CN117375341A - Stator winding installation method and motor stator - Google Patents
Stator winding installation method and motor stator Download PDFInfo
- Publication number
- CN117375341A CN117375341A CN202210770614.2A CN202210770614A CN117375341A CN 117375341 A CN117375341 A CN 117375341A CN 202210770614 A CN202210770614 A CN 202210770614A CN 117375341 A CN117375341 A CN 117375341A
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- Prior art keywords
- conductor
- bending
- stator
- forming
- installation method
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 238000000034 method Methods 0.000 title claims abstract description 95
- 238000004804 winding Methods 0.000 title claims abstract description 40
- 238000009434 installation Methods 0.000 title claims abstract description 22
- 239000004020 conductor Substances 0.000 claims abstract description 207
- 238000005452 bending Methods 0.000 claims abstract description 105
- 238000012545 processing Methods 0.000 claims description 2
- 230000008569 process Effects 0.000 abstract description 61
- 238000004519 manufacturing process Methods 0.000 abstract description 4
- 238000000465 moulding Methods 0.000 abstract 3
- 238000003780 insertion Methods 0.000 description 12
- 230000037431 insertion Effects 0.000 description 12
- 238000003466 welding Methods 0.000 description 4
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical group [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 2
- 229910052802 copper Inorganic materials 0.000 description 2
- 239000010949 copper Substances 0.000 description 2
- 230000008878 coupling Effects 0.000 description 2
- 238000010168 coupling process Methods 0.000 description 2
- 238000005859 coupling reaction Methods 0.000 description 2
- 238000005520 cutting process Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000011900 installation process Methods 0.000 description 2
- 238000003754 machining Methods 0.000 description 2
- 230000013011 mating Effects 0.000 description 2
- 230000004075 alteration Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000002309 gasification Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000000750 progressive effect Effects 0.000 description 1
- 238000012797 qualification Methods 0.000 description 1
Classifications
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/08—Forming windings by laying conductors into or around core parts
- H02K15/085—Forming windings by laying conductors into or around core parts by laying conductors into slotted stators
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
- H02K3/12—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors arranged in slots
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
- H02K3/28—Layout of windings or of connections between windings
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/46—Fastening of windings on the stator or rotor structure
- H02K3/48—Fastening of windings on the stator or rotor structure in slots
Abstract
The invention relates to the technical field of motor manufacturing, and provides a stator winding installation method and a motor stator, wherein the stator winding installation method comprises the steps of bending and forming a first end of a conductor; and inserting the conductor after bending and forming into the stator groove. The invention has the advantages that one end part of the conductor is bent and molded, so that the other end of the conductor inserted in the stator slot is only required to be bent and molded, the conductor inserted in the stator slot is only required to be bent and molded once, the pre-bending and molding process is not limited by the stator, the bending and molding process of the conductor is facilitated to be simplified, the bending and molding are only carried out on one end of the conductor before the conductor is inserted, the other end of the conductor maintains the original straight conductor structure, the process difficulty of inserting the conductor into the stator slot is reduced, and the inserting beat is accelerated.
Description
Technical Field
The invention relates to the technical field of motor manufacturing, in particular to a stator winding installation method and a motor stator.
Background
The current main flow stator winding production and manufacturing process of the flat wire motor is divided into two technical routes, namely a Hair-PIN process route with one end integrally bent and formed, also called a Hair-PIN process, and an I-PIN process route; the hairpin winding is formed by integrally forming the heads of the conductors of two adjacent sections, so that a U-shaped hairpin structure is formed, the hairpin structure is independently used as a conductor group, and two ends of the conductor under a Hair-PIN process route are required to be simultaneously inserted into a stator slot, so that the insertion process is difficult and the beat is slow; each conductor set in the I-PIN process route comprises a first conductor and a second conductor, the first conductor and the second conductor are mutually independent before being inserted into a stator slot, the first conductor and the second conductor can be independently inserted into the stator slot, then adjacent conductor heads are connected to form a conductor set, the conductor set acts like a hairpin winding, and the insertion process is simpler and the beat is faster;
the conventional insertion process of the conductor in the I-PIN process route is usually to insert the straight conductor into the stator slot, and then the head and tail of the straight conductor are required to be bent twice.
Disclosure of Invention
The invention aims to provide a stator winding installation method and a motor stator, wherein the installation method is based on an I-PIN process route, one end of a straight conductor is bent and formed in advance and then is inserted into a stator slot, so that the conductor inserted into the stator slot only needs one bending process, and the bending process of the conductor is simplified because the process of the preliminary bending and forming is not limited by the stator, the process difficulty of inserting the conductor into the stator slot is reduced, and the inserting beat is accelerated.
The stator winding mounting method in the present embodiment includes:
bending and forming a first end of the conductor;
and inserting the conductor after bending and forming into the stator groove.
Further, the first end is one end of the head of the conductor, and the head of the conductor is one end, which needs to be connected, of two conductors in the same conductor set.
Further, the conductor after bending and forming is inserted into the stator groove by the following method:
the second end of the conductor after bending and forming is axially inserted into the stator groove along one end of the stator groove and extends out from the other end of the stator groove.
Further, before the step of inserting the conductor after bending and forming into the stator slot, the method further comprises: a connection face is formed at the first and second ends of the conductor.
Further, before the step of forming the connection surface by machining the first end and the second end of the conductor, the method further comprises: removing the insulating layer at the first end and the second end forms a bare conductor end.
Further, the exposed conductor ends are beveled to form the connection face.
Further, the way of bending and forming the conductor comprises 2D bending and 3D bending, and the 3D bending acts on the bending section formed by the first end after the 2D bending.
Further, after the step of inserting the bent conductor into the stator slot, the method further comprises: and bending and forming the second end of the conductor.
The invention also provides a motor stator comprising a stator and a stator winding configured to be mounted within the stator by: bending and forming a first end of the conductor; and inserting the conductor after bending and forming into a stator groove of the stator.
Further, the first end is one end of the head of the conductor, and the head of the conductor is one end, which needs to be connected, of two conductors in the same conductor set.
In summary, the stator winding installation method provided by the invention includes bending and forming the first end of the conductor; and inserting the conductor after bending and forming into a stator groove of the stator.
So configured, the first end (31) of the conductor (30) is formed after bending, the conductor after bending is inserted into the stator slot, at this time, because one end of the conductor is bent and formed, the other end of the conductor inserted into the stator slot is only required to be bent and formed, so that the conductor inserted into the stator slot only needs one bending process, the pre-bending process is not limited by the stator, the whole bending process of the conductor is simplified, and the other end of the conductor is only bent and formed before the conductor is inserted into the stator slot, so that the process difficulty of inserting the conductor into the stator slot is reduced, and the inserting beat is accelerated.
Drawings
FIG. 1 is a schematic diagram of a prior art hairpin;
FIG. 2 is a schematic view of an improved stator winding connection structure 1;
FIG. 3 is a schematic view of an improved stator winding connection configuration 2;
FIG. 4 is a schematic view of a first end 2D bending structure of the conductor of the present invention;
FIG. 5 is a schematic view of a 3D bending structure of a first end of a conductor according to the present invention;
FIG. 6 is a schematic view of a conductor mounting structure of the present invention 1;
FIG. 7 is a schematic view of a conductor mounting structure of the present invention as shown in FIG. 2;
FIG. 8 is a conductor insertion process diagram of the present invention;
wherein, the reference numerals are as follows:
10-motor windings; 11-a first conductor; 12-a second conductor; 13-a connection face;
20-hairpin winding;
30-conductors; 31-a first end; 32-a second end;
40-stator core.
Detailed Description
The stator winding installation method according to the present invention will be described in further detail with reference to the accompanying drawings and specific embodiments. The advantages and features of the present invention will become more apparent from the following description. It should be noted that the drawings are in a very simplified form and are all to a non-precise scale, merely for convenience and clarity in aiding in the description of embodiments of the invention.
In the invention, the axial direction refers to the axial direction of the motor stator, and the radial direction refers to the radial direction of the motor stator;
as used in this disclosure, the singular forms "a," "an," and "the" include plural referents, the term "or" are generally used in the sense of comprising "and/or" and the term "several" are generally used in the sense of comprising "at least one," the term "at least two" are generally used in the sense of comprising "two or more," and the term "first," "second," and "third" are used for descriptive purposes only and are not to be construed as indicating or implying any relative importance or number of features indicated. Thus, a feature defining "a first", "a second", "a third" may include one or at least two such features, either explicitly or implicitly. Furthermore, as used in this disclosure, "mounted," "connected," and "disposed" with respect to another element should be construed broadly to mean generally only that there is a connection, coupling, mating or transmitting relationship between the two elements, and that there may be a direct connection, coupling, mating or transmitting relationship between the two elements or indirectly through intervening elements, and that no spatial relationship between the two elements is to be understood or implied, i.e., that an element may be in any orientation, such as internal, external, above, below, or to one side, of the other element unless the context clearly dictates otherwise. The specific meaning of the above terms in the present invention can be understood by those of ordinary skill in the art according to the specific circumstances. Furthermore, directional terms, such as above, below, upper, lower, upward, downward, left, right, etc., are used with respect to the exemplary embodiments as they are shown in the drawings, upward or upward toward the top of the corresponding drawing, downward or downward toward the bottom of the corresponding drawing.
The present embodiment is modified based on the I-PIN process route, which is essentially different from the Hair-PIN process route;
referring to fig. 1, in the conventional Hair-PIN process route, the conductor is bent to form an integral Hair-PIN winding 20 structure, and two ends of the conductor need to be inserted into corresponding stator slots at the same time, so that the process of inserting the conductor into the stator slots is difficult and the beat is slow;
referring to fig. 2, in the I-PIN process route, the motor winding 10 includes a plurality of conductor sets, each conductor set includes a first conductor 11 and a second conductor 12, wherein the heads of the first conductor 11 and the second conductor 12 are bent, so that the heads of the first conductor 11 and the second conductor 12 form an approximately parallel relationship after being inserted into a stator slot, and then the head positions of the first conductor 11 and the second conductor 12 are connected by laser welding; in the process, the first conductor 11 and the second conductor 12 can be respectively and independently inserted into two stator slots for reconnection, and the process of inserting the conductors into the stator slots is simpler and the beat is faster; the connection mode needs to bend the head part of the conductor twice, so that bending procedures are more;
please refer to the connection process shown in fig. 3, which belongs to the I-PIN process route, wherein the process is derived to form an X-PIN process route based on the process route shown in fig. 2, at this time, two conductor heads in the conductor set are processed to form connectors, the connectors do not need to be bent to form an approximately parallel structure as shown in fig. 1, one bending process can be reduced, an approximately X-shaped cross structure is formed after the two connectors are matched, and then the two connectors are connected by adopting a laser welding process; as shown in fig. 3, the first conductor 11 and the second conductor 12 are processed with a connecting surface 13, and the two connecting surfaces need to be welded and connected, so that the alignment degree of the two connecting surfaces directly influences the connection quality of the two conductors;
as shown in two I-PIN process routes in fig. 2 and 3, in the installation process of the motor winding, the straight conductor is usually inserted into the stator slot first, then the head and tail of the straight conductor need to be bent twice, and the bending process of the head and tail of the straight conductor is difficult and the tooling required by bending is complex because the straight conductor is limited by the stator after being inserted into the stator slot;
therefore, the patent proposes a stator winding installation method for simplifying the installation process of conductors;
the stator winding installation method comprises the following steps:
bending and forming a first end of the conductor;
and inserting the conductor after bending and forming into the stator groove.
In the I-PIN process route, the heads of two conductors in each conductor group are required to be connected, the tails of all conductors are also required to be connected after a bending process, the tails of the conductors are connected to realize corresponding circuit topology functions, for example, star connection or triangle connection structures can be formed after the tails of the conductors are connected;
the conductor has two ends of a head and a tail, where the end corresponding to the first end is not limited, and the first end may correspond to the head of the conductor or may correspond to the tail of the conductor;
referring to fig. 4 and 5, the conductor 30 has a first end 31 and a second end 32, the first end 31 of the conductor 30 is formed after a bending process, and the conductor after bending is inserted into the stator slot, as shown in fig. 6 and 7, at this time, since one end of the conductor is bent and formed, the other end of the conductor inserted into the stator slot is only required to be bent and formed, so that the conductor inserted into the stator slot only needs one bending process, and the pre-bending process is not limited by the stator, thereby facilitating the simplification of the bending process of the conductor, and only bending and forming one end of the conductor before insertion, while the other end maintains the original straight conductor structure, thereby reducing the process difficulty of inserting the conductor into the stator slot and accelerating the insertion beat.
Further, the first end is one end of the head of the conductor, and the head of the conductor is one end, which needs to be connected, of two conductors in the same conductor set.
Referring to fig. 4 to 5, one end of the conductor head is selected to be bent and preformed to give consideration to the connection accuracy of the conductor head; because the heads of the two conductors in each conductor set are required to be connected in the I-PIN process route, the positioning accuracy of the heads of the two conductors in each conductor set directly influences the connection quality of the two conductors, if the conductors are selected to be inserted into the stator slots and then bent and formed at one end of the heads of the conductors, on one hand, the bending process is difficult, on the other hand, the required bending shape is required to be considered in the bending process, and the relative position relationship of the heads of the two conductors in the same conductor set is required to be considered, so that the bending process is further complicated and difficult, and because of the uncertainty of bending, the position accuracy of the heads of the two conductors is greatly uncertainty, and the relative position accuracy of the heads of the two conductors is difficult to be ensured; therefore, before the insertion, one end of the conductor head is considered to be bent and preformed, and at the moment, the bending process is not constrained by the motor stator, so that the shape required by bending can be accurately controlled; when the connector is inserted, the position accuracy of the heads of the two conductors in the same conductor set can be guaranteed only by ensuring certain insertion accuracy, so that the bending process is simplified, the position accuracy of the heads of the two conductors in the same conductor set is improved, and the connection quality is improved.
Further, the conductor after bending and forming is inserted into the stator groove by the following method:
the second end of the conductor after bending and forming is axially inserted into the stator groove along one end of the stator groove and extends out from the other end of the stator groove.
The first end of the conductor is bent and preformed, the second end of the conductor keeps the original straight conductor end, and at the moment, the second end is inserted into the stator slot to realize the installation of the conductor, thereby being beneficial to simplifying the inserting process; the second end of the conductor extends out of the stator groove, and bending and forming of the second end are facilitated.
Further, before the step of inserting the conductor after bending and forming into the stator slot, the method further comprises: a connection face is formed at the first and second ends of the conductor.
The processing connecting surface can be positioned before the first end is bent and molded, or can be positioned after the first end is bent and molded; in this embodiment, the connection surface is preferably processed before the first end is bent and formed, and the connection surface is easy to process at both ends because the whole conductor is a straight conductor before the first end is bent and formed;
the first end is bent and formed before the inserting, and the connecting surfaces are formed at the positions of the two ends, so that the bending shape and the relative positions of the connecting surfaces after bending can be comprehensively considered, the requirement of the bending shape of the conductor and the requirement of the position accuracy of the connecting surfaces of two conductors in the same conductor set after the inserting are simultaneously met, and the product qualification rate is improved.
Further, before the step of forming the connection surface by machining the first end and the second end of the conductor, the method further comprises: removing the insulating layer at the first end and the second end forms a bare conductor end. .
Referring to fig. 4, a general conductor is a copper conductor, and since the I-PIN process route is applied to a flat wire motor, the copper conductor is a flat wire conductor, and is usually connected by a welding process in the process of connecting the conductors, and an insulating layer at the end of the conductor is removed and then processed to form a connection surface, so that the connection quality of the two connection surfaces can be prevented from being affected by high-temperature gasification of the insulating layer in the process of connecting the two connection surfaces.
Further, the exposed conductor ends are beveled to form the connection face.
The beveling refers to that the cutting direction is not perpendicular to the conductor, and referring to fig. 4, a larger connection surface is obtained by beveling, so as to increase the welding length.
Further, the way of bending and forming the conductor comprises 2D bending and 3D bending, and the 3D bending acts on the bending section formed by the first end after the 2D bending.
The 2D bending is plane bending, which means bending deformation in a corresponding plane, and the existing 2D bending machines and the like are all 2D bending; the 3D bending is also a spatial bending, which means bending under multiple degrees of freedom and generating spatial bending deformation, and the existing 3D bending machine and the like are all 3D bending;
referring to fig. 4, the heads of the conductors are bent at a certain angle through 2D to form a general shape, and then, as shown in fig. 5, the bending sections are bent at 3D to form a spatial bending structure, so that the heads of the two conductors in the same conductor set form a corresponding relative positional relationship to meet the connection requirement of the heads of the two conductors, and the specific bending shapes of the 2D bending and the 3D bending are not limited.
Further, after the step of inserting the bent conductor into the stator slot, the method further comprises: and bending and forming the second end of the conductor.
The second ends need to be connected after bending and forming, and correspond to fig. 4 and 5, the second ends are tail parts of the conductors, and then the second ends of the conductors are connected to realize corresponding circuit topology functions.
The embodiment also provides a motor stator, comprising a stator and a stator winding, wherein the stator winding is configured to be installed in the stator through the stator winding installation method.
As shown in fig. 6 and 7, the stator core 40 has a plurality of stator slots, in which only one conductor 30 is inserted into the stator slots, and the stator winding generally has several layers, and then the remaining conductors are inserted in a manner of sequentially inserting from the outer layer to the inner layer, and the conductors in the same layer in each stator slot are sequentially inserted into the slots in the circumferential direction to complete the installation of the stator winding of the layer;
referring to fig. 8, after the previous process is completed, a rod body is obtained, and an insulating layer is provided outside the rod body; then conducting PIN cutting operation, specifically comprising removing insulating layers at two ends of a conductor to form exposed conductor ends, and then chamfering to form a connecting surface; after the connection surface is processed, a bending forming process of a first section of the conductor is carried out, and the bending forming process specifically comprises 2D bending and 3D bending, wherein the 2D bending is performed through a 2D tool die, and the 3D bending is formed through profiling of a 3D tool die; in the process of conductor insertion, the motor stator winding is generally automatically inserted, n layers are arranged, conductors are sequentially inserted into all stator slots according to the number of layers of the motor stator winding, automatic insertion equipment judges whether conductor insertion in all stator slots in the motor winding of the current i layer is completed, if the insertion is completed, the relation between the current i layer and the n layers is judged, if the i layer is smaller than the n layers, the i+1 layers are continuously inserted until all motor winding layers are inserted, then a next procedure is carried out, and the next procedure comprises bending of the second end of the conductor and connection of the second end of the conductor after bending so as to realize corresponding circuit topology functions.
The embodiment also provides a motor, which comprises a stator and a rotor, wherein the stator adopts the motor stator.
For the flat wire motor, the mounting structure of the stator and the rotor is the prior art, and is not repeated here;
in the present specification, each embodiment is described in a progressive manner, and each embodiment is mainly described in a different point from other embodiments, and identical and similar parts between the embodiments are all enough to refer to each other.
The above description is only illustrative of the preferred embodiments of the present invention and is not intended to limit the scope of the present invention, and any alterations and modifications made by those skilled in the art based on the above disclosure shall fall within the scope of the appended claims.
Claims (10)
1. A stator winding installation method characterized by comprising the steps of:
bending and forming a first end of the conductor;
and inserting the conductor after bending and forming into the stator groove.
2. A stator winding installation method as claimed in claim 1, wherein: the first end is one end of the head of the conductor, and the head of the conductor is one end of the same conductor set, which is needed to be connected with two conductors.
3. A stator winding installation method as claimed in claim 1, wherein: the conductor after bending and forming is inserted into the stator groove by the following method:
the second end of the conductor after bending and forming is axially inserted into the stator groove along one end of the stator groove and extends out from the other end of the stator groove.
4. A stator winding installation method as claimed in claim 1, wherein: the step of inserting the conductor after bending and forming into the stator slot further comprises the following steps: a connection face is formed at the first and second ends of the conductor.
5. The stator winding installation method of claim 4, wherein: the step of forming the connection surface by processing the first end and the second end of the conductor further comprises: removing the insulating layer at the first end and the second end forms a bare conductor end.
6. The stator winding installation method of claim 5, wherein: the exposed conductor ends are beveled to form the connection face.
7. A stator winding installation method as claimed in claim 1, wherein: the mode of bending and forming the conductor comprises 2D bending and 3D bending, and the 3D bending acts on the bending section formed after the first end is bent in 2D.
8. A stator winding installation method as claimed in claim 1, wherein: after the step of inserting the conductor after bending forming into the stator groove, the method further comprises the following steps: and bending and forming the second end of the conductor.
9. A motor stator, characterized by: comprising a stator and a stator winding configured to be mounted within the stator by: bending and forming a first end of the conductor; and inserting the conductor after bending and forming into a stator groove of the stator.
10. The motor stator as claimed in claim 9, wherein: the first end is one end of the head of the conductor, and the head of the conductor is one end of the same conductor set, which is needed to be connected with two conductors.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202210770614.2A CN117375341A (en) | 2022-06-30 | 2022-06-30 | Stator winding installation method and motor stator |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202210770614.2A CN117375341A (en) | 2022-06-30 | 2022-06-30 | Stator winding installation method and motor stator |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN117375341A true CN117375341A (en) | 2024-01-09 |
Family
ID=89402818
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202210770614.2A Pending CN117375341A (en) | 2022-06-30 | 2022-06-30 | Stator winding installation method and motor stator |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN117375341A (en) |
-
2022
- 2022-06-30 CN CN202210770614.2A patent/CN117375341A/en active Pending
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