KR20160014148A - Stator assembly for hairpin winding motor - Google Patents

Abstract

According to an aspect of the present invention, a stator assembly of a hair pin winding motor comprises: a stator core having a plurality of slots provided along a circumference direction, wherein each slot has a plurality of layers in a radial direction; a plurality of hair pins with a straight line shape which are coupled to slots respectively; and first and second bridge units including a core pattern member composed of a plurality of conductive members connected to be selectively conductive to the hair pins, and a mold unit with an insulating material for covering the core pattern member. The first bridge unit is coupled to an upper side of the stator core, and the second bridge unit is coupled to a lower part of the stator core, thereby forming a coil by being electrically connected to both end units of the hair pin.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to a stator assembly for a hairpin winding motor,

The present invention relates to a stator assembly, and more particularly, to a stator assembly of a hairpin winding motor in which a plurality of hair fins are fastened and sequentially connected to a slot of a stator core to form coil windings of the stator.

With the rise of oil prices and environmental problems, various measures are being sought to increase fuel economy of vehicles. For example, an electric four-wheel drive system (e-4WD) has recently been proposed. As is known, the mechanical four-wheel drive system drives the front wheels through the engine, and transmits the driving force of the engine to the rear wheels through the propeller shaft and the coupling to drive the rear wheels. The electric four-wheel drive system is a system in which a conventional mechanical four-wheel drive system as described above is supplemented by a motor, and the front wheel is driven through the engine, and the rear wheel is driven through the motor. Therefore, it is known that the electric four-wheel drive system can remove the propeller shaft or coupling for transmitting the driving force of the engine, and is also known to have an effect of improving the fuel efficiency of the vehicle in combination with the regenerative braking system.

In order to effectively utilize the electric four-wheel drive system as described above or to increase the fuel efficiency sufficiently, it is required to develop a high-output miniaturized motor. This is also true of electric vehicles using electric power as main power, and hybrid vehicles of various types.

Generally, the output of the motor is known to be proportional to the number of turns of the coils wound on the stator core. However, if the number of turns of the coil is increased, the size of the stator core or the motor becomes inevitably large, which makes miniaturization of the motor difficult. Therefore, in order to improve the output of the motor without increasing the size of the motor, it may be considered to increase the drop rate of the coil wound on the stator core. In other words, it is possible to consider a method of minimizing the dead space between the stator core and the coil to be coiled or the dead space between the coils, thereby increasing the drop rate of the coil. In this connection, in recent years, a method of using a flat coil having a rectangular cross section has been actively sought instead of using an annular coil having a circular cross section in the coil winding. In the case of a rectangular coil, the cross sectional shape reduces the dead space and the drop rate compared to the annular coil.

In case of a rectangular coil, coil winding operation is relatively difficult as compared with an annular coil. In case of rectangular coil, it is manufactured to have a wider cross-sectional area than the annular coil in order to maximize the dot rate, which makes it difficult to use a winding machine due to increased rigidity. In such a manner, a method has been proposed in which a plurality of separated hair pins are respectively inserted into the stator cores and welded to each of the hair pins sequentially in a manner of facilitating coil winding of the rectangular coil to form coil windings have. A motor having a coil winding (hereinafter, referred to as a 'hairpin winding motor') has a plurality of hair pins formed in a substantially U-shape or V-shape and inserted into respective slots of the stator core, By successively welding the arranged hairpins, the coil winding of the stator core is formed. Therefore, in the case of the hairpin winding motor, it is possible to overcome the device limit due to the winding machine and to make the winding of the coil relatively easy even in the case of the rectangular coil, while making it possible to realize a high output miniaturized motor by increasing the drop rate of the coil.

However, as described above, the hairpin must be formed into a V or U shape, but since the coil can not be made into a V or U shape in the mold, the number of air holes increases because each hairpin must be bent.

In addition, since the V-shaped or U-shaped bending hairpin is inserted into the stator core and the rear end coil is connected to the same phase, a coil twisting operation is required. Since the twisted coils need to be connected to each other, a welder is necessary. In order to secure the welding portion of the coil, the height of the coil end is increased and the motor size is increased.

Further, since the insulation coating of the coil is damaged, the welding coil is additionally provided with a step of applying an insulator such as epoxy on the welded part, and it takes time to cure the insulator so that the next process is delayed by that time .

Embodiments of the present invention are directed to a hair pin winding motor in which a motor structure is simplified to simplify the structure of a hair pin for forming a winding of a coil connected to a stator core, Motor.

It is also intended to contribute to reduction in motor size by reducing the size of the coil end.

A stator assembly of a hairpin winding motor according to an aspect of the present invention includes a plurality of slots along a circumferential direction, each slot having a plurality of layers in a radial direction; A plurality of straight hairpins fastened to the slots; And a first and a second bridge unit including a core pattern member composed of a plurality of conductive members selectively connected to the plurality of hair pins in a conductive manner and an insulative mold member surrounding the core pattern member, The first bridge unit is coupled to the upper side of the stator core and the second bridge unit is coupled to the lower side of the stator core to form a coil through electrical connection with both ends of the hair pin.

The diameters of the outer and inner diameters of the first and second bridge units may correspond to diameters of the outer diameter and the inner diameter of the stator core.

The hairpin may protrude above and below the stator core at a predetermined height.

A plurality of hair pins may be inserted into each slot of the stator core.

The first bridge unit includes a first core pattern member including a first terminal corresponding to the number of the hair pins inserted into the slot and connecting ends of the hair pins to be energizable according to the design of the hair pins requiring interconnection; And a first mold part surrounding the first core pattern member and including a first connection groove formed at a position corresponding to the first terminal to expose the first terminal.

The first connection groove may be formed so as to be deeper than the protruded end of the hair pin.

The second bridge unit includes a second core pattern member including a number of second terminals corresponding to the number of the hair pins inserted per slot and connecting ends of the hair pins to be energizable according to the design of the hair pins requiring interconnection; And a second mold part surrounding the first core pattern member and including a second connection groove formed at a position corresponding to the second terminal to expose the second terminal.

The second connection groove may be formed to be deeper than the protruding end of the hair pin.

The first and second bridge units may be formed in the same shape.

The first and second bridge units may be assembled after the hairpin insertion process.

The stator assembly of a hairpin winding motor according to embodiments of the present invention includes a process of forming a hair pin into a V-shape or a U-shape to complete a coil winding, a process of twisting a coil end, a process of welding a coil end, The step of applying the insulator to the welded portion and the step of hardening the insulated body can all be omitted, and the productivity and assemblability of the motor can be improved.

Particularly, the assembling of the stator core can be completed only by assembling the first and second bridge units at the first and second end portions of the hairpin, so that the assembling time can be greatly reduced as described above, Since the height of the portion can be lowered, it is advantageous in downsizing the motor.

Further, since the height of the coil end portion can be reduced as described above, the amount of copper used can be reduced, the material cost can be saved, and the motor can be made lighter.

1 is a perspective view showing a stator core of a hairpin winding motor,
Fig. 2 is an exploded perspective view of Fig. 1,
3 is a perspective view of the first and second core pattern members according to the present embodiment,
4 is a perspective view of first and second mold parts molded with the first and second core pattern members of FIG. 3 as cores.

Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. It is to be understood, however, that the following examples are provided to facilitate understanding of the present invention, and the scope of the present invention is not limited to the following examples. In addition, the following embodiments are provided to explain the present invention more fully to those skilled in the art and those skilled in the art will appreciate that those skilled in the art, Will be omitted.

FIG. 3 is a perspective view of the first and second core pattern members according to the present embodiment, and FIG. 4 is a perspective view of the stator core of the hairpin winding motor of FIG. 1 and the second core pattern member as a core.

1 and 2 are a perspective view and an exploded perspective view showing a stator core of a hairpin winding motor.

Referring to FIG. 1, the hairpin winding motor may include a stator assembly and a rotor assembly, and the stator assembly may include a stator core 100. The stator core 100 may be formed in a circular ring or ring shape as a whole. Although not shown, a rotor assembly may be disposed inside the stator core 100. The rotor assembly may include a rotating shaft and may be formed to be rotatable and, as is known, may cause electromagnetic interference with the coil wound on the stator core 100 and may be rotated.

Meanwhile, the stator core 100 may include a plurality of slots 110. Each slot 110 may extend from the inner periphery to the outer periphery of the stator core 100. Alternatively, each slot 110 may extend in the radial direction of the stator core 100. The end of each slot 110 toward the inner circumferential side of the stator core 100 may be opened for coil winding.

Referring to the enlarged view of FIG. 1, each slot 110 may be formed in a multi-layer structure. In other words, each slot 110 may be provided with a plurality of layers 111 along the radial direction of the stator core 100. In the case of FIG. 1, four layers 111 are formed in one slot 110. However, the number of layers 111 formed in each slot 110 can be changed according to motor output, winding design method, and the like. For example, if necessary, the number of the layers 111 provided in one slot 110 may be two, eight, or the like. For convenience of explanation, the following description will be made with reference to FIG. 1, and each layer 111 is divided into first to fourth layers 111a and 111b , 111c, and 111d.

The stator core 100 may include a plurality of slots 110. The plurality of slots 110 may be radially disposed along the circumferential direction of the stator core 100. The number of slots 110 provided in the stator core 100 can be changed according to motor output, winding design method, and the like. For example, if necessary, 60 or 72 slots 110 may be formed in the stator core 100 along the circumferential direction.

2, a plurality of hair pins 200 may be inserted into the slots 110 of the stator core 100. In this case, For example, four or more hairpins 200 can be inserted into one slot, which can be variously changed according to the shape and specification of the motor. For the sake of understanding, the present embodiment will be described on the basis of insertion of four hair pins 200 in one slot 110.

In the conventional structure, the process of inserting the wire into the slot 110 and then connecting it by bending and twisting is absolutely necessary. However, the hair pin 200 according to the present embodiment is not required to be inserted into the stator core 100 Is required. At this time, both ends of the hairpin 200 may be protruded at a predetermined height. The height of the hairpin 200 may correspond to the height of the first and second terminals 311 and 411 of the first and second bridge units 300 and 400 ). ≪ / RTI >

Referring to FIGS. 1 and 2, the stator assembly of the hairpin winding motor may include a plurality of hair fins 200 for forming coil windings on the stator core 100. A plurality of hair pins 200 are inserted into the slots 110 of the stator core 100 and the plurality of hair pins 200 fastened to the slots 110 are formed in a straight shape And inserted into the slots 110 sequentially and connected at both ends to first and second bridge units 300 and 400 to be described later to form coil windings.

As shown, each hairpin 200 may be formed in an I-shape as a whole. The hair pin 200 may be formed of an electrical conductor such as copper for forming a coil winding, and the outer surface may be insulating coated.

The hairpin 200 may have a first end portion 210 and a second end portion 220 that are electrically conductive at both ends. The first bridge unit 300 may be coupled to the first end 210 and the second bridge unit 400 may be coupled to the second end 220.

Conventionally, a head portion is formed at an end of the hair pin 200, and the head portion is twisted to a predetermined degree. This is because each leg portion is twisted to a certain degree during processing of the hair pin 200 so that the leg portions of the hair pin can be inserted into different layers 111 in the slots 110, respectively. However, according to the present embodiment, since such a twist process is also unnecessary, a simpler and simpler assembly process can be performed. Therefore, in order to process the hair pin 200, it is possible to finish the hair pin 200 by cutting a straight flat coil into an appropriate length. The first and second ends 210 and 220 at both ends of the hairpin 200 are connected to the other hairpins through joining with the first and second bridge units 300 and 400 to be described later.

Meanwhile, the hair pin 200 may be formed of a flat coil having a substantially rectangular cross section. The square-shaped coil as described above increases the drop rate of the coil in the slot 110, thereby realizing a high-output, miniaturized motor.

2, the stator assembly of the hairpin winding motor includes a plurality of hairpins 200 described with reference to FIG. 2 in the stator core 100 described with reference to FIG. 1, and each hairpin 200 is sequentially inserted The connection of the hair pins 200 is completed by coupling the first and second bridge units 300 and 400 to the upper side and the lower side of the stator core 100, respectively.

In addition, one hairpin 200 fills each slot 110 with one layer 111. In other words, the I-shaped hair pins 200 are individually inserted into the respective layers 111 of the respective slots 110. 2, the entire I-shaped body of the hairpin 200 is inserted into the first to fourth layers 111a, 111b, 111c and 111d, The four hair pins 200 can be inserted and arranged along the radial direction.

When the plurality of hair pins 200 are fastened to the respective slots 110 of the stator core 100 as described above, each of the hair pins 200 may have first and second ends 210 220 may protrude above and below the stator core 100 at a constant height.

The first bridge unit 300 may include a first core pattern member 310 and a first mold part 320.

The first core pattern member 310 may include a plurality of first terminals 311 on a substantially annular body. The first terminal 311 may correspond to the number of the hair pins 200 inserted into the slot 110. The first terminal 311 may be in surface contact with the first end 210 of the hair pin 200. At this time, the first end 210 and the first terminal 311 may be electrically connected through physical contact without a separate welding and twisting process. At this time, the shape of the first core pattern member 310 can be determined according to the shape requiring wiring. 3, the first core pattern members 310 may be formed in a ring shape having a plurality of different diameters and may be disposed concentrically along the center.

As shown in FIG. 4, the first mold part 320 may be formed of a resin material covering the first core pattern member 310. The first terminal unit 311 may be disposed at the first end 210 of the hair pin 200. The first terminal unit 311 may be formed by injection molding the first core pattern member 310, The first connection groove 321 may be formed at a position corresponding to the first terminal 311 so as to be in contact with the first terminal 311. According to this configuration, the first end 210 may be inserted into the first connection groove 321 and connected to the first terminal 311.

Meanwhile, the second bridge unit 400 may include a second core pattern member 410 and a second mold unit 420.

The second core pattern member 410 may have a plurality of second terminals 411 on a substantially annular body. The second terminal 411 may correspond to the number of the hair pins 200 inserted into the slot 110. The second terminal 411 may be connected in surface contact with the second end 220 of the hair pin 200. At this time, the second end 220 and the second terminal 411 may be electrically connected through physical contact without a separate welding and twisting process. At this time, the shape of the second core pattern member 410 can be determined according to the form requiring wiring. 3, the second core pattern members 410 may be arranged in a ring shape having a plurality of different diameters and may be disposed concentrically along the center.

The second mold part 420 may be made of a resin material that surrounds the second core pattern member 410, as shown in FIG. The second terminal 420 may be formed by injecting the second core pattern member 410 into the metal mold 410. The second terminal 411 may be formed at the second end 220 of the hairpin 200, The second connection groove 421 may be formed at a position corresponding to the second terminal 411 so as to be in contact with the second terminal 411. According to this configuration, the second end 220 can be inserted into the second connection groove 421 and connected to the second terminal 411.

The diameters of the outer and inner diameters of the first and second bridge units 300 and 400 may correspond to diameters of the outer and inner diameters of the stator core 100. 1, the stator core 100 in which the first and second bridge units 300 and 400 are coupled vertically can maintain a substantially cylindrical shape.

The first and second connection grooves 321 and 421 may be formed to be deeper than the protruded first and second ends 210 and 220 of the hairpin. With this configuration, the ends of the first and second ends 210 and 220 can be connected to the first and second terminals 311 and 411.

Meanwhile, according to the present embodiment, the first and second bridge units 300 and 400 may be formed in the same shape. Alternatively, the directionality may be changed due to the vertical coupling, and the hairpin 200 may be vertically symmetrical in order to connect the hairpin 200 and wind it with a coil.

In addition, the first and second bridge units 300 and 400 may be assembled after the hairpin insertion process. That is, after the process of inserting the plurality of hair pins 200 into the slot 110 of the stator core 100 is completed, the first and second bridge units 300 and 400 are inserted into the slot 110 of the stator core 100, The upper and lower sides can be combined to complete the assembly.

According to this embodiment, in order to complete the coil winding, a process of forming the hair pin 200 into a V-shape or a U-shape, a process of twisting the coil end portion, a process of welding the coil end portion, a process of applying an insulator to the welding portion And the step of hardening the insulator can all be omitted, and the productivity and assemblability of the motor can be improved.

Particularly, the assembly of the stator core 100 can be finished only by assembling the first and second bridge units 300 and 400 to the first and second end portions 210 and 220 of the hair pin 200 As described above, the assembling time can be greatly reduced, and the height of the coil end portion can be reduced.

Further, since the height of the coil end portion can be reduced as described above, the amount of copper used can be reduced, the material cost can be saved, and the motor can be made lighter.

While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, many modifications and changes may be made by those skilled in the art without departing from the spirit and scope of the invention as defined in the appended claims. The present invention can be variously modified and changed by those skilled in the art, and it is also within the scope of the present invention.

100: stator core 110: slot
200: hairpin 300; The first bridge unit
310; A first core pattern member 311; First Terminal
320; A first mold part 321; The first connection groove
410; A second core pattern member 411; Second Terminal
420; A second mold part 421; The second connection groove

Claims (10)

A stator core having a plurality of slots along a circumferential direction, each slot having a plurality of layers in a radial direction;
A plurality of straight hairpins fastened to the slots; And
And a first and a second bridge unit including a core pattern member composed of a plurality of conductive members selectively connected to the plurality of hair pins in a conductive manner and an insulating molded member surrounding the core pattern member,
Wherein the first bridge unit is coupled to the upper side of the stator core and the second bridge unit is coupled to the lower side of the stator core to form a coil through electrical connection with both ends of the hair pin, . The method according to claim 1,
Wherein diameters of the outer diameter and the inner diameter of the first and second bridge units correspond to diameters of the outer diameter and the inner diameter of the stator core. The method according to claim 1,
Wherein the hairpin is protruded at a predetermined height above and below the stator core. The method according to claim 1,
Wherein a plurality of hair pins are inserted and coupled to each slot of the stator core. 2. The apparatus of claim 1, wherein the first bridge unit comprises:
A first core pattern member including a number of first terminals corresponding to the number of hair pins to be inserted per slot and connecting ends of the hair pins to be energizable according to the design of the hair pins requiring interconnection; And
And a first mold part surrounding the first core pattern member and including a first connection groove formed at a position corresponding to the first terminal to expose the first terminal. The connector according to claim 5,
Wherein a length of the protruding end of the hair pin is larger than a length of the protruding end of the hair pin. The apparatus of claim 1, wherein the second bridge unit comprises:
A second core pattern member including a number of second terminals corresponding to the number of the hair fins inserted per slot and connecting ends of the hair fins so as to be energized according to the design of the hairpin requiring interconnection; And
And a second mold part surrounding the first core pattern member and including a second connection groove formed at a position corresponding to the second terminal to expose the second terminal. 8. The connector according to claim 7,
Wherein a length of the protruding end of the hair pin is larger than a length of the protruding end of the hair pin. The method according to claim 1,
Wherein the first and second bridge units are formed in the same shape. The method according to claim 1,
Wherein the first and second bridge units are assembled after the step of inserting the hairpin.

Images