CN211046602U - Connecting structure of lead frame and winding coil - Google Patents

Abstract

The utility model relates to the field of motors, and discloses a connecting structure of a lead frame and a winding coil, which comprises the lead frame for placing a printed circuit board with a plurality of circuit board layers, and also comprises a stator core which is vertical to the axis of a rotating shaft of a generator or a motor, stator teeth are evenly distributed on the circumferential side surface of the stator core, a first coil winding, a second coil winding and a third coil winding are arranged on the stator teeth, two coil end parts of the first coil winding, the second coil winding and the third coil winding extend outwards or inwards along the radial direction of the stator core, the coil end parts of the first coil winding, the second coil winding and the third coil winding are rotated to the axial direction from the radial direction and finally arranged in the groove formed on the lead frame, and coupling coil ends of the first, second and third coil windings to the lead frame.

Description

Connecting structure of lead frame and winding coil

Technical Field

The utility model relates to a motor field has especially related to a connection structure of lead frame and winding coil.

Background

The motor system typically comprises an electric motor, the control unit of which is arranged to control the power of the electric motor. Known motor types include induction motors, synchronous brushless permanent magnet motors, switched reluctance motors, and linear motors. Since driving a vehicle requires high torque, the most common electric motor is a three-phase motor. A three-phase motor typically includes three coil windings, where each coil winding is arranged to generate a magnetic field associated with one of the three phases of the alternating voltage. In order to increase the number of magnetic poles formed in the machine, each coil winding typically has a number of coil sub-sets distributed around the machine, which coil sub-sets are driven to generate a rotating magnetic field. Chinese patent CN201710715959.7 provides a three-phase permanent magnet brushless dc hub motor.

As shown in fig. 1, a typical three-phase motor has three coil sets 14, 16, 18. Each coil set consists of four coil sub-sets connected in series, wherein the magnetic fields generated by the coil sub-sets will have a common phase for a given coil set. The three coil sets of a three-phase motor are typically arranged in a delta or star configuration. A control unit for a three-phase motor having a dc power supply typically includes an inverter-driven motor in which a three-phase bridge generates three-phase power. Each respective voltage phase is applied to a respective coil set of the motor. A three-phase bridge inverter includes a number of switching devices, such as power electronic switches, such as Insulated Gate Bipolar Transistor (IGBT) switches, for generating an alternating voltage from a direct current power source. In the context of electric vehicle motors, an increasingly popular drive design is one that is integrated within the wheel of the vehicle into which the motor and its associated control system are integrated. However, this may have an impact on the electric motor's power generation capability due to space constraints within the vehicle wheel into which the electric motor and its associated control system are integrated. The utility model provides a can provide motor lead frame of heavy current.

SUMMERY OF THE UTILITY MODEL

The utility model discloses can not provide the defect of big moment of torsion according to current in-wheel motor, provide a connection structure of lead frame and winding coil.

In order to solve the technical problem, the utility model discloses a following technical scheme can solve:

a lead frame to winding coil connection structure comprising a lead frame on which a printed circuit board having a plurality of circuit board layers is placed, each circuit board layer comprising an insulating substrate and a conductive layer formed on the insulating substrate, the circuit board layers comprising a first circuit board layer comprising a first conductive layer arranged to electrically couple to a first coil winding of a first set of coil windings and a first branch of a first inverter, a second circuit board layer, a third circuit board layer and a fourth circuit board layer; the second circuit board layer includes a second conductive layer arranged to electrically couple to a second coil winding of the first set of coil windings and a second leg of the first inverter; the third circuit board layer includes a third conductive layer arranged to electrically couple to a third coil winding of the first set of coil windings and a third leg of the first inverter; the fourth circuit board layer includes a fourth conductive layer having a plurality of conductive layer structures disposed to couple with the first, second, and third coil windings of the first set of coil windings to form a neutral point between the first, second, and third coil windings; the stator comprises a circumferential support and a first coil winding, a second coil winding and a third coil winding, the circumferential side face of the circumferential support is uniformly distributed with stator teeth, the first coil winding, the second coil winding and the third coil winding are arranged on the stator teeth, the coil end parts of the first coil winding, the second coil winding and the third coil winding extend outwards along the radial direction of the circumferential support to finally enable the coil end parts of the first coil winding, the second coil winding and the third coil winding to rotate to the axial direction from the radial direction to finally form in grooves formed in a lead frame, and the coil end parts of the first coil winding, the second coil winding and the third coil winding are coupled to the lead frame.

Preferably, the end of the first coil winding is mounted in a groove of the lead frame such that the first coil winding is electrically connected to the first conductive layer.

Preferably, an end portion of the second coil winding is mounted in the groove of the lead frame so that the second coil winding is electrically connected to the second conductive layer.

Preferably, an end of the third coil winding is mounted in a recess of the lead frame such that the third coil winding is electrically connected to the third conductive layer.

Preferably, the lead frame has an overall circular shape, or two lead frames having a semicircular shape are joined to form an overall circular lead frame.

Preferably, the circumferential support comprises means for positioning a lead frame at a predetermined position on the circumferential support, the ends of the first, second and third coil windings being adjacent to recesses in said lead frame to allow the lead frame to couple the respective coil windings into a multi-phase coil winding.

Preferably, the means for positioning the lead frame on the circumferential support comprises heat stakes, wherein the method further comprises melting the heat stakes when the lead frame has been mounted on the circumferential support to secure the lead frame to the circumferential support.

Preferably, the method further comprises placing the conductive sleeves in respective grooves on the lead frame, the respective end portions of the coil windings being arranged to fit within the conductive sleeves.

Preferably, the ends of the coil windings are soldered to the lead frame when the ends of the coil windings have been placed in corresponding recesses formed in the lead frame.

Preferably, the recesses are formed at inner and outer edges of the printed circuit board, each recess being arranged to receive a respective coil winding for electrically coupling the coil winding to the printed circuit board.

The utility model discloses owing to adopted above technical scheme, have apparent technological effect:

the utility model has the advantages that simplified the manufacturing process of installing the lead frame on the stator, the arrangement of lead frame makes and provides the heavy current between the dc-to-ac converter of motor or generator and coil winding to produce big moment of torsion and power value, the coil winding and the dc-to-ac converter that allow for reducing motor/generator simultaneously reduce space envelope.

Drawings

FIG. 1 illustrates a prior art three-phase motor;

figure 2 illustrates an exploded view of an electric machine incorporating the present invention;

FIG. 3 is a schematic diagram of a control device;

fig. 4A illustrates the electrical connections provided by the lead frame according to an embodiment of the present invention;

fig. 4B illustrates the electrical connections provided by the lead frame according to an embodiment of the present invention;

fig. 5 illustrates a lead frame according to an embodiment of the present invention;

fig. 6 illustrates a lead frame arrangement according to an embodiment of the invention;

fig. 7 illustrates a lead frame according to an embodiment of the present invention;

fig. 8 illustrates a lead frame arrangement according to an embodiment of the invention;

fig. 9 illustrates a conductive layer on a circuit board layer of a lead frame according to an embodiment of the present invention;

fig. 10 illustrates a lead frame according to an embodiment of the present invention;

fig. 11 shows a conductive layer on a circuit board layer of a lead frame according to an embodiment of the present invention;

fig. 12 illustrates a conductive layer on a circuit board layer of a lead frame according to an embodiment of the present invention;

fig. 13 illustrates a conductive layer on a circuit board layer of a lead frame according to an embodiment of the present invention.

Fig. 14 illustrates a conductive layer on a circuit board layer of a lead frame according to an embodiment of the present invention;

fig. 15 shows a lead frame according to an embodiment of the present invention;

fig. 16 is a schematic diagram of a coil end mated with a lead frame according to an embodiment of the invention;

fig. 17 illustrates a stator core, coil windings, and lead frame according to an embodiment of the present invention;

fig. 18 illustrates a schematic view of a cooling structure according to the present invention;

fig. 19 is a schematic structural view of a stator coil winding and a stator core;

fig. 20 is an exploded view of the stator coil winding unit and the stator core.

Detailed Description

Example 1

The utility model provides a connection structure of lead frame and winding coil, including placing the lead frame of the printed circuit board who has a plurality of circuit board layers, still include the circumference support piece 550 perpendicular with generator or motor rotation axis, evenly distributed has stator tooth 800 on the circumference side of circumference support piece, first coil winding, second coil winding and third coil winding are installed on stator tooth 800, the coil tip of first coil winding, second coil winding and third coil winding outwards extends along circumference support piece's radial and finally makes the coil tip of first coil winding, second coil winding and third coil winding rotate to the axial direction from the radial direction and finally form in the recess that offers on the lead frame, the coil tip of first coil winding, second coil winding and third coil winding couples to the lead frame.

Specifically, fig. 16 shows one coil end 1610 extending in a radial direction and then the end of each coil is rotated 90 degrees to extend into the pcb and leadframe 255 recesses 640 above each end of each coil, resulting in the coil ends 1620 extending in an axial direction. Any means may be used to rotate the ends into corresponding grooves formed on the inner and outer radial edges of the lead frame 255.

As a portion of the stator core is shown in fig. 17, six coils 400 are shown with their respective coil ends extending into inner and outer radial recesses 640, 640 formed in the lead frame 255 for coupling the respective coils to the lead frame 255. To improve the electrical contact between the ends of each coil and the lead frame 255, solder or some other conductive material may be used between the ends of the coil and the lead frame 255.

The present embodiment provides a lead frame 255 for coupling an inverter of a motor or a generator to a direct current power source; the electric motor in this embodiment is an in-wheel motor for an automobile wheel. As shown in fig. 2, the in-wheel motor includes a stator 252, the stator 252 includes a circumferential support serving as a heat sink 253, a plurality of coils 254, and two control devices 300, not shown, which are mounted on the circumferential support 253 at the rear of the stator for driving the coils. A capacitor and lead frame 255 is mounted between an axial edge of the coil 254 and an axial flange formed on the circumferential support 253 for connecting a control device to the coil 254. The coils 254 are embedded on the stator teeth 800 to form coil windings; a stator can is mounted to the rear of the stator 252, surrounds the control device and the annular capacitor to form the stator 252, and is then secured to the vehicle and does not rotate relative to the vehicle during use.

The stator comprises a circumferential supporting piece and a stator winding arranged on the circumferential supporting piece, the circumferential supporting piece is a stator core 600, the stator winding is composed of stator winding units 550, the stator winding units 550 are teeth wound with coils, each tooth is provided with a tooth socket 801, the outer circumference of the circumferential supporting piece is provided with stator teeth 800, and the tooth sockets 801 are inserted into the stator teeth 800 in an interference mode. The number of stator winding units 550 in this embodiment is 54 because there are 2 sets of coil windings, each set of coil windings including 3 coil windings, each coil winding including 3 coil phase windings (subsets), each coil phase winding including 3 coils.

As shown in fig. 3, each control device 300 includes one inverter 310, wherein one control device 300 includes a controller regulator 320, and in this embodiment, the control device 300 includes one processor for controlling the operation of two inverters 310. As shown in fig. 3, each control device 300 includes inverters 310, with one of the control devices including control logic 320, and with control logic 320 including a processor in this embodiment for controlling the operation of both inverters 310. As described below, each inverter is coupled to three sets of coil windings, which are electrically connected in parallel, forming a set of three-phase motors.

A ring capacitor is coupled between the inverter 310 and the dc power supply of the motor to reduce voltage fluctuations on the motor power lines, also referred to as the dc bus, and to reduce voltage overshoot during motor operation. In order to reduce the inductance, a capacitor is installed near the control device 300.

The magnets are adjacent to the coil windings on the stator 252 so that the magnetic field generated by the coils interacts with the magnets 242 disposed inside the cylindrical portion 221 of the rotor 240, thereby rotating the rotor 240. Since the permanent magnet 242 is used to generate a driving torque of the driving motor, the permanent magnet is generally referred to as a driving magnet. In this embodiment, the motor includes six coil windings, each having three coil sub-sets, also referred to as coil phase windings in this embodiment; the three coil sub-sets are coupled in a Y-configuration to form a three-phase sub-motor, such that the motor has six three-phase sub-motors. The operation of each sub-motor is controlled by one of the two control devices 300, as described below. Although the present embodiment describes a motor having six coil windings (i.e., a six-piece motor), the motor could equally have one or more coil sets with associated control means. Likewise, each coil set may have any number of coil sub-sets, allowing for two or more phases per sub-motor.

Fig. 3 illustrates the connections between the respective coil sets 60 and the control device 300, wherein three coil sets 60 are connected to respective three-phase inverters 310 on the control device 300. As is well known to those skilled in the art, a three-phase inverter includes six switches, wherein a three-phase alternating voltage may be generated by controlled operation of the six switches. However, the number of switches will depend on the number of voltage phases applied to the respective sub-motors, and any number of phases can be built on these sub-motors. Each control device 300 communicates with other control devices 300 through a communication bus.

One of the control devices 300 includes a processor 320 for controlling the operation of the inverter switches in both control devices 300, which is also electrically connected to the temperature sensor 503 for receiving signals from the temperature sensor 503 to determine whether the motor is operating within an acceptable temperature range. Furthermore, each control device 300 comprises an interface arrangement allowing communication between the respective control devices 300 via a communication bus 330, wherein one control device 300 is arranged to communicate with a vehicle controller mounted outside the electric motor.

The processor 320 is used to control the operation of the inverter switches installed in each control device 300 to allow each motor coil assembly 60 to be equipped with a three-phase voltage power supply, thereby allowing the respective coil sub-assemblies to generate a rotating magnetic field. As described above, although the present embodiment describes each coil set 60 as having three coil sub-sets, the present invention is not so limited, it being understood that each coil set 60 may have one or more coil sub-sets.

Under the control of the processor, each three-phase bridge inverter 310 is configured to provide pulse width modulated voltage control in the respective subset of coils to generate current in the respective subset of coils to provide the torque required by the respective sub-motor. The operating principle of PWM control is to drive the required current into the motor coil by averaging the applied pulse voltage with the motor inductance. The applied voltage is switched between the motor windings using pulse width modulation control. During the switching of the voltage through the motor coil, the current in the motor coil rises at a rate determined by its inductance and the applied voltage. The pulse width modulation voltage control is turned off before the current increases beyond the desired value, thereby achieving accurate control of the current. For a given coil set, the three-phase bridge inverter 310 switches are arranged to apply a single voltage phase across each coil sub-set. Using PWM switching, a plurality of switches are arranged to apply an alternating voltage across respective subsets of coils. The voltage envelope and the phase angle of the electrical signal are determined by the modulated voltage pulses.

An inverter formed on one control device is coupled to the three coil windings to form a first set of three-sub motors, and an inverter formed on the other control device is coupled to the other coil winding sets to form a second set of three-sub motors.

The two inverters 310 are coupled to respective coil sets by lead frames 255, with each leg of the respective inverter 310 coupled to the lead frame 255 by a respective phase winding bus. For the present embodiment, the different voltage phases produced by the three legs of the inverter are designated W, V and U. The coil windings are coupled to the lead frame 255 to allow current to flow from the dc power source to the coil windings through the respective inverters 310 in the control apparatus, thereby allowing the motor to generate a driving torque.

Fig. 4 illustrates the electrical connections provided by the lead frame 255 between the phase winding bus of one of the control devices and the coil windings mounted on the stator, wherein the lead frame 255 is arranged to couple the phase windings of the respective coil sub-sets in a Y-configuration. However, the lead frame 255 may be configured to couple the phase windings of the respective coil subsets in different configurations. As described above, each coil winding includes three coil sub-groups (i.e., phase windings) to form a three-phase sub-motor. The first coil winding, the second coil winding, and the third coil winding of the first group of coil windings correspond one-to-one to the following first sub-motor, second sub-motor, and third sub-motor in this embodiment.

With the present embodiment, each coil set forming a coil sub-set is formed of three separate coils, which are coupled by the circuit board layers of the lead frame 255.

Referring to fig. 4, the coil 401 forms a first phase winding of the first sub-motor 411, the coil 402 forms a second phase winding of the first sub-motor 411, and the coil 403 forms a third phase winding of the first sub-motor 411. For the second sub-motor 412, the coil 404 forms a first phase winding of the second sub-motor 412, the coil 405 forms a second phase winding of the second sub-motor 412, and the coil 406 forms a third phase winding of the second sub-motor 412. For the third sub-motor 413, the coil 407 forms a first phase winding of the third sub-motor 413, the coil 408 forms a second phase winding of the third sub-motor 413, and the coil 409 forms a third phase winding of the third sub-motor 413. Each coil 400 shown in fig. 4 corresponds to a coil on a single stator tooth 800, wherein the ends of each coil are arranged to couple with the lead frame 255 to achieve the coupling of the coils in the configuration shown in fig. 4.

The lead frame 255 is used to connect the W-phase inverter bus to the first coil 400 of the first phase winding 401 of the first sub-motor 411, the first phase winding 404 of the second sub-motor 412, and the first phase winding 407 of the third sub-motor 413. The lead frame 255 also connects the V-phase inverter bus to the first coil 400 of the second phase winding 402 of the first sub motor 411, the second phase winding 405 of the second sub motor 412, and the second phase winding 408 of the third sub motor 413, and connects the U-phase inverter to the first coil 400 of the third phase winding 403 of the first sub motor 411, the third phase winding 406 of the second sub motor 412, and the third phase winding 409 of the third sub motor 413.

As shown in fig. 4, the lead frame 255 connects the last coil 400 of the first phase winding 401 of the first sub-motor 411 to the last coils 400 of the second phase winding 402 and the third phase winding 403 of the first sub-motor 411. Likewise, the lead frame 255 also connects the last coil 400 of the first phase winding 404 of the second sub-motor 412 to the last coils 400 of the second phase winding 405 of the second sub-motor 412 and the third phase winding 406 of the second sub-motor 412, and connects the last coil 400 of the first phase winding 407 of the third sub-motor 413 to the last coils 400 of the second phase winding 408 and the third phase winding 409 of the third sub-motor 413. These connections act as star points per sub-motor.

Further, the lead frame 255 is arranged to electrically connect the respective coils 400 of each phase winding to form a serial connection between the respective coils 400 of each phase winding. Accordingly, the lead frame 255 provides electrical connections between the W, V, U-phase inverter busses and the respective coils 400 to form three sub-machines driven by a single inverter 310, with the coil windings of the respective sub-machines coupled in a Y-configuration.

Likewise, the lead frame 255 connects the phase winding bus of the inverter 310 of the other control device 300 and the coil mounted on the stator in the same manner, forming a three-sub motor driven by the inverter 310 in the second control device 300.

The structure of the lead frame 255 will now be described, wherein in a first embodiment, as shown in fig. 5, one substantially circumferential lead frame 255 is used to supply current from two control devices to respective coil sets.

The lead frame 255 includes a first set of three holes 660 for receiving respective bus bar lead frame pins for coupling the lead frame 255 to the inverter 310 in the first control device 300, and a second set of three holes 660 for receiving respective bus bar lead frame pins for coupling the lead frame 255 to the inverter 310 in the second set.

The lead frame 255 is opened with fixing holes at predetermined positions, and the heat stakes 630 are inserted into the fixing holes, wherein the heat stakes 630 are disposed at ends of the teeth of the stator winding unit 550, the ends being adjacent to the lead frame 255, the heat stakes 630 are designed at inner and outer sides of the stator winding unit 550, and the heat stakes 630 are disposed to extend through the holes formed in the lead frame 255. Once the lead frames 255 are mounted on the stator core 600 and the respective heat stakes 630 pass through the corresponding fixing holes formed in the lead frames 255, the heat stakes 630 melt, thereby fixing the lead frames 255 to the stator core 600. However, any suitable method of attaching the lead frame 255 to the stator core may be used.

As shown in fig. 6, the lead frame 255 includes a plurality of recesses 640 formed on the inner and outer radial edges of the lead frame 255 for receiving ends of the coil wound on the stator teeth 800 for coupling the coil 400 to the lead frame 255, as described below, wherein for each coil wound on the stator teeth 800, one portion is mounted in the recess 640 formed on the inner radial edge of the lead frame 255 and another portion is mounted in the recess 640 formed on the outer radial edge of the lead frame 255.

The uni-circumferential lead frame 255 serves as a current path from each inverter 310 within the control device 300 to each coil winding, wherein the lead frame 255 is a substantially circumferential printed circuit board having a plurality of circuit board layers. With the board layers having a conductive layer printed on each circuit board layer. Each circuit board layer includes a dielectric substrate; a conductive layer is formed on the insulating substrate. The number of inverters in the present embodiment is 2, in other words, one half circumference of the lead frame printed circuit board is allocated for coupling the first control device 300 to one group of coil windings to form three sub-motors formed of the first group of coil windings, and the other half circumference of the lead frame printed circuit board is allocated for coupling the second control device 300 to three sub-motors formed of the second group of coil windings. The plurality of circuit board layers are separated by respective insulating substrates.

To allow large currents to flow from the inverters 310 to the coil windings, thereby allowing the motor to generate sufficient torque to drive the vehicle, the conductive layers on each circuit board layer are arranged to extend over a substantial portion of each circuit board, with each conductive layer being arranged to correspond to a circuit path between a particular respective inverter 310 and coil winding and between different subsets of coils making up respective sub-machines, and thus each circuit board layer is optimized for current flow.

To achieve the circuit configuration shown in fig. 4, the configuration of the printed circuit board layer and the conductive layer printed on the circuit board layer will now be described. Each circuit board layer includes two sets of electrical connections for coupling a first set of three coil windings to one inverter and another set of three coil windings to another inverter, but each circuit board layer may include any number of conductive layers based on the number of inverters. For example, if one inverter is used to drive all the coil windings mounted on the stator, the conductive layers printed on each circuit board layer will be arranged to form specific circuit paths between the inverter and the coil windings and between the different coil subsets that make up the respective sub-motors, forming the respective sub-motors.

The lead frame 255 in this embodiment comprises a first lead frame 701 and a second lead frame 702, wherein both the first lead frame 701 and the second lead frame 702 are semi-circumferential, the first lead frame 701 and the second lead frame 702 forming a substantially circumferential lead frame 255 when mounted on the stator 252. As shown in fig. 8, each lead frame 255 is mounted on an axial mounting surface of the stator core 600, which constitutes a part of the stator 252, and a coil is wound on stator teeth 800 formed on the stator core 600.

The first and second lead frames 702 each comprise a set of three holes 660 for receiving respective bus bar lead frame pins for coupling the first and second lead frames 701, 702 to the inverters 310 in the first and second control devices 300, respectively.

The first and second lead frames 701 and 702 are mounted to the stator core 600 by being connected to heat stakes 630 at predetermined positions, the heat stakes 630 being arranged to extend through holes formed in the first and second lead frames 701 and 702. Once the first and second lead frames 701 and 702 are mounted on the stator core 600 and the respective heat stakes 630 pass through the respective holes formed in the first and second lead frames 701 and 702, the heat stakes 630 melt, thereby keeping the first and second lead frames 701 and 702 fixed to the stator core 600. However, the first and second lead frames 701 and 702 may be connected to the stator core 600 using any suitable method.

As shown in fig. 8, the first and second lead frames 701 and 702 include a plurality of grooves 640 formed on inner and outer radial edges of the first and second lead frames 701 and 702 for receiving end portions of the coil 400 wound on the stator teeth 800 for coupling, the coil 400 being connected to the first and second lead frames 701 and 702, respectively. For each coil wound on the stator teeth 800, one end is mounted in a groove 640 formed on the inner radial edge of the first lead frame 701 or the second lead frame 702, and the other end is mounted in a groove 640 formed on the outer radial edge of the corresponding lead frame 255 portion 701.

The circuit board layer of the first printed circuit board on the first lead frame 701 and the circuit board layer of the second printed circuit board on the second lead frame 702 are in a mirror image relationship, the first printed circuit board is responsible for three sub-motors (a first sub-motor, a second sub-motor, a third sub-motor or expressed as a sub-motor 1/2/3) formed by the first group of coil windings, and the second printed circuit board is responsible for three sub-motors (a fourth sub-motor, a fifth sub-motor, a sixth sub-motor or expressed as a sub-motor 4/5/6) formed by the second group of coil windings.

The circuit board layer and the circuit connection of the first lead frame will be described as an example.

The first printed circuit board comprises a first circuit board layer having a first conductive layer as shown in fig. 9 extending substantially to a first semi-circumferential portion of the circumferential circuit board arranged to be electrically coupled to the W-phase inverter 310 busbar and the first coil of the first phase winding 401 of the first sub-motor 411 of the first coil, the first coil of the first phase winding 404 of the second sub-motor 412 and the first coil of the first phase winding 407 of the third sub-motor 413. As described above, the printed circuit board on the second lead frame 702 has a circuit board layer corresponding to the first circuit board layer, and a conductive layer on the circuit board layer is arranged to be electrically coupled to the W-phase inverter bus bar of the second inverter and to be electrically coupled to the coil winding corresponding to the second set of coil windings mounted on the stator.

As shown in fig. 10, the W-phase inverter 310 busbars are coupled to the first circuit board layer by busbar lead frame pins 1010, which busbar lead frame 255 pins are cylindrical conductive elements coupled to the W-phase inverter 310 busbars, the busbar lead frame 255 pins extending through associated lead frame 255 pin holes 660 formed in the printed circuit board. The W bus bar lead frame pin 1010 is electrically coupled to the first conductive layer 900 at location 910. In order for the first coil of the first phase winding 401 of the first sub-motor 411, the first coil of the first phase winding 404 of the second sub-motor 412 and the first coil of the first phase winding 405 of the third sub-motor 413 to be coupled to the first conductive layer 900 at locations 920, 930, 940, the ends of the associated coils are mounted, as described above, within the recesses 640 formed in the inner and outer radial edges of the lead frame 255, with the ends of the coil windings mounted within the recesses 640 formed in the inner radial edge of the lead frame 255 at locations 920, 930, 940 and electrically coupled to the first conductive layer 900. The other ends of the first coil of the first phase winding of the first sub-motor, the second sub-motor and the third sub-motor and the ends of the remaining coil windings are mounted in respective grooves formed in the lead frame 255 and in the outer radial edge, electrically isolated from the first conductive layer 900.

The first printed circuit board comprises a second circuit board layer having a second conductive layer 1100 as shown in fig. 11, said second conductive layer extending substantially to a first semi-circumferential portion of said circumferential circuit board, said circumferential circuit board being arranged to be electrically coupled to said U-phase inverter 310 busbar and to a first coil of a second phase winding 402 of said first sub-motor 411, to a first coil of a second phase winding 405 of a second sub-motor 412 and to a first coil of a second phase winding 408 of a third sub-motor 413. The printed circuit board on the second lead frame 702 has a circuit board layer corresponding to the second circuit board layer, and the conductive layer on the circuit board layer is arranged to be electrically coupled to the U-phase inverter bus of the second inverter and to the corresponding coil winding of the second set of coil windings mounted on the stator.

As shown in fig. 10, the U-phase inverter 310 busbars are coupled to the second circuit board layer by busbar lead frame pins 1010, which busbar lead frame pins 1010 are cylindrical conductive elements coupled to the U-phase inverter 310 busbars that extend through associated lead frame 255 pin holes 660 formed in the printed circuit board. The U-shaped bus bar leadframe pin 1010 is electrically coupled to the second conductive layer 1100 at location 1110. In order to couple the first coil of the second phase winding 402 of the first sub-motor 411, the first coil of the second phase winding 405 of the second sub-motor 412 and the first coil of the second phase winding 408 of the third sub-motor 413 to the locations 1120, 1130, 1140, respectively, of the second conductive layer, and as described above, the associated coils are mounted in the recesses 640 formed in the inner and outer radial edges of the lead frame 255, wherein the ends of the coil windings mounted in the recesses formed in the inner radial edge of the lead frame 255 are electrically coupled with the second conductive layer at 1120, 1130, 1140. The other ends of the first coil of the second phase winding of the first, second and third sub-motors and the ends of the remaining coil windings are mounted in respective grooves formed in the radial edges inside and outside the lead frame 255, electrically isolated from the second conductive layer.

The printed circuit board comprises a third circuit board layer 1200 having a third conductive layer as shown in fig. 12 extending substantially to a first semi-circumferential portion of the circumferential circuit board arranged to be electrically coupled to the V-phase inverter 310 busbar and the phase winding 403 of the first coil first sub-motor 411, the first coil of the third phase winding 406 of the second sub-motor 412 and the first coil of the third phase winding 409 of the third sub-motor 413. As described above, the printed circuit board on the second lead frame 702 has a circuit board layer corresponding to the third circuit board layer, and the conductive layer on the circuit board layer is arranged to be electrically coupled to the V-phase inverter bus of the second inverter and to be electrically coupled to the coil winding corresponding to the second set of coil windings mounted on the stator. As shown in fig. 10, the V-phase inverter 310 busbars are coupled to the third circuit board layer by busbar lead frame pins 1010, which are cylindrical conductive elements coupled to the V-phase inverter 310 busbars that extend through associated lead frame 255 pin holes 660 formed in the printed circuit board. The V-bus lead frame pin 1010 is arranged to electrically couple to the third conductive layer 1200 of the printed circuit board at location 1210. In order to couple the first coil of the third phase winding 403 of the first sub-motor 411, the first coil of the third phase winding 406 of the second sub-motor 412 and the first coil of the third phase winding 409 of the third sub-motor 413 to the third conductive layer, the ends of the associated coils are arranged such that, as described above, the ends of the coil windings mounted in the recesses formed at the inner and outer radial edges of the lead frame 255 are electrically coupled to the third conductive layer in the recesses 640 formed in the lead frames 2551220, 1230, 1240. The other ends of the first coil of the third phase windings of the first, second and third sub-motors, as well as the ends of the remaining coil windings, are mounted in respective recesses formed in the lead frame 255 and in the outer radial edge, electrically isolated from the third conductive layer.

The printed circuit board includes a fourth circuit board layer having a fourth conductive layer 1310, a fifth conductive layer 1320, and a sixth conductive layer 1330, as shown in fig. 13, wherein the fourth conductive layer 1310, the fifth conductive layer 1320, and the sixth conductive layer 1330 together extend onto the first half-circumferential portion of the annular circuit board. The fourth conductive layer 1310, the fifth conductive layer 1320, and the sixth conductive layer 1330 are electrically isolated from each other.

The fourth conductive layer 1310 is arranged to electrically couple the last coil of the first phase winding 401 of the first sub-motor 411, the last coil of the second phase winding 402 of the first sub-motor 411 and the last coil of the third phase winding 403. A neutral point (i.e., a star point) is formed between the first coil winding 401, the second coil winding 402, and the third coil winding 403 of the first sub-motor 411. To couple the last coil of the first phase winding 401 of the first sub-motor 411, the last coil of the second phase winding 402 of the first sub-motor 411, and the last coil of the third phase winding 403 of the first sub-motor 411, the ends of the associated coils are mounted on the inner and outer radial edges formed on the lead frame 255 as described above, with the ends of the coil windings mounted in the recesses formed in the outer radial edge of the lead frame 255 being electrically coupled with the fourth conductive layer 1310 at 1311, 1312, 1313. The other end portion of the last coil of the first phase winding 401 of the first sub-motor 411, the second phase winding 402 of the last coil of the first sub-motor 411 and the last coil of the third phase winding 403 of the first sub-motor 411 and the end portions of the remaining coil windings are fitted in the respective grooves formed therein. The inner and outer radial edges of the lead frame 255 are electrically isolated from the fourth conductive layer 1310.

The fifth conductive layer 1320 is arranged to electrically couple the last coil of the first phase winding 404 of the second sub-motor 412, the last coil of the second phase winding 405 and the last coil of the third phase winding 406 of the second sub-motor 412. A neutral point (i.e., a star point) is formed between the first coil winding 404, the second coil winding 405 of the second sub-motor 412 and the third coil winding 405 of the second sub-motor 412. In order to couple the last coil of the first phase winding 404 of the second sub-motor 412, the last coil of the second phase winding 405 of the second sub-motor 412 and the last coil of the third phase winding 406 of the second sub-motor 412, the ends of the relevant coils are arranged to be mounted at the inner and outer radial edges of the lead frame 255 as described above, wherein the ends of the coil windings mounted in the recesses formed in the outer radial edges of the lead frame 255 are electrically coupled with the fifth conductive layer 1320 at 1321, 1322, 1323. The other end of the last coil of the first phase winding 404 of the second sub-motor 412, the second phase winding 405 of the last coil second sub-motor 412, and the last coil of the third phase winding 406 of the second sub-motor 412, and the ends of the remaining coil windings, which are mounted in the respective grooves 640 formed to thin the inner and outer radial edges of the lead frame 255, are electrically isolated from the fifth conductive layer 1320. Sixth conductive layer 1330 is arranged to electrically couple the last coil of first phase winding 407 of third sub-motor 413, the last coil of second phase winding 408 and the last coil of third phase winding 409 of third sub-motor 413. A neutral point (i.e., a star point) is formed between the first coil winding 407, the second coil winding 408 of the third sub-motor 413 and the third coil winding 409 of the third sub-motor 413.

The printed circuit board of the second lead frame 702 has the same structure of circuit board layers as the fifth circuit board layer for connecting the coils corresponding to the second set of coil windings, thereby forming a second set of sub-machines.

To couple the last coil of the first phase winding 401 of the first sub-motor 411, the last coil of the second phase winding 402 of the first sub-motor 411 and the last coil of the third phase winding 403 of the first sub-motor 411, the ends of the associated coils are mounted on the inner and outer radial edges of the lead frame 255 as described above, and the ends of the coil windings, particularly mounted in the recesses formed in the outer radial edge of the lead frame 255, are electrically coupled to the fourth conductive layer 1310 at 1311, 1312, 1313. The other end portion of the last coil of the first phase winding 407 of the third sub-motor 413, the last coil of the second phase winding 408 of the last coil third sub-motor 413 and the third phase winding 409 of the third sub-motor 413, and the end portions of the remaining coil windings are mounted in the corresponding respective grooves 640, and the inner and outer radial edges of the lead frame 255 are electrically isolated from the sixth conductive layer 1330.

The printed circuit board includes a fifth circuit board layer having a plurality of conductive layers shown in fig. 14 for electrically coupling the coil 400 forming the first phase winding 401 of the first sub-motor 411, the coil 400 forming the second phase winding 402 of the first sub-motor 411 and the coil 400 forming the third phase winding 402 of the first sub-motor 411. With respect to the second sub-motor, a plurality of conductive layers are arranged for electrically coupling the coil 400 forming the first phase winding 404 of the second sub-motor 412, the coil 400 forming the second phase winding 405 of the second sub-motor 412, and the coil 400 forming the third phase winding 406 of the second sub-motor 412 with respect to the third sub-motor, a plurality of conductive layers are arranged for electrically coupling the coil 400 forming the first phase winding 407 of the third sub-motor 413, the coil 400 forming the second phase winding 408 of the third sub-motor 413, and the coil 400 forming the third phase winding 409 of the third sub-motor 413.

The plurality of conductive layers on the fifth circuit board layer are arranged to allow the plurality of coils of each respective coil sub-set to be coupled such that each coil within the coil winding generates a magnetic field that is anti-parallel to its neighboring coils in a given current direction while having a common phase.

The second printed circuit board comprises a circuit board layer corresponding to the fifth circuit board layer, the circuit board layer having a plurality of conductive layers arranged to electrically couple the first, second, first, second and third phase windings of the second, third set of coil windings; the first, second and third phase windings each comprise a plurality of coils, and the plurality of conductive layers are arranged to allow the plurality of coils of each respective phase winding to be coupled with respect to each other such that each coil sub-set coil generates a magnetic field that is anti-parallel to an adjacent coil in a given current direction while having a common phase. The connection of the circuit board layer of the second printed circuit board corresponding to the fifth circuit board layer to the second set of coil windings is a mirror image of the connection of the fifth circuit board to the first coil windings.

Among the plurality of conductive layers formed on the fifth printed circuit board layer, two conductive layers 1501,1502 are used to form the coupling coil 400 of the first phase winding 401 of the first sub-motor 411, two conductive layers 1503,1504 are used to form the coupling coil 400 of the second phase winding 402 of the first sub-motor 411, and two conductive layers 1505,1506 are used to couple the coils 400 forming the third phase winding 403 of the first sub-motor 411. In the second sub-motor, two conductive layers 1507,1508 are used to form the coupling coil 400 of the first phase winding 404 of the second sub-motor 412, two conductive layers 1509,1510 are used to couple the phase winding 405 of the second sub-motor 412 forming the coil 400 of the second sub-motor 412 and two conductive layers 1511,1512 are used to couple the coil 400, which forms the third phase winding 406 of the second sub-motor 412 for the third sub-motor, two conductive layers 1513,1514 are used to form the coupling coil 400 of the first phase winding 407 of the third sub-motor 413, and two conductive layers 1515,1516 are used to couple. The coil 400 forming the second phase winding 408 of the third sub-motor 413 and the two conductive layers 1517,1518 are used to couple the coil 400, which forms the third phase winding 409 of the third sub-motor 413. As described above, one end portion of the first coil forming the coil group forming the first phase winding 401 of the first sub-motor 411 is mounted in the groove 640 formed at the position 920 on the inner radial edge of the lead frame 255. Is electrically coupled to a first conductive layer 900 formed on a first circuit board layer while being electrically isolated from any other conductive layers on other circuit board layers. The other end of the first coil is mounted in an opposing groove formed on the outer radial edge of the lead frame 255 at location 950 and is electrically coupled to the conductive layer 1502 on the fifth circuit board layer.

One end of the second coil of the coil group forming the first phase winding 401 of the first sub-motor 411 is mounted in a groove formed at a position 951 at an outer radial edge of the lead frame 255 and electrically coupled to the layer 1502 on the conductive fifth circuit board layer, thereby electrically connecting the second coil to the W-phase bus bar pin through the first coil. The other end of the second coil is mounted in an opposing recess formed at position 952 on the inner radial edge of leadframe 255 and electrically coupled to a conductive layer 1501 on the fifth circuit board layer, which conductive layer 1501 is electrically isolated from conductive layer 1502. One end portion of the third coil of the coil group forming the first phase winding 401 of the first sub-motor 411 is mounted in a groove formed at a position 953 at the inner radial edge of the lead frame 255 and electrically coupled to the layer 1501 on the conductive fifth circuit board layer, thereby electrically connecting the third coil to the W-phase bus bar pin through the first and second coils. The other end of the third coil is mounted in an opposing recess formed on the outer radial edge of the lead frame 255 at location 954 and is electrically connected to a fourth conductive layer 1310 on a fourth circuit board layer for coupling the third coil to the respective coils for forming the second phase winding 402 and the third phase winding 403 of the first sub-motor 411.

The next two conductive layers 1503,1504 on the fifth circuit board layer are used to couple the coils 400 forming the second phase windings 402 of the first sub-motor 411 to the V-phase busbar pins and the next two conductive layers 1505,1506 on the fifth circuit board layer are used to couple the coils 400 forming the third phase windings 403 of the first sub-motor 411 to the U-phase busbar pins. The next two conductive layers 1507,1508 on the fifth circuit board layer are used to couple the coils 400 forming the first phase winding 404 of the second sub-motor 412 to the W-phase bus pins of the next two conductive layers 1509,1510 on the fifth circuit board layer are used to couple the coils 400 forming the second phase winding 405 of the second sub-motor 412 to the V-phase bus pins, and 1511,1512 on the fifth circuit board layer are used to couple the coils 400 forming the third phase winding 406 of the second sub-motor 412 to the U-phase bus pins. The next two conductive layers 1513,1514 on the fifth circuit board layer are used to couple the coils 400 forming the first phase winding 407 of the third sub-motor 413 to the W-phase bus pins of the next two conductive layers 1515,1516 on the fifth circuit board layer is used to couple the coils 400 forming the second phase winding 408 of the third sub-motor 413 to the V-phase bus pins, and the next two conductive layers 1517,1518 on the fifth circuit board layer are used to couple the coils 400 forming the third phase winding 409 of the third sub-motor 413 to the U-phase bus pins.

The electrical connections for coupling the W, U, V phase bus bar pins and corresponding coils to the lead frame 255 will now be described. For the electrical connections used to couple the phase busbar pins 1010 to the corresponding conductive layers printed on the circuit board layer of the lead frame 255, conductive sleeves 1600 are inserted W, U, V into corresponding holes formed in the lead frame 255 of the phase busbar pins 1010, as shown in fig. 15. When the W, U, V phase bus pin is inserted into a corresponding conductive sleeve 1600, the phase bus pin 1010 is placed in electrical contact with the sleeve 1600. To improve the electrical contact between the pin 1010 and the sleeve 1600, solder or other conductive material may be used.

For any conductive layers formed on the respective circuit board layers that need to be electrically connected to the phase buss pin 1010, the respective conductive layers are arranged to extend and make electrical contact with the conductive sleeve 1600. For any conductive layers formed on the circuit board layers that are electrically isolated from the phase bus pins 1010, the conductive layers are arranged to be electrically isolated from the conductive sleeve 1600. For example, referring to fig. 15, the lead frame 255 includes ten circuit boards of which the first two circuit board layers 1611,1612 correspond to the first circuit board layer described above for coupling the W bus lead frame pins to the lead frame 255, the next two circuit board layers 1613,1614 correspond to the second circuit board layers for connecting the U bus lead frame pins to the lead frame 255, the next two circuit board layers 1615,1616 correspond to either the third circuit board layer for coupling the V bus lead frame pins to the lead frame 255, the next two circuit board layers 1617,1618 correspond to the fourth circuit board layer for coupling the first phase windings, the second phase windings and the third phase windings of the respective sub-motors, and the next two circuit board layers 1619,1620 correspond to the fifth circuit board layers for coupling the coils of the respective phase windings. As shown in fig. 15, the first conductive layer on the first two circuit board layers 1611,1612 is in contact with a conductive sleeve for coupling the W-bar lead frame pins to the two conductive layers. Instead, the conductive layers printed on the other circuit board layers are electrically isolated from the conductive sleeve.

Although the present embodiment uses the conductive sleeve 1600 to electrically couple the bus bar leadframe pin 1010 to the leadframe 255, any mechanism may be used to couple the respective inverter leg to the leadframe 255. With respect to the end portion corresponding coils, a similar arrangement as used for electrically coupling the phase buss pins 1010 may be used to electrically couple the corresponding end portions of the coil 400 to the desired conductive layers printed on the one or more circuit board layers, with semi-circular conductive sleeves placed within corresponding grooves formed in the inner and outer radial edges of the lead frame 255. Alternatively, the ends of each coil 400 may be placed directly within the recesses 640 formed in the inner and outer radial edges of the lead frame 255, with conductive material placed between the ends of the coil and the associated conductive layers for improving electrical conductivity between the ends of each coil and the conductive layers, which are electrically connected to the conductive layers. A preferred process of mounting the ends of the coil 400 in the inner and outer radial recesses 640 and 640 of the lead frame 255 will now be described.

Before the lead frame 255 is mounted to the stator core 600, the ends of the coil are arranged to extend radially away from the stator core 600 and on the same plane as the axial mounting surface of the stator core 600. In this structure, the ends of the coils on the outer radial edge of the stator core 600 are arranged to extend away from the center of the stator core 600 in the radial direction. The inner radial edge of the stator core 600 is arranged to extend in the radial direction toward the center of the stator core 600. Preferably, by using the heat stake 310, wherein the grooves formed in the inner and outer radial edges of the lead frame 255 are arranged to align with the ends of the coil, such that the respective grooves 640 formed in the inner and outer radial directions are positioned on the respective end sections of the lead frame 255 coil.

The present embodiment provides a structure for cooling a lead frame and a coil, as shown in fig. 18, the lead frame 255 is mounted on a stator core 600, and the end of the coil has been connected to the lead frame 255, the stator core 600 being provided to be mounted to a stator heat sink 253. Preferably, stator core 600 is mounted on stator heat sink 253 via a heat sink mechanism. For cooling the stator core 600, the coil 400 and the lead frame 255, the lead frame has a cooling channel with a first section 1810, the first section 1810 extending along the inner axial edges of the stator teeth 800 and the stator core 600, and a second section 1820, the second section 1820 being arranged to extend in a radially outward direction parallel to the axial mounting face of the stator core 600 to which the lead frame is mounted.

As shown in the cross-sectional view of the stator shown in fig. 18. To improve thermal conductivity between stator heat sink 253 and lead frame 255, potting material 1830 is placed between heat sink 253 and lead frame 255 and between lead frame 255 and stator coil 400. The potting material 1830 that is typically used is arranged to provide good thermal conductivity. One example of a suitable potting material is a ceramic filled epoxy; however, other types of potting materials may be used. With this embodiment, since each lead frame 255 portion forms only a semi-circular portion, this has the advantage of reducing the manufacturing cost of the entire lead frame 255 arrangement compared to the manufacturing cost of a single circumferential lead frame 255.

Example 2

This embodiment provides a generator or motor having the stator of embodiment 1.

Example 3

The present embodiment provides a vehicle having a generator or motor of the stator described in embodiment 2.

In short, the above description is only a preferred embodiment of the present invention, and all the equivalent changes and modifications made in accordance with the claims of the present invention should be covered by the scope of the present invention.

Claims (10)

1. A connection structure of a lead frame and a winding coil, comprising a lead frame on which a printed circuit board having a plurality of circuit board layers is placed, characterized in that: each circuit board layer comprises an insulating substrate and a conductive layer formed on the insulating substrate, the circuit board layers comprise a first circuit board layer, a second circuit board layer, a third circuit board layer and a fourth circuit board layer, the first circuit board layer comprises a first conductive layer arranged to be electrically coupled to a first coil winding of the first set of coil windings and a first branch of the first inverter; the second circuit board layer includes a second conductive layer arranged to electrically couple to a second coil winding of the first set of coil windings and a second leg of the first inverter; the third circuit board layer includes a third conductive layer arranged to electrically couple to a third coil winding of the first set of coil windings and a third leg of the first inverter; the fourth circuit board layer includes a fourth conductive layer configured to couple with the first, second, and third coil windings of the first set of coil windings to form a neutral point between the first, second, and third coil windings; the stator comprises a stator body, a stator core, a lead frame, a first coil winding, a second coil winding, a third coil winding, a first lead frame, a second lead frame, a third lead frame, a first coil winding, a second coil winding, a third coil winding, a second lead frame, a third coil winding, a third lead frame and a fourth coil winding.

2. The connection structure of a lead frame and a winding coil according to claim 1, wherein: the ends of the first coil winding are mounted in the grooves of the lead frame such that the first coil winding is electrically connected to the first conductive layer.

3. The connection structure of a lead frame and a winding coil according to claim 1, wherein: an end portion of the second coil winding is mounted in the groove of the lead frame such that the second coil winding is electrically connected with the second conductive layer.

4. The connection structure of a lead frame and a winding coil according to claim 1, wherein: an end of the third coil winding is mounted in the groove of the lead frame such that the third coil winding is electrically connected to the third conductive layer.

5. The connection structure of a lead frame and a winding coil according to claim 1, wherein: the lead frame is of a whole circumference shape, or the lead frame is formed by splicing two semi-circumference lead frames into a whole circumference shape.

6. The connection structure of a lead frame and a winding coil according to claim 3, wherein: the circumferential support comprises means for positioning a lead frame at a predetermined position on the circumferential support, the ends of the first, second and third coil windings being adjacent to the recesses in the lead frame to allow the lead frame to couple the respective coil windings into a multi-phase coil winding.

7. The connection structure of a lead frame and a winding coil according to claim 6, wherein: the means for positioning the lead frame on the circumferential support comprises heat stakes, wherein the heat stakes melt the lead frame to the circumferential support when the lead frame has been mounted on the circumferential support.

8. The connection structure of a lead frame and a winding coil according to claim 1, wherein: further comprising an electrically conductive sleeve, and placing the electrically conductive sleeve in a corresponding groove on the lead frame, the corresponding end portion of the coil winding being arranged to fit within said electrically conductive sleeve.

9. The connection structure of a lead frame and a winding coil according to claim 1, wherein: the ends of the coil windings are soldered to the lead frame when the ends of the coil windings have been placed in corresponding grooves formed in the lead frame.

10. The connection structure of a lead frame and a winding coil according to claim 1, wherein: the grooves are formed at inner and outer edges of the printed circuit board, each groove being arranged to receive a respective coil winding for electrically coupling the coil winding to the printed circuit board.

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