CN216216160U - Flat wire for flat wire motor, stator assembly and flat wire motor - Google Patents
Flat wire for flat wire motor, stator assembly and flat wire motor Download PDFInfo
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- CN216216160U CN216216160U CN202122410052.4U CN202122410052U CN216216160U CN 216216160 U CN216216160 U CN 216216160U CN 202122410052 U CN202122410052 U CN 202122410052U CN 216216160 U CN216216160 U CN 216216160U
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Abstract
The utility model relates to the technical field of motors, in particular to a flat wire for a flat wire motor, a stator assembly and the flat wire motorThe second connecting part is connected through a transition part; wherein, the first connecting part is connected with the transition part in a bending way, and the radius of the bending radian of the first connecting part is R1Greater than or equal to the section length of the flat wire section. The utility model provides a flat wire for a flat wire motor, which is characterized in that the middle part of the flat wire with a large length-width ratio is improved, a first connecting part is connected with a transition part in a bending way, and the radius of a bending radian R of the flat wire1The section length of the flat wire is larger than or equal to that of the flat wire, so that the linear type can meet the manufacturing process of punch forming, repeated investment and modification of equipment and process are avoided, the quality of products can be improved, and the cost can be reduced.
Description
Technical Field
The utility model relates to the technical field of motors, in particular to a flat wire for a flat wire motor, a stator assembly and the flat wire motor.
Background
With the rapid development of new energy automobile technology, the performance requirements on the automobile motor are higher and higher, and while the high slot filling rate, the high power density and the high torque density of the motor are continuously pursued, the circular wire motor is difficult to break through the bottleneck of the new performance requirements of the existing driving motor. The appearance of the flat wire motor realizes the performance requirement which can not be met by the round wire motor, has high slot filling rate, high power density, good heat dissipation performance and NVH performance, can greatly reduce the height of the end part of the motor winding, reduces the copper consumption of the winding by using the copper amount, and further improves the efficiency of the vehicle driving motor.
In the prior art, the forming method of the flat wire mainly includes bending forming, splitting and drawing forming and punch forming. The bending forming automation degree is high, the equipment cost is high, and the problem that the forming size cannot be strictly in place exists; the head of the split-drawn flat wire is large in overall size, so that the overall space design of the motor is not favorable, only one flat wire can be formed at a time, and the efficiency is low; the flat wire formed by stamping has the advantages of good quality, low cost and high mass production efficiency.
However, for the existing flat wire with the length-width ratio greater than 1.8, as shown in fig. 1 and 2, the flat wire with the ordinary linear shape can only be formed by splitting and drawing due to the flat shape and deep bending of the head, and cannot be formed by stamping, and the use of splitting and drawing can cause the problems of large structural deformation, conductor damage, easy cracking and expansion due to the internal stress or strain generated in the bending process of the flat wire, and the flat wire is applied to a motor and has poor mechanical properties. Therefore, for a flat wire with a high aspect ratio, a flat wire shape satisfying a press forming process is required.
SUMMERY OF THE UTILITY MODEL
In order to solve the defect that the large length-width ratio cannot be realized by a punch forming process in the prior art, the utility model provides a flat wire for a flat wire motor, which comprises a first straight line part and a second straight line part, wherein the first straight line part and the second straight line part are embedded into a stator groove, and one end of the first straight line part is connected with one end of the second straight line partThe first connecting part is connected, one end of the second straight line part is connected with the second connecting part, and the first connecting part and the second connecting part are connected through a transition part; wherein, the first connecting part is connected with the transition part in a bending way, and the radius of the bending radian of the first connecting part is R1Greater than or equal to the section length of the flat wire section.
In one embodiment, the second connecting portion is connected with the transition portion in a bending way, and the bending radian radius R of the second connecting portion is2Greater than or equal to 1.2 times of the width of the section of the flat wire.
In an embodiment, the included angles between the first straight line portion and the first connection portion, between the first connection portion and the second connection portion, and between the second connection portion and the second straight line portion are all obtuse angles.
In one embodiment, when viewed from the plane orthographic projection determined by the first straight line part and the second straight line part of the flat wire, the projection included angle theta between the first connecting part and the second connecting part is in the range of 110 degrees to 120 degrees.
In one embodiment, the flat wire is made of an enameled flat copper wire.
In one embodiment, the flat wire is of an integrally formed stamped structure.
In one embodiment, the device further comprises a first supporting leg arranged at the other end of the first straight line part and a second supporting leg arranged at the other end of the second straight line part, and the first supporting leg and the second supporting leg are bent towards the outer side in the opposite direction or are bent along one side in the same direction.
The utility model also provides a stator assembly, which comprises a stator core and a stator winding, wherein a plurality of stator slots are arranged on the inner wall of the stator core at intervals along the circumferential direction of the stator core, the stator winding is arranged in each stator slot, the stator winding is composed of flat wires which are regularly arranged, and the flat wires are the flat wires for the flat wire motor.
The utility model also provides a flat wire motor, which adopts the flat wire for the flat wire motor.
Based on the above, compared with the prior art, the flat wire for the flat wire motor provided by the utility model has the advantages that the first connecting part is made by improving the middle part of the flat wire with the large length-width ratioIs connected with the transition part in a bending way, and has a bending radian radius R1The section length of the flat wire is larger than or equal to that of the flat wire, so that the linear type can meet the manufacturing process of punch forming, repeated investment and modification of equipment and process are avoided, the quality of products can be improved, and the cost can be reduced.
Additional features and advantages of the utility model will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the utility model. The objectives and other advantages of the utility model will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings needed to be used in the description of the embodiments or the prior art will be briefly introduced below, and it is obvious that the drawings in the following description are some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the drawings without creative efforts; in the following description, the drawings are illustrated in a schematic view, and the drawings are not intended to limit the present invention.
FIG. 1 is a schematic diagram of a conventional flat wire structure in the prior art;
FIG. 2 is a schematic view of a conventional flat wire assembled into a stator core according to the prior art;
FIG. 3 is a schematic view of a flat wire structure for a flat wire motor according to the present invention;
FIG. 4 is a front view and a top view of the novel flat wire formed by a projection plane a and a top plane b;
FIG. 5 is a top view of the flat wire for a flat wire motor provided by the present invention;
FIG. 6 is a front view of the flat wire for the flat wire motor provided by the present invention;
FIG. 7 is a perspective view of a flat wire for a flat wire motor in accordance with another embodiment of the present invention;
FIG. 8 is a top view of a flat wire for a flat wire motor in accordance with another embodiment of the present invention;
FIG. 9 is a side view of a flat wire for a flat wire motor in accordance with another embodiment of the present invention;
fig. 10 is a perspective view of a stator assembly provided by the present invention.
Reference numerals:
10 first straight line part 20 second straight line part 30 first connection part
40 second connecting portion 50 transition portion 60 first leg
70 second leg 2 stator core 1 stator winding
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are some embodiments of the present invention, but not all embodiments; the technical features designed in the different embodiments of the present invention described below can be combined with each other as long as they do not conflict with each other; all other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
In the description of the present invention, it is to be noted that all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the present invention belongs, and are not to be construed as limiting the present invention; it will be further understood that terms used herein should be interpreted as having a meaning that is consistent with their meaning in the context of this specification and the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
Aiming at the existing flat wire with high length-width ratio of the cross section, the linear structure of the flat wireThe utility model provides a flat wire for a flat wire motor, which has the cross-sectional aspect ratio of more than or equal to 1.8 and comprises a first straight line part 10 and a second straight line part 20 which are embedded into a stator slot, wherein one end of the first straight line part 10 is connected with a first connecting part 30, one end of the second straight line part 20 is connected with a second connecting part 40, and the first connecting part 30 and the second connecting part 40 are connected through a transition part 50; wherein, the first connection portion 30 is connected with the transition portion 50 in a bending way, and the bending radian radius R of the first connection portion is1Greater than or equal to the length of the cross section of the flat wire.
In specific implementation, as shown in fig. 3, 4, 5, and 6, the cross-sectional aspect ratio of the flat wire is greater than or equal to 1.8, the flat wire is generally U-shaped as a whole, and includes a first straight portion 10 and a second straight portion 20, the first straight portion 10 and the second straight portion 20 are arranged in parallel, and the distance between the first straight portion 10 and the second straight portion is formed by the number of stator slots spanned by the first straight portion 10 and the second straight portion in the stator of the electric motor, so that the span should be set according to the requirement of the actual stator of the electric motor, and the inclination angle between the two portions should be set according to the different stator slot spans at different radial positions required by the actual stator of the electric motor, which is not limited herein. The end parts of the first straight line part 10 and the second straight line part 20 are respectively provided with a first connecting part 30 and a second connecting part 40, the first connecting part 30 and the second connecting part 40 are bent towards the center and are connected through a transition part 50, and compared with the common flat line type, the flat transition is carried out by adopting the transition part 50, so that the occupied space of the head part of the flat line assembled into the stator is reduced, the flat line material and the cost are saved, and the compact structure degree of the stator winding can be further ensured.
Wherein, first connecting portion 30 and transition portion 50 are connected in a bending way, in order to guarantee that high aspect ratio's flat line can be applicable to stamping forming technology, this embodiment is injectd the radius of bending radian for its bending radian radius R1The length of the section of the flat wire is more than or equal to the length of the section of the flat wire, so that the realizability of the punch forming process is ensured. The flat wire arc transition formed by stamping according to the design has good quality, the deformation of the internal structure is not large, and the insulation damage and the cracking are not easy to occur; it can be applied to motor to ensure good performanceInsulation properties and mechanical properties. Preferably, its radius of curvature R1May be 1.2 to 1.5 times the length of the flat wire section.
The utility model provides a flat wire for a flat wire motor, which is characterized in that the middle part of the flat wire with a large length-width ratio is improved, a first connecting part is connected with a transition part in a bending way, and the radius of a bending radian R of the flat wire1The section length of the flat wire is larger than or equal to that of the flat wire, so that the linear type can meet the manufacturing process of punch forming, repeated investment and modification of equipment and process are avoided, the quality of products can be improved, and the cost can be reduced.
Preferably, the second connecting portion 40 is connected to the transition portion 50 in a bending manner, and the bending radian radius R2 is more than or equal to 1.2 times of the cross-sectional width of the flat wire.
In specific implementation, as shown in fig. 4 and 5, the second connecting portion 40 and the transition portion 50 are further curved and connected to each other at a radian radius R in the embodiment2And limiting to be more than or equal to 1.2 times of the section width of the flat wire. Radius of curvature R2Preferably 1.25 times, 1.3 times, 1.4 times, and 1.5 times. After experimental study, if R2The radius is too small, the paint skin of the flat wire is easy to be damaged in the stamping process, and R is2When the width of the section of the flat wire is more than or equal to 1.2 times of the width of the section of the flat wire, the forming quality is good, and the qualification rate is high. Of course, R2Too large is not suitable, and the flat wire made of metal materials is damaged due to too large mechanical deformation, so that the flat wire is difficult to machine and form. Preferably, the first connecting portion 30 and the transition portion 50 are convexly curved outward, and the second connecting portion 40 and the transition portion 50 are concavely curved inward.
Preferably, the included angles between the first straight line portion 10 and the first connection portion 30, between the first connection portion 30 and the second connection portion 40, and between the second connection portion 40 and the second straight line portion 20 are all obtuse angles. Preferably, the included angles between the first linear portion 10 and the first connection portion 30 and between the second connection portion 40 and the second linear portion 20 range from 100 ° to 130 °. The flat wire is arranged to be an obtuse angle, so that the flat wire is conveniently inserted into the stator slot; on the other hand, the interference preventing effect between adjacent flat wires of the assembled stator winding is better, and the reliability is high.
Preferably, the projection angle theta between the first connecting part 30 and the second connecting part 40 is 110 degrees to 120 degrees when viewed from the plane orthographic projection determined by the first straight part 10 and the second straight part 20 of the flat wire.
In specific implementation, as shown in fig. 10, the angle change of the included angle between the first connecting portion 30 and the second connecting portion 40 affects the quality of the flat wire after assembly. Therefore, in the present embodiment, the projection is performed based on the plane defined by the first straight portion 10 and the second straight portion 20 of the flat wire, so as to obtain the projection plane a, as shown in the upper diagram of fig. 4 and the front diagram of fig. 6, it is determined through research that the included angle θ between the first connecting portion 30 and the second connecting portion 40 in the projection plane a is in the range of 110 ° to 120 °, which is most suitable. If the angle theta is selected to be too large or too small, the interference of the flat wire can be caused; meanwhile, when the span between the first straight line part 10 and the second straight line part 20 is constant, different θ angles have a great influence on the height of the flat wire head, and an excessively large θ angle may cause an excessively long assembled flat wire head, which may result in an increase in cost and an incompact structure, thereby affecting the performance of the motor.
Further, when viewed from the transition portion 50 of the flat wire toward the tail portion of the flat wire, a plane perpendicular to the projection plane a is a top plan b, as shown in fig. 4 and 5; when the first connecting part 30, the second connecting part 40 and the transition part 50 of the flat wire head are designed, a three-dimensional line segment can be formed by intersecting two-dimensional line segments in the projection plane a and the top plane b, and the three-dimensional line segment is formed by scanning through modeling software.
Preferably, the flat wire is made of an enameled flat copper wire. Of course, the possibility of using other materials that can be used for the stator winding is not excluded.
Preferably, the flat wire is of an integrally formed stamping structure. The structure of the device is rigid enough, the forming quality is good, the device is beneficial to batch production, and the production efficiency is improved.
Preferably, the first leg 60 is disposed at the other end of the first linear portion 10, and the second leg 70 is disposed at the other end of the second linear portion 20, wherein the first leg 60 and the second leg 70 are bent in opposite directions to the outside or in the same direction along one side.
In specific implementation, as shown in fig. 7, 8 and 9, the first leg 60 is disposed at the other end of the first linear portion 10, and the second leg 70 is disposed at the other end of the second linear portion 20; after the flat wire is inserted into the motor stator, the first supporting leg 60 and the second supporting leg 70 are twisted and bent outwards in the reverse direction or twisted and bent along one side in the same direction through a wire twisting device, and particularly, the twisting and bending are performed according to the winding wiring mode of the actual motor stator, so that the subsequent welding between the supporting legs is facilitated.
Preferably, the ends of the first leg 60 and the second leg 70 are provided with chamfers, so that the insertion of the stator core 200 is facilitated, and meanwhile, the risk of scratching the paint skin of the adjacent flat wire during the insertion can be reduced, and the reliability of the motor is improved. In addition, welding is also facilitated.
The utility model also provides a stator assembly, which comprises a stator core 2 and a stator winding 1, wherein a plurality of stator slots are arranged on the inner wall of the stator core 2 at intervals along the circumferential direction of the stator core, the stator winding 1 is arranged in each stator slot, the stator winding 1 is composed of flat wires which are regularly arranged, and the flat wires are the flat wires for the flat wire motor. As shown in fig. 10, after the flat wires formed by stamping are assembled into the stator core, the structure is compact, no interference is generated between adjacent flat wires, the height of the head of the flat wire occupies small space, the cost is effectively saved, and the performance of the stator assembly is better. Specifically, as can be seen from fig. 2 and 10, the stator assembly using the flat wire provided by the utility model has a more compact structure and occupies a smaller space.
In summary, the method for applying the flat wire to the stator assembly includes:
s1, flat wire forming, namely stamping the straight flat wire with the high length-width ratio into a U-shaped flat wire line type with a first straight line part, a second straight line part, a first connecting part, a second connecting part and a transition part at one time through stamping forming equipment;
s2, inserting wires, and automatically inserting the flat wires into stator slots of a stator core in a stator assembly according to a certain arrangement rule through grabbing equipment;
s3, twisting the wires, and twisting the tail ends of the first linear part and the second linear part of the flat wire in the radial direction of the stator assembly according to different winding methods to form a first supporting leg and a second supporting leg;
and S4, welding the first support leg and the second support leg.
The utility model also provides a flat wire motor, which adopts the flat wire for the flat wire motor. The effects and actions are as described above and will not be described in detail herein.
In addition, it will be appreciated by those skilled in the art that, although there may be many problems with the prior art, each embodiment or aspect of the present invention may be improved only in one or several respects, without necessarily simultaneously solving all the technical problems listed in the prior art or in the background. It will be understood by those skilled in the art that nothing in a claim should be taken as a limitation on that claim.
Although terms such as first straight portion, second straight portion, first connection portion, second connection portion, transition portion, first leg, second leg, stator core, stator winding, etc. are used more herein, the possibility of using other terms is not excluded. These terms are used merely to more conveniently describe and explain the nature of the present invention; they are to be construed as being without limitation to any additional limitations that may be imposed by the spirit of the present invention; the terms "first," "second," and the like in the description and in the claims, and in the drawings, if any, are used for distinguishing between similar elements and not necessarily for describing a particular sequential or chronological order.
Finally, it should be noted that: the above embodiments are only used to illustrate the technical solution of the present invention, and not to limit the same; while the utility model has been described in detail and with reference to the foregoing embodiments, it will be understood by those skilled in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some or all of the technical features may be equivalently replaced; and the modifications or the substitutions do not make the essence of the corresponding technical solutions depart from the scope of the technical solutions of the embodiments of the present invention.
Claims (9)
1. The utility model provides a flat wire for flat wire motor which characterized in that: the stator structure comprises a first straight line part (10) and a second straight line part (20) which are embedded into a stator slot, wherein one end of the first straight line part (10) is connected with a first connecting part (30), one end of the second straight line part (20) is connected with a second connecting part (40), and the first connecting part (30) is connected with the second connecting part (40) through a transition part (50); wherein the first connecting part (30) is connected with the transition part (50) in a bending way, and the radius of the bending radian of the first connecting part is R1Greater than or equal to the length of the cross section of the flat wire.
2. The flat wire for a flat wire motor according to claim 1, characterized in that: the second connecting part (40) is connected with the transition part (50) in a bending way, and the radius of the bending radian of the second connecting part (40) is R2Greater than or equal to 1.2 times of the width of the section of the flat wire.
3. The flat wire for a flat wire motor according to claim 1, characterized in that: the included angles between the first straight line part (10) and the first connecting part (30), between the first connecting part (30) and the second connecting part (40) and between the second connecting part (40) and the second straight line part (20) are all obtuse angles.
4. The flat wire for a flat wire motor according to claim 3, characterized in that: when viewed from the plane orthographic projection determined by the first straight line part (10) and the second straight line part (20) of the flat wire, the projection included angle theta between the first connecting part (30) and the second connecting part (40) is larger than or equal to 110 degrees and smaller than or equal to 120 degrees.
5. The flat wire for a flat wire motor according to claim 1, characterized in that: the flat wire is made of enameled copper flat wires.
6. The flat wire for a flat wire motor according to any one of claims 1 to 5, characterized in that: the flat wire is of an integrally formed stamping structure.
7. The flat wire for a flat wire motor according to claim 6, characterized in that: the novel straight line part comprises a first straight line part (10) and a second straight line part (20), and further comprises a first supporting leg (60) arranged at the other end of the first straight line part (10) and a second supporting leg (70) arranged at the other end of the second straight line part (20), wherein the first supporting leg (60) and the second supporting leg (70) are bent towards the outer side in the opposite direction or are bent along one side in the same direction.
8. A stator assembly, characterized by: the stator comprises a stator core (2) and a stator winding (1), wherein a plurality of stator slots are arranged on the inner wall of the stator core (2) at intervals along the circumferential direction of the stator core, the stator winding (1) is arranged in each stator slot, the stator winding (1) is composed of flat wires which are regularly arranged, and the flat wires are the flat wires for the flat wire motor according to any one of claims 1 to 7.
9. A flat wire motor is characterized in that: use of a flat wire according to any of claims 1-7 for a flat wire electrical machine.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202122410052.4U CN216216160U (en) | 2021-09-30 | 2021-09-30 | Flat wire for flat wire motor, stator assembly and flat wire motor |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202122410052.4U CN216216160U (en) | 2021-09-30 | 2021-09-30 | Flat wire for flat wire motor, stator assembly and flat wire motor |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN216216160U true CN216216160U (en) | 2022-04-05 |
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Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202122410052.4U Active CN216216160U (en) | 2021-09-30 | 2021-09-30 | Flat wire for flat wire motor, stator assembly and flat wire motor |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN216216160U (en) |
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2021
- 2021-09-30 CN CN202122410052.4U patent/CN216216160U/en active Active
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