departing from the spirit and scope of the invention.

It is understood that the terms "a" and "an" should be interpreted as meaning that a number of one element or element is one in one embodiment, while a number of other elements is one in another embodiment, and the terms "a" and "an" should not be interpreted as limiting the number.

Referring to fig. 1 to 12, the present invention discloses a three-phase and multi-phase stator structure of a motor and a method for manufacturing the same, wherein the three-phase and multi-phase stator structure comprises the following parts: the stator structure comprises at least three stator cores, at least three flat wire windings and at least two adapter plates, wherein the stator cores are axially connected with each other through the adapter plates to form a three-phase stator structure and a stator structure with more than three phases, a winding wire slot is formed in the inner side of each stator core, the flat wire windings are installed in the winding wire slots in the inner sides of the stator cores, and the at least two stator cores enable the plurality of stator cores to form the multiphase stator structure through the axial fixing effect of the adapter plates.

It is worth mentioning that one of the advantages of the present invention is that the structure of the flat wire winding is provided with a lead-out structure of the winding, wherein the flat wire winding adopts a double-helix winding to form a double-layer or multi-layer winding structure, specifically, referring to fig. 2-4, the flat wire winding is a flat copper wire, the starting end of the flat wire winding is the inner side of the first layer of flat wire winding (the winding is close to the circle center side), the first layer of winding is annularly wound from the starting end of the inner side of the flat wire winding, the first layer of flat wire winding is wound to a preset number of turns according to the preset number of turns, and the action end of the first layer of winding is located at the outer side of the flat wire winding. And further controlling the action end of the first layer of winding to bend towards the axial direction of the first layer of winding to form a transition line, and executing the winding operation of the second layer of winding through the transition line. And attaching the first layer of winding to the action end part of the transition line according to the winding direction of the first layer of winding to perform annular winding until the action end part is wound to the end with the same number of turns as the first layer of winding. The winding method of the flat wire winding can realize double-layer and multi-layer winding, the double-spiral flat wire structure formed by winding the flat wire has higher slot filling rate due to the wire type difference and the winding method compared with the traditional iron core winding wound by a single-spiral round wire, and the eddy current loss of the winding in a stator iron core is smaller due to the flat copper wire having the characteristic of being flatter. It should be noted that the number of the double spiral winding coils must be even, so that the convenience of wire outgoing can be ensured.

Referring to fig. 5-6, the stator structure of the present invention is a double-row stator yoke structure, wherein a staggered angle between two rows of adjacent teeth of the double-row stator yoke structure is a fixed angle, wherein the fixed angle is α 1= α 2= 180 °/Z, wherein Z is a single-row tooth number of the stator, wherein the staggered angle is adjusted according to a characteristic of a cogging torque, and is further equivalent to a skewed pole by adjusting, wherein the staggered angle is equal to a number of cycles of a cogging torque of a motor, and is required to satisfy the requirement from the viewpoint of reducing the cogging torque:

α1=180°/ Z +360/Z/β

wherein, beta =2P/GCD (Z,2P), Z is the number of single-row teeth of the motor stator, P is the pole pair number of the motor, and GCD (Z,2P) represents the maximum common divisor of the number of slots and the number of stages 2P. It should be noted that, the stator core of the present invention is configured as a split structure, and compared with an integrally formed stator structure, the split stator core of the present invention has advantages of production and manufacture, and the split stator core is also easier to assemble and disassemble.

The adapter plate is configured to be a C-shaped structure, wherein the adapter plate is provided with two phase connecting holes and two petal connecting holes, correspondingly, when the adapter plate is installed between two adjacent stator cores, two phase fixing holes and two petal fixing holes are provided on opposite side surfaces of the two adjacent stator cores, wherein the phase connecting holes and the phase fixing holes are arranged oppositely, and the two petal connecting holes and the two petal fixing holes are arranged oppositely, so that a connecting piece (such as a rivet) respectively penetrates through the phase connecting holes on the adapter plate and the phase fixing holes on the upper side surface of the corresponding stator core to realize the relative fixation of the two adjacent different-phase stators; the connecting pieces respectively penetrate through the bivalve connecting holes in the adapter plate and the bivalve fixing holes in the side faces of the stator cores to realize bivalve relative fixing of the single core, the fixing mode is axial fixing on the whole, namely two stator cores and the adapter plate in the middle are arranged on the same rotating shaft, the installation mode is modular installation, and an installation module can be independently formed without adjacent stator cores and adapter plates, so that the structure of the invention can take the tolerance matching limit of the manufacturing process into account, and the integral installation efficiency is also improved.

It should be noted that, referring to fig. 9 and 10, the stator core assembly of the present invention is configured to be at least three phases, and the present invention is illustrated by a three-phase stator core assembly: the stator core's outside is equipped with the lead wire groove on the surface, wherein the lead wire groove sets up along the axial of stator, just the lead wire groove the stator core outside surface is local setting, at reduce cost under not influencing electromagnetic properties. The adapter plate is configured to be a C-shaped structure, wherein a lead notch is formed in the C-shaped adapter plate and used for leading out a lead in a penetrating mode. Referring specifically to fig. 10, in one preferred embodiment of the present invention, the stator core assembly includes an a-phase stator core assembly and a B-phase stator core assembly. The flat wire winding is arranged in the winding wire slots of the A-phase stator iron core component and the B-phase stator iron core component, the adapter plate is arranged on the opposite side surfaces of the A-phase stator iron core component and the B-phase stator iron core component, when the adapter plate is arranged between the A-phase stator iron core component and the B-phase stator iron core component, a certain gap is formed between the side surfaces of the A-phase stator iron core component and the B-phase stator iron core component through the lead gap of the adapter plate, the gap can accommodate the corresponding flat wire winding lead-out of the A-phase stator iron core component and the B-phase stator iron core component, two lead terminals of the flat wire winding of the B-phase stator iron core component are respectively led out from the inner side of the flat wire winding along the grooves of different tooth rows, the lead of one lead terminal is led to the lead gap from the groove of one tooth row and led out to the lead groove on the outer side surface of the A-phase stator iron core component, and the other lead terminal lead is led out from the groove of the other tooth row of the B-phase stator iron core component to a lead groove on the outer side surface of the B-phase stator iron core component. Further configuration the lateral surface lead wire groove of A looks stator core subassembly and B looks stator core subassembly all is in the same or similar position, makes can through connection between the lateral surface lead wire groove of A looks stator core subassembly and B looks stator core subassembly. Further, the axial lateral surface of B looks stator core subassembly is through the side of another keysets connection C looks stator core subassembly, wherein install in the winding wire casing of C looks stator core subassembly flat wire winding, just the lead wire breach that the keysets that C looks stator core subassembly and B looks iron core stator subassembly are connected corresponds and the lead wire breach of another keysets is in the same or similar axial position, makes the lead wire groove of A, B, C three-phase stator core subassembly's lateral surface link up each other.

It should be noted that, the flat wire winding of the stator core subassembly of A looks and C looks stator core subassembly will be according to B looks stator core subassembly's flat wire winding carries out the lead wire of the same both sides and draws forth, because the lead wire breach can cover a plurality of lead wire grooves, and link up each other between the lead wire groove of different looks, consequently, the flat wire winding of the stator core subassembly of A looks and C looks stator core subassembly and the lead wire of the flat wire winding of B looks stator core subassembly can be drawn forth in the same lead wire groove to can realize the concentrated of different looks leads and assemble, reduced the degree of difficulty of appearing of lead wire by a wide margin, and be convenient for the assembly of different looks stator core.

The stator core is required to be provided with a rotor and is further used for constructing a driving assembly of a motor. The magnetic material and the magnetic conduction blocks are mutually matched and alternately arranged circumferentially. Such an arrangement can ensure the roundness of the rotor assembly on the one hand. On the other hand, the alternative circumferential arrangement mode of the magnetic material and the magnetic conduction blocks can reduce the probability of secondary processing and increase the fault tolerance of the rotor assembly.

It will be understood by those skilled in the art that the embodiments of the present invention described above and illustrated in the drawings are given by way of example only and not by way of limitation, the objects of the invention having been fully and effectively achieved, the functional and structural principles of the present invention having been shown and described in the embodiments, and that various changes or modifications may be made in the embodiments of the present invention without departing from such principles.

Claims

1. A stator structure for three-phase and multi-phase electric machines, said structure comprising:

at least three stator cores;

at least three flat wire windings;

at least two adapter plates;

the outer side face of each stator core is provided with a lead slot, the inner side face of each stator core comprises winding slots, the flat wire winding is installed in the winding slots, a double-spiral winding structure is formed by double-spiral winding, a lead end used for outgoing wires is formed on the inner side of the winding, and each adapter plate is axially and fixedly connected with two adjacent stator cores, so that the two adjacent stator cores form a fixed angle.

2. The stator structure of three-phase and multi-phase motor according to claim 1, wherein the flat wire winding has at least two layers of parallel winding structure, and two outlet ends of the flat wire winding are both located at the inner side of the flat wire winding, and the outlet ends of the flat wire winding have corresponding lead wires respectively, and the lead wires are led out from the inner side of the flat wire winding.

3. The stator structure of three-phase and multi-phase motor according to claim 1, wherein the adapter plate is a C-shaped structure, the side surface of the adapter plate has a connecting hole, the adjacent side surfaces of two adjacent stator cores have a fixing hole corresponding to the position of the adapter plate connecting hole, and a connecting member penetrates through the adapter plate connecting hole and the stator core fixing hole to fixedly connect the adjacent stator cores.

4. The stator structure of three-phase and multi-phase motor according to claim 1, wherein the C-shaped structure of the adapter plate has a lead gap, the adapter plate is a plate-shaped structure, and the adapter plate and two adjacent stator cores are axially connected side by side.

5. The stator structure of three-phase and multi-phase motor according to claim 4, wherein the lead notches of the adapter plate are disposed on the outer side surfaces of the adjacent stator cores and have lead slot positions, when the adapter plate axially fixes the adjacent stator cores, the lead notches of the adjacent stator cores have gaps, and the stator core leads extend from the lead notches.

6. The stator structure of three-and multi-phase electric motor according to claim 1, wherein the lead wire of the stator core has a transition wire connecting the flat wire windings of different layers.

7. The stator structure of three-and multi-phase electric motor according to claim 1, wherein the stator core is a double-row stator yoke structure, and the double-row stator yoke structure is staggered by a fixed angle between different rows of teeth in the axial direction, wherein the fixed angle is staggered: α 1=180 °/Z, where α 1 is the stagger angle and Z is the single row tooth count; wherein the staggering fixing angle α 1 needs to satisfy: α 1=180 °/Z +360/Z/β, where β =2P/GCD (Z,2P), Z being the number of teeth of a single row of the stator of the machine, P being the number of pole pairs of the machine, GCD (Z,2P) representing the number of slots and the greatest common divisor of the number of steps 2P.

8. The stator structure of three-phase and multi-phase motor according to claim 1, wherein the stator core is a double-petal structure, the adapter plate comprises a phase connection hole and a double-petal connection hole, the double petals of the corresponding stator core are respectively provided with a corresponding phase fixing hole and a corresponding double-petal fixing hole, and a connecting piece penetrates through the phase connection hole and the phase fixing hole to fix two adjacent stator cores to form a two-phase structure; the connecting piece penetrates through the double-petal connecting hole and the double-petal fixing hole to fix two different petals of the same stator core, and the stator core is used for forming a single-phase stator core.

9. The stator structure of three-phase and multi-phase motor according to claim 1, wherein the stator core is provided with a rotor, the magnetic material and the magnetic conductive blocks on the outer surface of the rotor are formed by connecting a plurality of mutually inverted trapezoidal blocks in series, and the trapezoidal blocks are alternately arranged in a circumferential manner to form a circular structure of the rotor.

10. A method of manufacturing a stator for an electrical machine, the method comprising:

obtaining a flat copper conductor, and weaving the flat copper conductor in a double-spiral surrounding manner to form a layered flat wire winding;

winding a single-layer winding from the inner side of the flat wire winding serving as a starting break to the outside, winding a transition wire after winding a preset number of turns, and winding the other single-layer winding inwards through the transition wire;