CN220797915U

CN220797915U - Stator assembly, motor, power assembly and vehicle

Info

Publication number: CN220797915U
Application number: CN202322337542.5U
Authority: CN
Inventors: 周涛; 李耀歧; 田凯丽
Original assignee: BYD Co Ltd
Current assignee: BYD Co Ltd
Priority date: 2023-08-29
Filing date: 2023-08-29
Publication date: 2024-04-16
Anticipated expiration: 2033-08-29

Abstract

The application discloses a stator module, motor, power assembly and vehicle. The stator assembly comprises a stator core and stator windings. M stator slots are distributed on the inner wall surface of the stator core along the circumferential direction, and N slot layers are distributed on the stator slots along the radial direction of the stator core. The stator winding comprises three-phase windings arranged on the stator core, and each phase winding comprises a plurality of flat wire hairpin connected with M stator slots; the flat wire hairpin in each phase winding comprises a plurality of same-layer hairpin and a plurality of cross-layer hairpin, and the flat wire hairpin is arranged along the radial direction of the stator core; the span of the same-layer card sender is i, j or k, the span of the cross-layer card sender is i, the whole distance of the winding is h, and i is less than h=j less than k, or i is less than h less than j=k. Compared with the existing stator assembly, the stator assembly has the advantages of less required card issuing types, simple manufacturing process, reduced production cost and easy realization of mass production.

Description

Stator assembly, motor, power assembly and vehicle

Technical Field

The application relates to the technical field of driving devices, in particular to a stator assembly, a motor, a power assembly and a vehicle.

Background

In the related art, the stator winding comprises a plurality of hairpin coils, and the plurality of hairpin coils penetrate into slots of a stator core according to a certain arrangement mode to form the required windings of a single-phase motor or a multi-phase motor. However, in most of the existing motors, the types of hairpin coils used for the stator windings are large, the manufacturing process is complex, the production cost is high, and the processing efficiency is low.

Disclosure of Invention

The present application aims to solve at least one of the problems with the prior art. Therefore, the stator assembly, the motor, the power assembly and the vehicle are provided, the number of the required hair-clamping types of the stator assembly is small, the manufacturing process is simple, the production cost is reduced, and the mass production is easy to realize.

To achieve the above object, a first aspect of the present application provides a stator assembly including a stator core and a stator winding. M stator slots are circumferentially distributed on the inner wall surface of the stator core, the stator slots penetrate through the stator core along the axial direction of the stator core, the stator slots comprise N slot layers radially distributed along the stator core, M is a multiple of 3 and an even number, and N is an even number greater than or equal to 4; the stator winding comprises a three-phase winding arranged on the stator core, each phase winding comprises a plurality of flat wire hairpins connected with M stator slots, each flat wire hairpin comprises a pair of in-slot conductor parts inserted into different stator slots, and each slot layer of each stator slot accommodates one in-slot conductor part; the flat wire hairpin in each phase winding comprises a plurality of same-layer hairpin and a plurality of cross-layer hairpin, the same-layer hairpin in each phase winding is positioned at the groove layers of the outermost layer and the innermost layer along the radial direction of the stator core, the cross-layer hairpin is positioned at the middle groove layer, the groove layers of a pair of inner groove conductor parts of the same-layer hairpin are the same two groove layers, and the groove layers of a pair of inner groove conductor parts of the cross-layer hairpin are two adjacent groove layers; the span of the same-layer card clips at the innermost layer and the span of the cross-layer card clips are i, the span of the same-layer card clips at the outermost layer is j and k, the whole distance of each phase winding is h, i is less than h=j less than k, or i is less than h less than j=k.

In one embodiment, the number of stator slots is 48, each stator slot includes 6 slot layers, and the stator assembly is configured to be used with an electric machine having an electric machine pole number of 8; the cross-layer hairpin comprises a first cross-layer hairpin, a second cross-layer hairpin and a third cross-layer hairpin, and the spans of the first cross-layer hairpin, the second cross-layer hairpin and the third cross-layer hairpin are all 5; the same-layer hairpin comprises a first same-layer hairpin, a second same-layer hairpin and a third same-layer hairpin, wherein the span of the first same-layer hairpin is 5, the span of the second same-layer hairpin is 6, the span of the third same-layer hairpin is 7, the first same-layer hairpin is located on the innermost groove layer, and the second same-layer hairpin and the third same-layer hairpin are located on the outermost groove layer.

In one embodiment, each phase winding comprises two first hairpin groups, a plurality of second hairpin groups and a plurality of third hairpin groups connected in series in a preset order; the first card issuing group is formed by serially connecting a second same-layer card issuing, two third cross-layer card issuing, two second cross-layer card issuing and a first cross-layer card issuing in a set sequence, and the second card issuing group is formed by serially connecting a third same-layer card issuing, two third cross-layer card issuing, two second cross-layer card issuing and a first cross-layer card issuing in the set sequence; the third card issuing group is formed by serially connecting a first same-layer card issuing, a first cross-layer card issuing, two second cross-layer card issuing and two third cross-layer card issuing in a set sequence.

In one embodiment, 48 stator slots are numbered 1, 2, … …,48, 6 slots are numbered a, b, c, d, e, f in sequence along the radial direction of the stator core, a is the innermost layer, f is the outermost layer, and the winding sequence of one phase of the windings is as follows:

1f-43f-38e-43d-38c-43b-38a-33a-38b-33c-38d-33e-38f-31f-26e-31d-26c-31b-26a-21a-26b-21c-26d-21e-26f-19f-14e-19d-14c-19b-14a-9a-14b-9c-14d-9e-14f-7f-2e-7d-2c-7b-2a-45a-2b-45c-2d-45e-2f-8f-3e-8d-3c-8b-3a-8a-13b-8c-13d-8e-13f-20f-15e-20d-15c-20b-15a-20a-25b-20c-25d-20e-25f-32f-27e-32d-27c-32b-27a-32a-37b-32c-37d-32e-37f-44f-39e-44d-39c-44b-39a-44a-1b-44c-1d-44e。

in one embodiment, the three phases of the windings are symmetrically distributed, and each phase of the windings is separated by two stator slots.

In one embodiment, each flat wire hairpin further comprises a bending part and a pair of welding parts, wherein two ends of the bending part are respectively connected with the same ends of the pair of in-slot conductor parts, and the pair of welding parts are respectively connected with the other ends of the pair of in-slot conductor parts; the stator core is provided with two sides which are opposite along the axial direction, the bending part of each flat wire hairpin is positioned at one side of the stator core, and the welding part of each flat wire hairpin is positioned at the other side of the stator core.

In one embodiment, each of the flat wire clips further includes a pair of connection portions through which the solder portion is connected to the in-slot conductor portion; the same-layer hairpin and the first cross-layer hairpin are parallel in bending direction of the pair of connecting parts, and the second cross-layer hairpin and the third cross-layer hairpin are symmetrically arranged and opposite in bending direction.

In one embodiment, all outgoing lines and star points of the three-phase winding are concentrated in a 6 th slot layer of a different stator slot, and all star points of the three-phase winding are concentrated in a 5 th slot layer of a different stator slot.

In one embodiment, the number of stator slots is 48, each stator slot includes 6 slot layers, and the stator assembly is configured to be used with an electric machine having an electric machine pole number of 8; the cross-layer hairpin comprises a first cross-layer hairpin, a second cross-layer hairpin and a third cross-layer hairpin, and the spans of the first cross-layer hairpin, the second cross-layer hairpin and the third cross-layer hairpin are all 5; the same-layer hair clip comprises a first same-layer hair clip, a second same-layer hair clip and a third same-layer hair clip, wherein the span of the first same-layer hair clip is 5, the span of the second same-layer hair clip and the span of the third same-layer hair clip are both 7, the first same-layer hair clip is positioned on the innermost layer of the groove layer, and the second same-layer hair clip and the third same-layer hair clip are positioned on the outermost layer of the groove layer.

In one embodiment, each phase winding comprises two parallel sub-windings, each sub-winding comprises a plurality of first hairpin groups and a plurality of second hairpin groups which are connected in series in a preset sequence; the first card issuing group is formed by serially connecting a second same-layer card issuing, two third cross-layer card issuing, two second cross-layer card issuing and a first cross-layer card issuing in a set sequence, and the second card issuing group is formed by serially connecting a first same-layer card issuing, a first cross-layer card issuing, two second cross-layer card issuing and two third cross-layer card issuing in the set sequence.

In one embodiment, 48 stator slots are numbered 1, 2, … …,48, 6 slot layers are numbered a, b, c, d, e, f in sequence along the radial direction of the stator core, a is the innermost layer, f is the outermost layer, and one phase of the winding is formed by connecting two groups of sub-windings in parallel:

the winding sequence of one of the sub windings is as follows:

1f-8f-3e-8d-3c-8b-3a-8a-13b-8c-13d-8e-13f-20f-15e-20d-15c-20b-15a-20a-25b-20c-25d-20e-25f-32f-27e-32d-27c-32b-27a-32a-37b-32c-37d-32e-37f-44f-39e-44d-39c-44b-39a-44a-1b-44c-1d-44e；

the winding sequence of the other sub-winding is as follows:

7f-14f-9e-14d-9c-14b-9a-14a-19b-14c-19d-14e-19f-26f-21e-26d-21c-26b-21a-26a-31b-26c-31d-26e-31f-38f-33e-38d-33c-38b-33a-38a-43b-38c-43d-38e-43f-2f-45e-2d-45c-2b-45a-2a-7b-2c-7d-2e。

In one embodiment, all outgoing lines of the three-phase winding are intensively distributed on the 6 th slot layer of the different stator slots, and all star point lines of the three-phase winding are intensively distributed on the 5 th slot layer of the different stator slots.

A second aspect of the present application provides an electric machine, including a rotor and a stator assembly according to any one of the above phases, wherein the rotor is disposed in the stator assembly in a penetrating manner and is rotatable relative to the stator assembly.

The third aspect of the application provides a power assembly, which comprises a speed reducer and the motor, wherein the speed reducer is in transmission connection with the motor.

A fourth aspect of the present application provides a vehicle comprising a powertrain as described above.

The application provides a stator assembly, including stator core and stator winding. M stator slots are circumferentially distributed on the inner wall surface of the stator core, the stator slots penetrate through the stator core along the axial direction of the stator core, the stator slots comprise N slot layers radially distributed along the stator core, M is a multiple of 3 and an even number, and N is an even number greater than or equal to 4; the stator winding comprises a three-phase winding arranged on the stator core, each phase winding comprises a plurality of flat wire hairpins connected with M stator slots, each flat wire hairpin comprises a pair of in-slot conductor parts inserted into different stator slots, and each slot layer of each stator slot accommodates one in-slot conductor part; the flat wire hairpin in each phase winding comprises a plurality of same-layer hairpin and a plurality of cross-layer hairpin, the same-layer hairpin in each phase winding is positioned at the groove layers of the outermost layer and the innermost layer along the radial direction of the stator core, the cross-layer hairpin is positioned at the middle groove layer, the groove layers of a pair of inner groove conductor parts of the same-layer hairpin are the same two groove layers, and the groove layers of a pair of inner groove conductor parts of the cross-layer hairpin are two adjacent groove layers; the span of the same-layer card clips at the innermost layer and the span of the cross-layer card clips are i, the span of the same-layer card clips at the outermost layer is j and k, the whole distance of each phase winding is h, i is less than h=j less than k, or i is less than h less than j=k.

In this application, each phase winding is formed by a plurality of same-layer hairpin and a plurality of cross-layer hairpin with specific order coiling, compares in current stator module, and stator module needs the hairpin kind few, and manufacturing process is simple, has reduced manufacturing cost, realizes batch production moreover easily.

In addition, in the application, part of the cards are short-distance cards (the cards with the span of i), and compared with the whole-distance cards (the cards with the span of j), the short-distance cards have the advantages of reduced height, material saving and cost reduction.

Additional aspects and advantages of the application will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the application.

Drawings

In order to more clearly illustrate the technical solutions of the present application, the drawings that are required to be used in the embodiments will be briefly described below.

Fig. 1 is a diagram of any one phase winding layout of a stator assembly provided in an embodiment of the present application.

Fig. 2 is a three-phase winding wiring diagram in a stator assembly provided in an embodiment of the present application.

Fig. 3 is a three-dimensional schematic diagram of a stator assembly provided in an embodiment of the present application.

Fig. 4 is a schematic diagram of a first sandwich hairpin structure in a stator assembly according to an embodiment of the disclosure.

Fig. 5 is a schematic diagram of a first cross-layer hairpin structure in a stator assembly according to an embodiment of the disclosure.

Fig. 6 is a schematic diagram of a second cross-layer hairpin structure in a stator assembly according to an embodiment of the disclosure.

Fig. 7 is a schematic diagram of a third cross-layer hairpin structure in a stator assembly according to an embodiment of the disclosure.

Fig. 8 is a schematic diagram of a third identical layer hairpin structure in a stator assembly according to an embodiment of the disclosure.

Fig. 9 is a schematic diagram of a second identical layer hairpin structure in a stator assembly according to an embodiment of the disclosure.

Fig. 10 is a 1 st wiring diagram in one of the three-phase two-phase windings.

Fig. 11 is a 2 nd wiring diagram in one of the three-phase two-phase windings.

Fig. 12 is a three-phase two-way wiring diagram.

Fig. 13 is a schematic three-phase two-way three-dimensional structure of a stator core.

Fig. 14 is a schematic view of stator slots in a stator core.

Reference numerals illustrate: 100-stator core; 110-stator slots; 200-stator windings; 210-a first phase winding; 220-a second phase winding; 230-a third phase winding; 300-flat wire hairpin; 301-a conductor section in the slot; 302-bending part; 303-weld; 304-a connection; 310-first layer hairpins; 320-second same-layer card issuing; 330-third same-layer hairpin; 340-a first cross-layer hairpin; 350-second cross-layer card issuing; 360-third cross-layer card issuing; 400-star point lines; 500-outgoing lines; 600-connection terminals.

Detailed Description

The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application.

Referring to fig. 2 and 3, a stator assembly according to a first aspect of the present embodiment includes a stator core 100 and a stator winding 200. The stator winding 200 includes three-phase windings, i.e., a first phase winding 210, a second phase winding 220, and a third phase winding 230, wherein the first phase winding 210 may be a U-phase winding, the second phase winding 220 may be a V-phase winding, the third phase winding 230 may be a W-phase winding, and the three-phase windings are different from each other in electrical phase, and it will be understood by those skilled in the art that the winding manner of each of the three-phase windings is the same and only different from each other in electrical phase, therefore, the winding manner of any one of the three-phase windings will be described in detail hereinafter, and the winding manners of the other two-phase windings will be referred to in analogy, and will not be described in detail.

Referring to fig. 3, 13 and 14, in the embodiment of the present application, the stator core 100 is in a hollow cylindrical structure, the stator core 100 is axially provided with through holes penetrating through two ends, and the stator core 100 has an outer wall and an inner wall disposed opposite to each other in a radial direction. The inner wall of the stator core 100 (i.e., the inner wall of the through hole) is circumferentially provided with M stator slots 110 distributed at preset slot pitch intervals, each stator slot 110 is a bar-shaped slot extending along the axial direction of the stator core 100 to penetrate through opposite ends of the stator core 100, where M is a multiple of 3 and an even number, and it can be understood by those skilled in the art that the M stator slots 110 are equally distributed along the circumferential direction. The stator slot 110 includes N slot layers distributed in a radial direction of the stator core 100, N being an even number greater than or equal to 4.

The stator core 100 may be used in a motor having a number of poles of 8, and a stator core having 48 stator slots 110, each of which stator slots 110 includes 6 slot layers, will be described in detail. The 48 stator slots 110 and the 6 slot layers of the stator core 100 are numbered first, and the 48 stator slots 110 are numbered sequentially with 1, 2, … … and 48 along the circumferential direction, which may be, of course, clockwise or counterclockwise, without affecting the implementation of the embodiments of the present application. The 6 slot layers are numbered a, b, c, d, e, f sequentially in the radial direction of the stator core 100, a being the innermost layer and f being the outermost layer. It will be appreciated by those skilled in the art that the innermost layer is the side of the inner wall of the stator core and the outermost layer is the side adjacent to the outer wall of the stator core 100. Thus, each slot layer will have a unique reference numeral, for example, layer 1 of slot 1 may be denoted by 1a, and likewise layer 6 of slot 48 may be denoted by numeral 48 f. It will also be appreciated by those skilled in the art that since the stator slots 110 are arranged circumferentially, slot 49 will occur subsequently due to the span calculation, i.e., a wrap is completed, back to slot 1, i.e., slot 49 is slot 1, and so on.

Referring to fig. 1 to 9 and 14, the stator winding 200 includes three-phase windings mounted on the stator core 100, each phase winding includes a plurality of flat wire clips 300 connected to the M stator slots 110, each flat wire clip 300 includes a pair of in-slot conductor portions 301 inserted into different stator slots 110, and each slot layer of each stator slot 110 accommodates one of the in-slot conductor portions 301. That is, the stator slot 110 having N slot layers is inserted with the in-slot conductor portions 301 of the N flat wire hairpin 300, and the in-slot conductor portions 301 of the N flat wire hairpin 300 are stacked in one stator slot 110, thereby dividing the stator slot 110 into N layers. In the embodiment of the present application, the stator slot 110 has 6 slot layers, that is, the slot conductor portion 301 in which 6 flat wire clips 300 are stacked in one stator slot 110. It will also be appreciated by those skilled in the art that insulating paper is also provided between the in-slot conductor portions 301 between adjacent two slot layers in the same stator slot 110.

Further, in this embodiment of the present application, the span of the same-layer card clips located at the innermost layer and the span of the cross-layer card clips are i, the span of the same-layer card clips located at the outermost layer are j and k, the whole distance of each phase winding is h, and i < h=j < k, or i < h < j=k. As will be appreciated by those skilled in the art, when i < h=j < k, the windings are arranged one way in one phase; when i < h < j=k, the windings are arranged in one phase and two paths. i. h, j and k are positive integers.

It will also be understood by those skilled in the art that the span is the number of stator slots 110 spaced between the stator slots 110 in which the two in-slot conductor portions 301 of one flat wire hairpin 300 are located, for example, one in-slot conductor portion 301 of one flat wire hairpin 300 is located in the 1 st stator slot 110, the other in-slot conductor portion 301 of the flat wire hairpin 300 is located in the 7 th stator slot 110, the span of the flat wire hairpin 300 is 6 (7-1=6), and for example, one in-slot conductor portion 301 of one flat wire hairpin 300 is located in the 7 th stator slot 110, and if the span of the flat wire hairpin 300 is 6, the other in-slot conductor portion 301 of the flat wire hairpin 300 is located in the 1 st stator slot 110 (7-6=1) or 13 (7+6=13).

Further, the same-layer hairpins in each phase of the winding are located at the slot layers of the outermost layer and the innermost layer in the radial direction of the stator core 100. Specifically, for example, one of the in-slot conductor portions 301 of the same-layer card having a span i is located in the f-layer slot layer of the 1 st stator slot 110, and then the other of the in-slot conductor portions 301 of the same-layer card is located in the f-layer slot layer of the 1 st ±i stator slot 110. The cross-layer hairpin is located in the middle of the groove layers, the groove layers where the pair of in-groove conductor parts 301 of the same-layer hairpin are located are the same two groove layers, and the groove layers where the pair of in-groove conductor parts 301 of the cross-layer hairpin are located are two adjacent groove layers. It will also be appreciated that, for example, one of the in-slot conductor portions 301 of a cross-layer hairpin having a span i is located in the b-th slot layer of the 1 st stator slot 110, then the other in-slot conductor portion 301 of the cross-layer hairpin is located in the a-th slot layer or c-th slot layer of the 1 st ± i stator slot 110, i.e. the two slot layers in which the two in-slot conductor portions 301 of the same cross-layer hairpin are located differ by 1 in the radial direction of the stator core.

In this application embodiment, each phase winding is formed by a plurality of same-layer hairpin and a plurality of cross-layer hairpin according to specific order coiling, compares in current stator module, and the stator module in this application embodiment needs the hairpin kind few, and manufacturing process is simple, has reduced manufacturing cost, realizes batch production easily moreover. Since the whole distance of each phase winding is h, it will be understood by those skilled in the art that the whole distance h is the number of slots M of the stator core divided by the number of slots N, and in this application, part of the hair pins are short-distance hair pins (i-span hair pins), the height of the short-distance hair pins is reduced compared to the whole-distance hair pins (j-span hair pins), and the material is saved and the cost is reduced.

Referring to fig. 3 to 9 and fig. 13, in one embodiment, each flat wire hairpin 300 further includes a bending portion 302 and a pair of welding portions 303, wherein two ends of the bending portion 302 are respectively connected to the same ends of the pair of in-slot conductor portions 301, and the pair of welding portions 303 are respectively connected to the other ends of the pair of in-slot conductor portions 301; the stator core 100 has two opposite sides along the axial direction, the bending portion 302 of each flat wire hairpin 300 is located at one side of the stator core 100, and the welding portion 303 of each flat wire hairpin 300 is located at the other side of the stator core 100. In this embodiment of the present application, the bending portions 302 of all the flat wire hairpin 300 are located at one side of the stator assembly along the axial direction, and the welding portions 303 of all the flat wire hairpin 300 are located at the other side of the stator assembly along the axial direction, so that it can be ensured that the flat wire hairpin 300 can be more regular during winding. As will be appreciated by those skilled in the art, one end of each of the two in-slot conductor portions 301 of the flat wire hairpin 300 is connected by the bent portion 302, and the welded portion 303 of the flat wire hairpin 300 may be connected in welded communication with the welded portion 303 of an adjacent flat wire hairpin 300. In this manner, a plurality of flat wire clips 300 for each phase winding may be connected in series.

With continued reference to fig. 3-9 and 13, in one embodiment, each flat wire hairpin 300 further includes a pair of connection portions 304, and the soldering portion 303 is connected to the in-slot conductor portion 301 through the connection portions 304. In this embodiment, by adding the connection portion 304 to the welding portion 303 of the off-line hairpin, the final position of the welding portion 303 can be changed by bending the connection portion 304, so that welding between adjacent flat wire hairpin 300 can be facilitated.

Referring to fig. 1 to 9, in a specific embodiment, the cross-layer card issuer includes a first cross-layer card issuer 340, a second cross-layer card issuer 350, and a third cross-layer card issuer 360, where a span i of the first cross-layer card issuer 340, the second cross-layer card issuer 350, and the third cross-layer card issuer 360 is 5; the co-layer card sender comprises a first co-layer card sender 310, a second co-layer card sender 320 and a third co-layer card sender 330, wherein the span i of the first co-layer card sender 310 is 5, the span j of the second co-layer card sender 320 is 6, the span k of the third co-layer card sender 330 is 7, the first co-layer card sender 310 is positioned on the innermost layer of the groove layer, and the second co-layer card sender 320 and the third co-layer card sender 330 are positioned on the outermost layer of the groove layer. In this embodiment, the first cross-layer card sender 340 and the first same-layer card sender 310 have the same structure. In this application embodiment, to 48 slot 8 utmost point motors, its whole distance h is 6, and this application adopts short moment winding, and the span is little, and the tip compares whole distance height reduction, can eliminate 5/7 th harmonic.

To accommodate such a cross-layer card and the co-layer card, a phase winding is wound, in this embodiment, the bending directions of the pair of connection portions 304 of the first co-layer card 310, the second co-layer card 320, the third co-layer card 330 and the first cross-layer card 340 are parallel, that is, the pair of welding portions 303 of the first co-layer card 310, the second co-layer card 320, the third co-layer card 330 and the first cross-layer card 340 are bent and arranged in parallel in one direction. The pair of connection portions 304 of the second cross-layer card sender 350 and the third cross-layer card sender 360 are symmetrically arranged and have opposite bending directions, that is, the pair of welding portions 303 of the second cross-layer card sender 350 and the third cross-layer card sender 360 are close to each other.

It will be appreciated by those skilled in the art that the bending direction of the welding portion 303 of the flat wire hairpin 300 in the embodiment of the application is to facilitate the welding connection of the flat wire hairpin 300 in each phase winding in the embodiment of the application. In particular, in the embodiment of the present application, the first peer card 310 is located in the a-th slot layer; the second co-layer hairpin 320 and the third co-layer hairpin 330 are located in the f-layer slot layer; two in-slot conductor portions 301 in the first cross-layer hairpin 340 are located in the a-th and b-th slot layers, respectively; the two in-slot conductor portions 301 of the second cross-layer hairpin 350 are located in the b-th and c-th slot layers, or the c-th and d-th slot layers, respectively; the two in-slot conductor portions 301 of the third cross-layer hairpin 360 are located in the d-th and e-th slot layers, or the e-th and f-th slot layers, respectively.

Of course, according to different winding manners of each phase winding, the connection portions 304 of the flat wire hairpin 300 may have different bending directions, for example, a pair of connection portions 304 in the flat wire hairpin 300 may be far away from each other, so long as the welding portions 303 of the flat wire hairpin 300 are convenient to weld.

Referring to fig. 1 and 3, in one embodiment, each phase winding includes two first hairpin groups, a plurality of second hairpin groups, and a plurality of third hairpin groups connected in series in a predetermined order; the first card issuing group is formed by serially connecting a second same-layer card issuing 320, two third cross-layer card issuing 360, two second cross-layer card issuing 350 and a first cross-layer card issuing 340 in a set sequence, and the second card issuing group is formed by serially connecting a third same-layer card issuing 330, two third cross-layer card issuing 360, two second cross-layer card issuing 350 and the first cross-layer card issuing 340 in the set sequence; the third card group is formed by serially connecting a first same-layer card sender 310, a first cross-layer card sender 340, two second cross-layer card senders 350 and two third cross-layer card senders 360 in a set order.

Specifically, please continue to refer to fig. 1, in fig. 1, X pulls out the outgoing line from 1f, and a pulls out the star point line from 44 e. In an 8-pole 48-slot stator assembly, one phase is routed:

In combination with the arrangement positions of the first co-layer card clip 310, the second co-layer card clip 320, the third co-layer card clip 330, the first cross-layer card clip 340, the second cross-layer card clip 350, and the third cross-layer card clip 360 in the radial direction of the stator core 100, and the relationship between the span of each type of the flat wire card clip 300 and the slot layers where the pair of in-slot conductor portions 301 are located, the serial order of the plurality of flat wire card clips 300 in any one phase winding in the 48 stator slots 110 can be known as follows:

second same-layer card sender 320- & gt third cross-layer card sender 360- & gt second cross-layer card sender 350- & gt first cross-layer card sender 340- & gt (first card sender group)

First same-layer hairpin 310- & gt first cross-layer hairpin 340- & gt second cross-layer hairpin 350- & gt third cross-layer hairpin 360- & gt (third hairpin group)

Third same-layer hairpin 330- & gt third cross-layer hairpin 360- & gt second cross-layer hairpin 350- & gt first cross-layer hairpin 340- & gt (second hairpin group)

First same-layer card sender 310- & gt first cross-layer card sender 340- & gt second cross-layer card sender 350- & gt third cross-layer card sender 360. (third hairpin group)

Referring to fig. 2 and 3, it is also known to those skilled in the art that the three-phase windings are symmetrically distributed, and two stator slots 110 are spaced between each phase of windings. I.e. for example the first phase winding 210 starts from 1f, the second phase winding 220 starts from 3f and the third phase winding 230 starts from 5 f. Referring to fig. 2 and 3, more specifically, the first phase winding 210 starts at 1f and ends at 44e; the second phase winding 220 may start at 3f and end at 46e; the third phase winding 230 starts from phase 5f and ends at 48e. The winding manner of the hairpin coil in each winding may be referred to the above description, and will not be repeated here.

Referring to fig. 2 and 3, all outgoing lines 500 of the three-phase winding are concentrated in the 6 th slot layer of the different stator slots 110, and all star points 400 of the three-phase winding are concentrated in the 5 th slot layer of the different stator slots 110. And the star point lines 400 are all arranged at the welding ends, and the outgoing lines 500 are respectively connected with the star point lines 400 and uniformly distributed, so that the height of the welding ends can be fully utilized. As shown in fig. 2, wherein a draws the lead of the first phase winding 210 from 1f, B draws the lead of the second phase winding 220 from 3f, C draws the lead of the third phase winding 230 from 5 f; wherein X draws the star point of the first phase winding 210 from 44e, Y draws the star point of the second phase winding 220 from 46e, and Z draws the star point of the third phase winding 230 from 48 e. As can be appreciated by those skilled in the art, in the embodiment of the present application, the welding operation of the bus bars is facilitated by intensively distributing all the outgoing lines 500 and the star point lines 400 of the three-phase winding on the radially outermost slot layer of the stator core 100. Those skilled in the art will also appreciate that a terminal 600 is also connected to the other end of the outlet 500 to facilitate connection.

Referring to fig. 10 to 13, the present application further provides an embodiment of a wiring manner of the flat wire hairpin 300, in which the number of the stator slots 110 is 48, each stator slot 110 includes 6 slot layers, and the stator assembly is configured to be used with a motor having a motor pole number of 8; the cross-layer card sender comprises a first cross-layer card sender 340, a second cross-layer card sender 350 and a third cross-layer card sender 360, wherein the spans of the first cross-layer card sender 340, the second cross-layer card sender 350 and the third cross-layer card sender 360 are all 5; the co-layer card sender comprises a first co-layer card sender 310, a second co-layer card sender 320 and a third co-layer card sender 330, wherein the span i of the first co-layer card sender 310 is 5, the span j of the second co-layer card sender 320 and the span k of the third co-layer card sender 330 are both 7, the first co-layer card sender 310 is located at the innermost layer of the groove layer, and the second co-layer card sender 320 and the third co-layer card sender 330 are located at the outermost layer of the groove layer. That is, in this embodiment, the same-layer card sender includes only two spans, that is, the span of the same-layer card sender at the f-th layer is 7, and the span of the same-layer card sender at the a-th layer is 5. With such a span setting, a 1-phase 2-way wiring pattern will be obtained, as shown in fig. 10 and 11. Fig. 10 is a 1 st wiring pattern in the 1-phase 2 wiring pattern, and fig. 11 is a 2 nd wiring pattern in the 1-phase 2 wiring pattern.

Specifically, please refer to fig. 10, wherein, A1 leads out a first path of outgoing line of the first phase winding 210 from 1f, X1 leads out a star point line of the first path of the first phase winding 210 from 44e, and a wiring diagram of the first path of the first phase is:

1f-8f-3e-8d-3c-8b-3a-8a-13b-8c-13d-8e-13f-20f-15e-20d-15c-20b-15a-20a-25b-20c-25d-20e-25f-32f-27e-32d-27c-32b-27a-32a-37b-32c-37d-32e-37f-44f-39e-44d-39c-44b-39a-44a-1b-44c-1d-44e。

referring to fig. 11, A2 is a lead wire of the second path of the first phase winding 210 from 7f, and X2 is a star point of the second path of the first phase winding 210 from 2 e. The wiring diagram of the first phase second path is as follows:

in combination with the arrangement positions of the first co-layer card 310, the second co-layer card 320, the third co-layer card 330, the first cross-layer card 340, the second cross-layer card 350, and the third cross-layer card 360 in the radial direction of the stator core 100, wherein the second co-layer card 320 and the third co-layer card 330 are the same, and the relationship between the span of each type of flat wire card 300 and the slot layers where the pair of in-slot conductor portions 301 are located, the serial connection sequence of the plurality of flat wire card 300 in the 1-phase 2-way winding in 48 stator slots 110 can be known as follows:

First same-layer hairpin 310- & gt first cross-layer hairpin 340- & gt second cross-layer hairpin 350- & gt third cross-layer hairpin 360- & gt (second hairpin group)

First same-layer card sender 310- & gt first cross-layer card sender 340- & gt second cross-layer card sender 350- & gt third cross-layer card sender 360. (second hairpin group)

The serial order of the plurality of flat wire hairpin 300 in the second one of the 1-phase 2 windings is as follows:

Further, please refer to fig. 12 and 13, which are three-phase two-way wiring diagrams, wherein, A1 leads out the lead-out wire of the first way of the first phase winding 210 from 1f, B1 leads out the lead-out wire of the first way of the second phase winding 220 from 5f, C1 leads out the lead-out wire of the first way of the third phase winding 230 from 9 f; a2 leads from 7f to the second leg of the first phase winding 210, B2 leads from 11f to the second leg of the second phase winding 220, and C2 leads from 15f to the second leg of the third phase winding 230.

Wherein X1 draws the star point line of the first path of the first phase winding 210 from 44e, Y1 draws the star point line of the first path of the second phase winding 220 from 48e, and Z1 draws the star point line of the first path of the third phase winding 230 from 4 e; wherein X2 draws the star point of the second path of the first phase winding 210 from 2e, Y2 draws the star point of the second path of the second phase winding 220 from 6e, and Z2 draws the star point of the second path of the third phase winding 230 from 10 e. It will also be appreciated by those skilled in the art that the two paths in each phase winding are in parallel.

It should be understood that, in this embodiment of the present application, the number of stator slots 110 of the stator core 100 may also be 96 slots, each stator slot 110 may include 12 slot layers, and each phase winding of the stator assembly may still be formed by a plurality of same-layer hairpins with a preset span and a plurality of cross-layer hairpins according to a preset arrangement manner, which will not be described herein.

A second aspect of the present application provides an embodiment of an electric machine, in which the electric machine comprises a rotor and a stator assembly according to any one of the phases described above, the rotor being disposed through the stator assembly and being rotatable relative to the stator assembly. The stator assembly includes all the technical solutions of all the embodiments, so at least has all the beneficial effects brought by the technical solutions of the embodiments, and will not be described in detail herein.

A third aspect of the present application provides an embodiment of a powertrain, in which the powertrain includes a speed reducer and the motor described above, the speed reducer being in driving connection with the motor. The motor of the powertrain includes the stator assembly, so that at least the stator assembly of the above embodiment has all the advantages, which are not described in detail herein.

A fourth aspect of the present application provides an embodiment of a vehicle in which the vehicle comprises a powertrain as described above. The power assembly of the vehicle includes the stator assembly, and therefore has at least all the advantages of the stator assembly of the above embodiments, which are not described in detail herein.

The vehicle may be an electric vehicle or an electric motorcycle, and is not limited thereto.

The foregoing has outlined rather broadly the more detailed description of embodiments of the present application, wherein specific examples are provided herein to illustrate the principles and embodiments of the present application, and wherein the above examples are provided to assist in the understanding of the methods and concepts of the present application.

Claims

1. A stator assembly, comprising: a stator core and a stator winding;

m stator slots are circumferentially distributed on the inner wall surface of the stator core, the stator slots penetrate through the stator core along the axial direction of the stator core, the stator slots comprise N slot layers radially distributed along the stator core, M is a multiple of 3 and an even number, and N is an even number greater than or equal to 4;

the stator winding comprises a three-phase winding arranged on the stator core, each phase winding comprises a plurality of flat wire hairpins connected with M stator slots, each flat wire hairpin comprises a pair of in-slot conductor parts inserted into different stator slots, and each slot layer of each stator slot accommodates one in-slot conductor part;

The flat wire hairpin in each phase winding comprises a plurality of same-layer hairpin and a plurality of cross-layer hairpin, the same-layer hairpin in each phase winding is positioned at the groove layers of the outermost layer and the innermost layer along the radial direction of the stator core, the cross-layer hairpin is positioned at the middle groove layer, the groove layers of a pair of inner groove conductor parts of the same-layer hairpin are the same two groove layers, and the groove layers of a pair of inner groove conductor parts of the cross-layer hairpin are two adjacent groove layers; the span of the same-layer card clips at the innermost layer and the span of the cross-layer card clips are i, the span of the same-layer card clips at the outermost layer is j and k, the whole distance of each phase winding is h, i is less than h=j less than k, or i is less than h less than j=k.

2. The stator assembly of claim 1, wherein the number of stator slots is 48, each stator slot comprising 6 slot layers, the stator assembly configured to be used with an electric machine having an electric machine pole count of 8;

the cross-layer hairpin comprises a first cross-layer hairpin, a second cross-layer hairpin and a third cross-layer hairpin, and the spans of the first cross-layer hairpin, the second cross-layer hairpin and the third cross-layer hairpin are all 5; the same-layer hairpin comprises a first same-layer hairpin, a second same-layer hairpin and a third same-layer hairpin, wherein the span of the first same-layer hairpin is 5, the span of the second same-layer hairpin is 6, the span of the third same-layer hairpin is 7, the first same-layer hairpin is located on the innermost groove layer, and the second same-layer hairpin and the third same-layer hairpin are located on the outermost groove layer.

3. The stator assembly of claim 2, wherein each phase winding comprises two first hairpin groups, a plurality of second hairpin groups, and a plurality of third hairpin groups in series in a predetermined order;

the first card issuing group is formed by serially connecting a second same-layer card issuing, two third cross-layer card issuing, two second cross-layer card issuing and a first cross-layer card issuing in a set sequence, and the second card issuing group is formed by serially connecting a third same-layer card issuing, two third cross-layer card issuing, two second cross-layer card issuing and a first cross-layer card issuing in the set sequence; the third card issuing group is formed by serially connecting a first same-layer card issuing, a first cross-layer card issuing, two second cross-layer card issuing and two third cross-layer card issuing in a set sequence.

4. A stator assembly according to claim 3, wherein 48 stator slots are numbered sequentially in the circumferential direction as 1, 2, … …,48, 6 slot layers are numbered sequentially in the radial direction of the stator core as a, b, c, d, e, f, a is the innermost layer, f is the outermost layer, and wherein the winding sequence of one phase of the windings is:

5. the stator assembly of claim 4 wherein the three phases of windings are symmetrically distributed and each phase of windings is separated by two stator slots.

6. A stator assembly in accordance with claim 3 wherein each of said flat wire clips further comprises a bent portion and a pair of welded portions, both ends of said bent portion being respectively connected to the same ends of a pair of in-slot conductor portions, and a pair of said welded portions being respectively connected to the other ends of a pair of in-slot conductor portions;

the stator core is provided with two sides which are opposite along the axial direction, the bending part of each flat wire hairpin is positioned at one side of the stator core, and the welding part of each flat wire hairpin is positioned at the other side of the stator core.

7. The stator assembly according to claim 6, wherein each of said flat wire clips further includes a pair of connection portions, said weld being connected to said in-slot conductor portions by said connection portions;

the same-layer hairpin and the first cross-layer hairpin are parallel in bending direction of the pair of connecting parts, and the second cross-layer hairpin and the third cross-layer hairpin are symmetrically arranged and opposite in bending direction.

8. The stator assembly of claim 2 wherein all outgoing lines of the three-phase winding are centrally located in a 6 th slot layer of a different one of the stator slots and all star points of the three-phase winding are centrally located in a 5 th slot layer of a different one of the stator slots.

9. The stator assembly of claim 1, wherein the number of stator slots is 48, each stator slot comprising 6 slot layers, the stator assembly configured to be used with an electric machine having an electric machine pole count of 8;

the cross-layer hairpin comprises a first cross-layer hairpin, a second cross-layer hairpin and a third cross-layer hairpin, and the spans of the first cross-layer hairpin, the second cross-layer hairpin and the third cross-layer hairpin are all 5; the same-layer hair clip comprises a first same-layer hair clip, a second same-layer hair clip and a third same-layer hair clip, wherein the span of the first same-layer hair clip is 5, the span of the second same-layer hair clip and the span of the third same-layer hair clip are both 7, the first same-layer hair clip is positioned on the innermost layer of the groove layer, and the second same-layer hair clip and the third same-layer hair clip are positioned on the outermost layer of the groove layer.

10. The stator assembly of claim 9, wherein each phase winding comprises two parallel sub-windings, each sub-winding comprising a plurality of first hairpin groups and a plurality of second hairpin groups connected in series in a predetermined order;

the first card issuing group is formed by serially connecting a second same-layer card issuing, two third cross-layer card issuing, two second cross-layer card issuing and a first cross-layer card issuing in a set sequence, and the second card issuing group is formed by serially connecting a first same-layer card issuing, a first cross-layer card issuing, two second cross-layer card issuing and two third cross-layer card issuing in the set sequence.

11. The stator assembly of claim 10, wherein 48 stator slots are numbered sequentially in the circumferential direction as 1, 2, … …,48, 6 slot layers are numbered sequentially in the radial direction of the stator core as a, b, c, d, e, f, a is the innermost layer, and f is the outermost layer, wherein one phase of the windings consists of two sets of the sub-windings in parallel:

the winding sequence of one of the sub windings is as follows:

the winding sequence of the other sub-winding is as follows:

12. the stator assembly of claim 11 wherein the three phases of windings are symmetrically distributed and each phase of windings is separated by two stator slots.

13. The stator assembly according to claim 10, wherein each of the flat wire clips further comprises a bent portion and a pair of welded portions, both ends of the bent portion being connected to the same ends of the pair of in-slot conductor portions, respectively, and the pair of welded portions being connected to the other ends of the pair of in-slot conductor portions, respectively;

14. The stator assembly according to claim 13 wherein each of said flat wire clips further includes a pair of connection portions, said weld being connected to said in-slot conductor portions by said connection portions;

15. The stator assembly of claim 9 wherein all outgoing lines of the three-phase winding are centrally located in a 6 th slot layer of a different one of the stator slots and all star points of the three-phase winding are centrally located in a 5 th slot layer of a different one of the stator slots.

16. An electric machine comprising a rotor and a stator assembly according to any one of claims 1 to 15, the rotor being disposed through the stator assembly and rotatable relative to the stator assembly.

17. A powertrain comprising a decelerator and the motor of claim 16, the decelerator in driving connection with the motor.

18. A vehicle comprising the powertrain of claim 17.