CN212935610U - Stator assembly, motor and vehicle - Google Patents
Stator assembly, motor and vehicle Download PDFInfo
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- CN212935610U CN212935610U CN201922456406.1U CN201922456406U CN212935610U CN 212935610 U CN212935610 U CN 212935610U CN 201922456406 U CN201922456406 U CN 201922456406U CN 212935610 U CN212935610 U CN 212935610U
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Abstract
The utility model provides a stator component, a motor and a vehicle, wherein the stator component comprises a stator core, a stator winding and a star point structure, the shape and the structure of the star point structure are pre-manufactured, the stator comprises a central node and at least three peripheral nodes connected with the central node through corresponding lead wires, wherein the surface of the part of the lead wires inserted into the stator slots is wrapped with an insulating layer, therefore, the welding between the leading-out wires and the insulation treatment between the leading-out wires and the conductor sections of the leading-out wires, the stator core and the stator winding are not needed to be carried out on the subsequent star point structure, thereby improving the production efficiency, simultaneously, the star point structure is well combined with the stator winding into a whole through the peripheral nodes thereof, space is not increased in the radial direction and the axial direction, special torsion is not generated, and reliability of the stator winding is improved. The motor comprises the stator assembly and a rotor assembly arranged on the inner side of the stator assembly.
Description
Technical Field
The utility model relates to an automotive filed especially relates to a stator module, motor and vehicle.
Background
The driving motor on the electric automobile is one of the cores of the whole set of motor driving motor, and the service life and the reliability of the driving motor are directly related to the service life and the safety of the whole automobile. Therefore, the reliability and compactness of the motor winding design are particularly important for the development of the driving motor for the vehicle. The novel hairpin (hairpin) winding greatly improves the slot fullness rate of the motor, has a good heat dissipation effect, greatly improves the peak value and the continuity of the motor, has a lower end part height, and improves the power density of the motor, so the hairpin winding has become the development trend of the vehicle-used driving motor.
The design of the old generation hairpin winding at the wire outlet part of the motor is not optimized, the axial length is increased, and the winding reliability is reduced. Meanwhile, the production difficulty is improved, and the production efficiency is greatly reduced.
One end of a star point lead-out wire adopted in the industry at present is connected to a bent turning part of a conductor section of a winding, and the other end of the star point lead-out wire is a star point, so that the star point is lifted up, then is welded with a bus, and finally is insulated; or bending the star point outgoing line at a large angle, lifting, then carrying out subsequent welding, and finally carrying out insulation. The disadvantages are as follows: the process complexity is improved, the production efficiency is greatly reduced, and the cost is improved; the axial or radial size of the winding is enlarged; subsequent welding causes great insulation difficulty and risk, and winding reliability is difficult to ensure.
SUMMERY OF THE UTILITY MODEL
An object of the utility model is to provide a stator module, motor and vehicle can ensure the reliability and the reduce cost of winding.
To achieve the above and other related objects, the present invention provides a stator assembly, including a stator core, a stator winding, and a star point structure, wherein the stator core has a plurality of stator slots; the stator winding comprises a plurality of conductor segments, each conductor segment is inserted into the corresponding stator slot and exposes two ends of the conductor segment to the outside of the stator core, and one ends of the plurality of conductor segments form welding ends; the star point structure is provided with a central node and at least three peripheral nodes connected with the central node through corresponding outgoing lines, the outgoing lines between the central node and each peripheral node are at least partially inserted into the stator slot, each peripheral node penetrates out of the stator slot and then is welded with the welding end, and the surface of the part of the outgoing line inserted into the stator slot is coated with an insulating layer.
Optionally, in the stator assembly, the star point structure includes a first star point outgoing line, a second star point outgoing line, and a third star point outgoing line, one end of each of the three star point outgoing lines is connected together and serves as a central node, the other end of each of the three star point outgoing lines serves as a corresponding peripheral node, the star point outgoing lines are inserted into the stator slots and penetrate out of the stator slots and then are welded to the welding ends of the conductor segments, and the central node is a welding point of the star point structure.
Optionally, in the stator assembly, the star point outgoing line is an enameled wire, and the insulating layer is a paint coating wrapping the wire.
Optionally, in the stator assembly, the welding spot is exposed by a coating of the enameled wire of each star point outgoing line.
Optionally, in the stator assembly, the star point structure is an integrally formed structure, and one ends of the three star point outgoing lines are connected together in an integrally formed manner to serve as the welding point.
Optionally, in the stator assembly, one ends of the three star point outgoing lines are connected together in a welding manner to serve as the welding point.
Optionally, in the stator assembly, the stator slots are formed in an inner peripheral wall of the stator core and axially penetrate through the stator core, the stator slots are arranged at intervals in a circumferential direction of the stator core, and a depth direction of the stator slots is consistent with a radial direction of the stator core.
Optionally, in the stator assembly, the conductor segment is a U-shaped conductor segment, the U-shaped conductor segment includes a first in-slot portion and a second in-slot portion that are disposed in a stator slot, one end of the conductor segment is a U-shaped bent portion that connects one end of the first in-slot portion and one end of the second in-slot portion, the U-shaped bent portions of the conductor segments form a hairpin end of the stator winding, and the other end of the first in-slot portion and the other end of the second in-slot portion are not connected to each other and form a welding end of the stator winding.
In order to achieve the above and other related objects, the present invention further provides a motor, including a stator assembly and a rotor assembly disposed inside the stator assembly, the stator assembly including a stator core, a stator winding and a star point structure, wherein the stator core has a plurality of stator slots; the stator winding comprises a plurality of conductor segments, each conductor segment is inserted into the corresponding stator slot and exposes two ends of the conductor segment to the outside of the stator core, and one ends of the plurality of conductor segments form welding ends; the star point structure is provided with a central node and at least three peripheral nodes connected with the central node through corresponding outgoing lines, the outgoing lines between the central node and each peripheral node are at least partially inserted into the stator slot, each peripheral node penetrates out of the stator slot and then is welded with the welding end, and the surface of the part of the outgoing line inserted into the stator slot is coated with an insulating layer.
To achieve the above and other related objects, the present invention also provides a vehicle including a motor, the motor including a stator assembly and a rotor assembly disposed inside the stator assembly, the stator assembly including a stator core, a stator winding and a star point structure, wherein the stator core has a plurality of stator slots; the stator winding comprises a plurality of conductor segments, each conductor segment is inserted into the corresponding stator slot and exposes two ends of the conductor segment to the outside of the stator core, and one ends of the plurality of conductor segments form welding ends; the star point structure is provided with a central node and at least three peripheral nodes connected with the central node through corresponding outgoing lines, the outgoing lines between the central node and each peripheral node are at least partially inserted into the stator slot, each peripheral node penetrates out of the stator slot and then is welded with the welding end, and the surface of the part of the outgoing line inserted into the stator slot is coated with an insulating layer.
To sum up, the utility model provides a stator module includes stator core, stator winding and star point structure, just the shape and the structure of star point structure are made in advance, star point structure have the central node and through corresponding lead-out wire with the at least three peripheral node that the central node is connected, the lead-out wire inserts the part in the stator slot on the surface parcel has the insulating layer, consequently need not follow-up to star point structure again carry on the welding between the lead-out wire and to the lead-out wire respectively with the insulating processing between the conductor section of lead-out wire, stator core and stator winding, also need not use the plastics insulation board of embedded generating line, improved production efficiency, the cost is reduced. Meanwhile, the star point structure is well combined with the stator winding into a whole through peripheral nodes of the star point structure, no space is increased in the radial direction and the axial direction, no special torsion is generated, and the reliability of the winding is improved.
Drawings
FIG. 1 is a schematic connection diagram of a star point lead;
fig. 2 is a schematic diagram of a star point structure inserted into a stator slot to form a winding according to the present invention;
fig. 3 is a schematic structural diagram of a star point structure in the present invention;
wherein in FIG. 1:
01-stator core, 02-conductor segment, 03-star point, 04-insulating plastic plate;
in fig. 2 to 3:
10-stator core, 20-conductor segment, 301-first star point outgoing line, 302-second star point outgoing line, 303-third star point outgoing line, 304-welding spot, 305-coat-removed bare copper part.
Detailed Description
Reference will now be made in detail to embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the same or similar elements or elements having the same or similar function throughout. The embodiments described below with reference to the drawings are exemplary only for the purpose of explaining the present invention, and should not be construed as limiting the present invention.
Referring to fig. 1, a stator assembly generally includes a stator core 01, a stator winding and star point outgoing lines (not shown), wherein the stator core 01 has a plurality of stator slots thereon, the stator winding includes a plurality of conductor segments 02, the conductor segments 02 are U-shaped conductor segments, the U-shaped conductor segments include a first in-slot portion and a second in-slot portion disposed in the stator slots, one end of the conductor segments 02 is a U-shaped bent portion connecting one end of the first in-slot portion and one end of the second in-slot portion, the U-shaped bent portions of the plurality of conductor segments form a hairpin end of the stator winding, and the other end of the first in-slot portion and the other end of the second in-slot portion are not connected to each other and form a welding end of the stator winding, and the welding end is bent to a proper position according to a process requirement and welded together. One end of the star point outgoing line is connected with the U-shaped bending part through welding. The other end of the star point outgoing line is a star point 03, the star point 03 can be lifted, and then the star point 03 is welded with a bus. The bus is preferably a copper bar, and the bus is embedded in the insulating plastic plate 04 and is insulated through the insulating plastic plate 04. The star point outgoing line can be bent at a large angle, all star points are raised, subsequent welding is performed, and finally insulation processing between the outgoing line and the outgoing line, between the outgoing line and the conductor sections of the stator core and between the outgoing line and the conductor sections of the stator winding is performed. The stator assembly described above has the following disadvantages: the insulating plastic plate 04 with the embedded bus is expensive, and the cost is increased; the process complexity is improved, and the production efficiency is greatly reduced; the axial or radial size of the winding is enlarged; subsequent welding and insulation difficulties and risks are high and it is difficult to ensure winding reliability.
In order to overcome the defects, the utility model provides a stator assembly, included the star point structure, adopted to make in advance and have specific structure and specific shape and have insulating star point structure in specific area promptly and insert stator core's stator slot, the star point structure can be regarded as a ordinary semiconductor segment completely for the production line need not carry out subsequent welding and insulating treatment, has improved the reliability of production efficiency and winding.
Referring to fig. 2, the stator assembly includes a stator core 10, a stator winding, and a star point structure, wherein the stator core 10 has a plurality of stator slots; the stator winding includes a plurality of conductor segments 20, each conductor segment 20 being inserted into a corresponding one of the stator slots and having both ends exposed to the outside of the stator core 10, one end of the plurality of conductor segments 20 forming a welding terminal; the star point structure is provided with a central node and at least three peripheral nodes connected with the central node through corresponding outgoing lines, the outgoing lines between the central node and each peripheral node are at least partially inserted into the stator slot, each peripheral node penetrates out of the stator slot and then is welded with the welding end, and the surface of the part of the outgoing line inserted into the stator slot is coated with an insulating layer.
The stator core 10 is preferably cylindrical, and the stator core has a plurality of stator slots formed on an inner circumferential wall of the stator core 10 and penetrating the stator core 10 along an axial direction, and the plurality of stator slots are arranged at intervals along a circumferential direction of the stator core 10, and a depth direction of the stator slots is identical to a radial direction of the stator core 10. The number of the stator slots can be changed along with different motor powers and winding design methods. For example, 40 or 60 slots may be formed in the stator, as desired.
The conductor segments 20 are preferably U-shaped conductor segments, but are not limited thereto, and may have conductor segments that change their axial direction by more than 90 °, such as about 180 °. When the conductor segment 20 is a U-shaped conductor segment, the U-shaped conductor segment includes a first in-slot portion and a second in-slot portion provided in a stator slot, one end of the conductor segment 20 is a U-shaped bent portion connecting one end of the first in-slot portion and one end of the second in-slot portion, the U-shaped bent portions of the plurality of conductor segments 20 form a hairpin end of the stator winding, and the other end of the first in-slot portion and the other end of the second in-slot portion are not connected to each other and form a weld end of the stator winding, and then the weld end is bent to an appropriate position.
In this embodiment, the star point structure is formed after design forming, pre-welding, and pre-insulation are performed through a star point outgoing line, where the pre-welding method includes gas shielded welding or automatic submerged arc welding. For example, the star point structure includes a first star point outgoing line 301, a second star point outgoing line 302, and a third star point outgoing line 303, and one ends of the three star point outgoing lines are connected together by a welding method to be a welding point 304, that is, a central node of the star point structure. The other ends of the first star point outgoing line 301, the second star point outgoing line 302 and the third star point outgoing line 303 are all used as peripheral nodes connected with the welding point 304 through corresponding outgoing lines, that is, the star point structure of the embodiment has one central node and three peripheral nodes.
Of course, in other embodiments of the present invention, the star point structure may also be an integrally formed structure, and one end of the three star point outgoing lines is connected together as the solder joint 304 by an integrally formed manner. In the integral molding process, for example, the wires of the first star point lead wire 301, the second star point lead wire 302, and the third star point lead wire 303 are integrally molded by a wire drawing process.
Each star point lead-out wire can be the enameled wire, and the enameled wire forms through wrapping up the skin of lacquer promptly on the wire surface, at this moment, insulating layer in the star point structure is the skin of lacquer of parcel wire, the skin of lacquer is got rid of to the one end of every star point lead-out wire and is formed the skin of lacquer naked copper part 305 to the one end welding that will get rid of the skin of lacquer forms solder joint 304 together, promptly the solder joint 304 is by each the skin of lacquer of the enameled wire of star point lead-out wire exposes. That is, the solder pads 304 and the peripheral nodes in the star-point structure are exposed by the insulating layer, and the surfaces of the star-point structure except the solder pads 304 and the peripheral nodes are covered by the insulating layer.
In some embodiments of the present invention, each of the star point lead wires may be designed and formed, and pre-insulated after being pre-welded, to form the star point structure, where the pre-insulated method includes a coating process or a potting process, and is preferably a coating process. After the star point outgoing line is pre-insulated, 100% detection can be carried out through a ball bath experiment, so that the insulation of the star point structure is judged.
After the star point outgoing lines are detected by 100%, the other ends of the three star point outgoing lines are respectively inserted into the stator slots of the stator core 10 and penetrate out to serve as three peripheral nodes, and are respectively bent to appropriate positions together with the corresponding welding ends of the conductor segments 20 according to the process requirements, and finally are welded together with the corresponding welding ends to complete the final winding.
The utility model provides a pair of stator module, including stator core, stator winding and star point structure, star point structure have the central node and through corresponding lead-out wire with the at least three peripheral node that the central node is connected, at least part of lead-out wire between central node and each peripheral node inserts in the stator slot to make each peripheral node follow wear out in the stator slot back with the welding end welding together, just the lead-out wire inserts the part in the stator slot wraps up on the surface has the insulating layer. The star point structure is formed by at least three star point leading wires after design forming, pre-welding and pre-insulation, and the star point structure is inserted into the stator slot and welded with the welding end of the conductor segment. The star point structure is inserted into stator slots of a stator core, and the star point structure and the welding ends are bent to proper positions according to process requirements and finally connected together with the welding ends to form a final winding. The star point structure can be completely used as a common conductor section (common electrode plug pin) for a production line, subsequent welding and insulation treatment are not needed, and the production efficiency is improved; an insulating plastic plate with a bus embedded in the insulating plastic plate is not needed, the structure is simple, and the cost can be reduced; meanwhile, the star point structure can be well combined with the stator winding into a whole, no space is increased in the radial direction and the axial direction, no special torsion is generated, and the reliability of the winding is improved.
An embodiment of the present invention further provides a motor, including the above-mentioned stator assembly and a rotor assembly disposed inside the stator assembly, wherein the stator assembly includes a stator core, a stator winding and a star point structure, and the stator core has a plurality of stator slots; the stator winding comprises a plurality of conductor segments, each conductor segment is inserted into the corresponding stator slot and exposes two ends of the conductor segment to the outside of the stator core, and one ends of the plurality of conductor segments form welding ends; the star point structure is provided with a central node and at least three peripheral nodes connected with the central node through corresponding outgoing lines, the outgoing lines between the central node and each peripheral node are at least partially inserted into the stator slot, each peripheral node penetrates out of the stator slot and then is welded with the welding end, and the surface of the part of the outgoing line inserted into the stator slot is coated with an insulating layer. The motor has the utility model discloses a stator module so the reliability is improved and can have less size.
The utility model also provides a vehicle, including above-mentioned motor, the motor includes stator module and arranges the rotor subassembly in the stator module inboard, the stator module includes stator core, stator winding and star point structure, wherein have a plurality of stator slots on the stator core; the stator winding comprises a plurality of conductor segments, each conductor segment is inserted into the corresponding stator slot and exposes two ends of the conductor segment to the outside of the stator core, and one ends of the plurality of conductor segments form welding ends; the star point structure is provided with a central node and at least three peripheral nodes connected with the central node through corresponding outgoing lines, the outgoing lines between the central node and each peripheral node are at least partially inserted into the stator slot, each peripheral node penetrates out of the stator slot and then is welded with the welding end, and the surface of the part of the outgoing line inserted into the stator slot is coated with an insulating layer. The vehicle is because have the utility model discloses a motor, so the reliability is improved.
In the description of the present invention, it is to be noted that, unless otherwise explicitly specified or limited, the terms "connected" and "connected" are to be interpreted broadly, and may be, for example, fixedly connected, detachably connected, or integrally connected; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meaning of the above terms in the present invention can be understood in specific cases to those skilled in the art.
In the description of the present invention, it is to be understood that the terms "axial," "radial," and the like refer to orientations or positional relationships based on those shown in the drawings, which are merely for convenience of description and simplicity of description, and do not indicate or imply that the device or element referred to must have a particular orientation, be constructed and operated in a particular orientation, and thus, should not be considered as limiting the present invention. Furthermore, the terms "first", "second" and "first" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of the present invention, "a plurality" means two or more unless otherwise specified.
The above description is only for the preferred embodiment of the present invention, and is not intended to limit the scope of the present invention. All equivalent changes and modifications made according to the content of the claims of the present invention shall fall within the technical scope of the present invention.
Claims (10)
1. A stator assembly, comprising a stator core, a stator winding, and a star point structure, wherein the stator core has a plurality of stator slots thereon; the stator winding comprises a plurality of conductor segments, each conductor segment is inserted into the corresponding stator slot and exposes two ends of the conductor segment to the outside of the stator core, and one ends of the plurality of conductor segments form welding ends; the star point structure is provided with a central node and at least three peripheral nodes connected with the central node through corresponding outgoing lines, the outgoing lines between the central node and each peripheral node are at least partially inserted into the stator slot, each peripheral node penetrates out of the stator slot and then is welded with the welding end, and the surface of the part of the outgoing line inserted into the stator slot is coated with an insulating layer.
2. The stator assembly of claim 1, wherein the star point structure comprises a first star point lead, a second star point lead and a third star point lead, one end of the three star point leads are connected together and serve as a central node, the other end of the three star point leads serve as the corresponding peripheral node, the star point leads are inserted into the stator slots and penetrate out of the stator slots and then are welded with the welding ends of the conductor segments, and the central node is a welding point of the star point structure.
3. The stator assembly according to claim 2, wherein the star point lead-out wires are enameled wires, and the insulation layer is a coating wrapping the wires.
4. The stator assembly according to claim 3, wherein the solder joints are exposed by a skin of the enamel wire of each of the star point lead wires.
5. The stator assembly according to any one of claims 2-4, wherein the star point structure is an integrally formed structure, and one ends of three star point outgoing lines are connected together in an integrally formed mode to serve as the welding point.
6. The stator assembly according to any of claims 2-4, wherein one ends of three star point outgoing lines are connected together by welding to serve as the welding point.
7. The stator assembly according to claim 1, wherein the stator slots are formed on an inner circumferential wall of the stator core and penetrate the stator core in an axial direction, and a plurality of the stator slots are arranged at intervals in a circumferential direction of the stator core, and a depth direction of the stator slots coincides with a radial direction of the stator core.
8. The stator assembly of claim 1 wherein the conductor segments are U-shaped conductor segments, the U-shaped conductor segments including a first in-slot portion and a second in-slot portion disposed in a stator slot, one end of the conductor segments being a U-bend connecting one end of the first in-slot portion and one end of the second in-slot portion, the U-bends of the plurality of conductor segments forming a hairpin end of the stator winding, and the other end of the first in-slot portion and the other end of the second in-slot portion not being connected to each other and forming a weld end of the stator winding.
9. An electric machine comprising a stator assembly and a rotor assembly disposed inside the stator assembly, the stator assembly comprising a stator core, a stator winding, and a star point structure, wherein the stator core has a plurality of stator slots thereon; the stator winding comprises a plurality of conductor segments, each conductor segment is inserted into the corresponding stator slot and exposes two ends of the conductor segment to the outside of the stator core, and one ends of the plurality of conductor segments form welding ends; the star point structure is provided with a central node and at least three peripheral nodes connected with the central node through corresponding outgoing lines, the outgoing lines between the central node and each peripheral node are at least partially inserted into the stator slot, each peripheral node penetrates out of the stator slot and then is welded with the welding end, and the surface of the part of the outgoing line inserted into the stator slot is coated with an insulating layer.
10. A vehicle comprising an electric machine including a stator assembly and a rotor assembly disposed inside the stator assembly, the stator assembly including a stator core, stator windings, and a star point structure, wherein the stator core has a plurality of stator slots thereon; the stator winding comprises a plurality of conductor segments, each conductor segment is inserted into the corresponding stator slot and exposes two ends of the conductor segment to the outside of the stator core, and one ends of the plurality of conductor segments form welding ends; the star point structure is provided with a central node and at least three peripheral nodes connected with the central node through corresponding outgoing lines, the outgoing lines between the central node and each peripheral node are at least partially inserted into the stator slot, each peripheral node penetrates out of the stator slot and then is welded with the welding end, and the surface of the part of the outgoing line inserted into the stator slot is coated with an insulating layer.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201922456406.1U CN212935610U (en) | 2019-12-30 | 2019-12-30 | Stator assembly, motor and vehicle |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201922456406.1U CN212935610U (en) | 2019-12-30 | 2019-12-30 | Stator assembly, motor and vehicle |
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| Publication Number | Publication Date |
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| CN212935610U true CN212935610U (en) | 2021-04-09 |
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| Application Number | Title | Priority Date | Filing Date |
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| CN201922456406.1U Active CN212935610U (en) | 2019-12-30 | 2019-12-30 | Stator assembly, motor and vehicle |
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| CN (1) | CN212935610U (en) |
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2019
- 2019-12-30 CN CN201922456406.1U patent/CN212935610U/en active Active
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