TWI664793B - Motor stator structure and forming method thereof - Google Patents

Abstract

A motor stator includes an iron core and a plurality of hairpin-shaped wires. The iron core has a plurality of slots, an insertion side, and an extension side. Each slot has an innermost layer, a sub-inner layer, a sub-outer layer and an outermost layer in the radial direction of the iron core. The first cross-slot distance of the hairpin-shaped wire inserted into the innermost layer is different from the second cross-slot distance of the hairpin-shaped wire inserted into the second inner layer. The third span of the hairpin-shaped wire inserted into the outer layer is different from the fourth span of the hairpin-shaped wire inserted into the outermost layer. The first spanning distance is the same as the fourth spanning distance, and the second spanning distance is the same as the third spanning distance.

Description

Motor stator and forming method thereof

The invention relates to a motor stator and a manufacturing method thereof, and more particularly, to a motor stator including a hairpin-shaped wire and a manufacturing method thereof.

The conventional winding method of the motor stator of the hairpin-shaped conductor is generally the same as the number of spans that are bent and extended after protruding the slot, so the gap between each layer of the conductor and the conductor is the same. When the current passing through the wire of the motor stator is larger or the space occupied by the motor stator is smaller, the motor stator faces problems such as heat dissipation or safety insulation.

The invention proposes a motor stator and a forming method, which solves the problems of the prior art.

In one embodiment of the present invention, a motor stator includes an iron core and a plurality of hairpin-shaped wires. The iron core has a plurality of slots, and the iron core has an insertion side and an extension side opposite to the insertion side, wherein each slot has an innermost layer, an inner layer, and an outer layer in the radial direction of the iron core. And an outermost layer. A plurality of hairpin-shaped wires are inserted into the slots from the insertion side and protruded from the extension side and are bent and extended across the slot in the circumferential direction of the iron core. The hairpin wires are connected at the extension side to form a winding structure. . The first cross-slot distance of the hairpin-shaped wires inserted in the innermost layer is different from the second cross-slot distance of the hairpin-shaped wires inserted in the second inner layer. The third spanning distance of the hairpin conductors inserted into the outer layer is different from the fourth spanning distance of the hairpin conductors inserted into the outermost layer. The first spanning distance is the same as the fourth spanning distance, and the second spanning distance is the same as the third spanning distance.

In an embodiment of the present invention, the first spanning distance is greater than the second spanning distance, and the fourth spanning distance is greater than the third spanning distance.

In an embodiment of the present invention, the first spanning distance is smaller than the second spanning distance, and the fourth spanning distance is shorter than the third spanning distance.

In an embodiment of the present invention, the hairpin conductors include a plurality of first winding hairpin conductors, and the first winding hairpin conductors have a first leg and a second leg, which are respectively disposed on the legs. The innermost layer and the second inner layer of the slot, which are bent in the first direction and the second direction respectively and extend the distance between the first span and the second span, wherein each first foot is connected to the immediately adjacent second foot. To form a first winding, the hairpin conductors further include a plurality of second winding hairpin conductors. The second winding hairpin conductors have a third pin and a fourth pin, and are respectively disposed on the plugs. The second outer layer and the outermost layer of the groove are bent toward the third direction and the fourth direction, respectively, and extend the distance between the third span and the fourth span, wherein each third foot is connected to the immediately adjacent fourth foot to form a Second winding.

In an embodiment of the present invention, the motor stator further includes at least one neutral wire for connecting an electrical neutral terminal and at least one terminal wire for connecting at least one electrical phase terminal, wherein the first windings are hairpin-shaped The conductive wire, the second winding hairpin-shaped conductive wires, the at least one neutral conductive wire and the at least one terminal conductive wire are arranged in all the slots, and are protruded and bent at the extension side and connected to form an end of the conductive wire. The three-phase motor stator winding structure, wherein the connection at the end of the wire is configured such that the end of the wire protruding from the innermost layer is connected to the end of the wire protruding from the next inner layer, and the end of the wire protruding from the second outer layer is connected to The ends of the immediately protruding outer wires are connected.

In an embodiment of the present invention, the first direction and the third direction are the same circumferential direction, and the second direction and the fourth direction are the same circumferential direction.

In an embodiment of the present invention, the sum of the first spanning distance and the second spanning distance of each first winding hairpin conductor is equal to the third spanning distance and the first spanning distance of each second winding hairpin conductor. The sum of the distances of the four spans.

In an embodiment of the present invention, the vertical distances between the first ends of the first winding hairpin conductors and the ends of the adjacent second legs protruding from the iron core are equal.

In an embodiment of the present invention, the vertical distances between the end of each of the first legs of the second winding hairpin conductors and the end of the second leg protruded from the iron core are equal.

In one embodiment of the present invention, a motor stator includes an iron core, a plurality of first hairpin-shaped wires, and a plurality of second hairpin-shaped wires. The iron core has a plurality of slots, and the iron core has an insertion side and an extension side opposite to the insertion side, wherein each slot defines the first layer, the second layer, and the third layer from the inside to the core. And the fourth floor. Each first hairpin-shaped wire has a first leg and a second leg. Each first leg is inserted into the first layer of the slots from the insertion side and protrudes from the extension side to bend and extend in a first direction. A first spanning distance, and each second foot inserted into the second layer of the slots from the insertion side and protruding from the extension side to bend in a second direction and extend a second spanning distance. The first span-to-slot distance is different from the second span-to-slot distance. Each first leg is connected to an immediately adjacent second leg to form a first winding. Each second hairpin-shaped wire has a third leg and a fourth leg, and the third leg is inserted into the third layer of the slots from the insertion side and protrudes from the extension side in a third direction to bend and extend a first pin. The distance between the three spans, and the fourth foot is inserted into the fourth layer of the slots from the insertion side and protrudes from the extension side in a fourth direction to bend and extend a fourth span distance. The third span-to-slot distance is different from the fourth span-to-slot distance. Each fourth leg is connected to the immediately adjacent third leg to form a second winding.

In an embodiment of the present invention, a size of the first hairpin-shaped wires is equal to a size of the second hairpin-shaped wires.

In an embodiment of the present invention, the first direction and the third direction are the same circumferential direction, and the second direction and the fourth direction are the same circumferential direction.

In an embodiment of the present invention, each of the first and second hairpin conductors is covered with an insulating layer, and the ends of the two legs of each of the first and second hairpin conductors are exposed from the insulation layer.

In an embodiment of the present invention, a method for forming a motor stator includes: providing an iron core having a plurality of slots, the iron core having an insertion side and an extension side opposite to the insertion side, each of which The slot has an innermost layer, an inner layer, an outer layer, and an outer layer in the radial direction of the slot; a plurality of first winding hairpin-shaped wires are inserted into the slots so that the first windings A first pin and a second pin of a hairpin-shaped wire are respectively inserted into the innermost layer and the second inner layer of the slots from the insertion side and protrude from the extension side; a plurality of second winding hairpin-shaped wires are inserted into these In the slots, a third leg and a fourth leg of one of the second winding hairpin conductors are respectively inserted into the second outer layer and the outermost layer of the slots from the insertion side and protrude from the extension side; each first Bend your feet in a first direction so that they extend a first cross-slot distance; bend each second foot in a second direction so that they extend a second cross-slot distance; move each third foot to a first Bend in three directions to extend a third span distance; and move each fourth foot toward Bending in the fourth direction to extend a fourth spanning distance; wherein the first spanning distance is different from the second spanning distance, and the third spanning distance is different from the fourth spanning distance; The distance between the four spans is the same, and the distance between the second span and the third span is the same.

In an embodiment of the present invention, the first direction and the third direction are the same circumferential direction, and the second direction and the fourth direction are the same circumferential direction.

In an embodiment of the present invention, the first spanning distance is greater than the second spanning distance, and the fourth spanning distance is greater than the third spanning distance.

In an embodiment of the present invention, the first spanning distance is smaller than the second spanning distance, and the fourth spanning distance is shorter than the third spanning distance.

In an embodiment of the present invention, the method for forming a motor stator further includes: performing the steps of bending each first leg and each of the third legs simultaneously; and performing the bending of each second leg and the bending simultaneously. Every fourth step.

In an embodiment of the present invention, the method for forming a motor stator further includes: connecting each first leg and a second leg immediately adjacent to form a first winding; and connecting each third leg and a fourth leg immediately adjacent to each other. A second winding is formed.

In an embodiment of the present invention, the method for forming a motor stator further includes: inserting at least one neutral wire and at least one terminal wire, so that the first winding hairpin conductor, the second winding hairpin conductor, and at least one neutral The wires and at least one terminal wire are arranged in all of the slots, wherein at least one neutral wire is used to connect the electrical neutral terminal, and at least one terminal wire is used to connect at least one electrical phase terminal; bent at least one neutral The end of the wire; bending the end of at least one terminal wire; connecting the first winding hairpin wire, the second winding hairpin wire, at least one neutral wire and at least one terminal wire at the end of the wire, wherein the wire The connection at the end is configured as: the end of the wire protruding from the innermost layer is connected to the end of the wire protruding from the second inner layer; and the end of the wire protruding from the second outer layer is connected to the end of the wire protruding from the outermost layer.

In summary, the present invention utilizes hairpin-shaped wires to protrude the extended side of the iron core and bend them at different distances between the innermost layer, sub-inner layer, sub-outer layer, and outermost layer. This improves the heat dissipation efficiency of the conductor and ensures The lead gap meets the requirements for safe insulation design.

The above description will be described in detail in the following embodiments, and further explanation will be provided for the technical solution of the present invention.

In order to make the description of the present invention more detailed and complete, reference may be made to the accompanying drawings and various embodiments described below. The same numbers in the drawings represent the same or similar elements. On the other hand, well-known elements and steps have not been described in the embodiments, so as to avoid unnecessary limitation to the present invention.

Please refer to FIGS. 1 and 2, which respectively show perspective views of a motor stator and an iron core according to an embodiment of the present invention. The motor stator 100 basically includes an iron core 110 and a plurality of hairpin-shaped wires (for example, hairpin-shaped wires 120, 130) and the like inserted thereon. The iron core 110 has a plurality of slots 112 for inserting and connecting hairpin-shaped wires. In this embodiment, the number of the slots 112 is 120, but this case is not limited thereto. In other embodiments, the number of the slots 112 may be 60 or 48. The number of slots can be configured according to the design requirements of the motor stator. Within the limits of the design specification, the configuration of most slots may form a denser wire configuration, so that the gap between the wires and the wires is closer. Therefore, the number of slots and the slot layer The cross-slot distance of the wire feet and the way the wires are connected are factors that need to be considered in the design of the motor stator. The iron core 110 has an insertion side 110 a and an extension side 110 b opposite to the insertion side, that is, the insertion side 110 a and the extension side 110 b are two opposite sides of the iron core 110. Each slot 112 has an innermost layer 112a, a first inner layer 112b, a first outer layer 112c, and an outermost layer 112d in a radial direction 114 of the iron core 110. Alternatively, the innermost layer 112a, the second inner layer 112b, the second outer layer 112c, and the outermost layer 112d of each slot 112 are defined as the first layer of the iron core from the inside to the outside (for example, from the inner side 110c to the outer side 110d of the iron core), The second, third, and fourth layers. The radial direction 114 is substantially perpendicular to the circumferential direction 115 of the core 110.

In other embodiments, when each slot can accommodate more than four layers of wires (for example, six layers), the innermost layer and the second inner layer are defined as the first layer and the second layer from the inside to the outside. The outer layer and the outermost layer are defined as the fifth and sixth layers of the iron core from the inside to the outside. When each slot can accommodate eight layers of wires, the innermost layer and the second inner layer are defined as the first and second layers of the iron core from the inside to the outside, and the second outer layer and the outermost layer are defined as the iron core from the inside to the outside. The seventh and eighth floors. In this embodiment, although each slot can accommodate four layers of wires as an example, this case does not limit the number of wires that each slot can accommodate.

Please refer to Figs. 3, 4A, 4B, and 5. Fig. 3 is a perspective view showing a motor stator and a hairpin-shaped wire according to an embodiment of the present invention; Fig. 4A is a diagram showing a motor stator and a hairpin of Fig. 3 4B is a schematic view showing the relationship between the cross-slot distance of a hairpin-shaped wire and the clearance of an inclined portion according to an embodiment of the present invention; FIG. 5B is a diagram showing a motor stator and a hairpin of FIG. 3 Side view of a clip wire. The motor stator 100a includes an iron core 110 and a plurality of hairpin-shaped wires inserted thereon. In order to clearly illustrate the insertion core, bending and connection of the hairpin-shaped wire, only part of the hairpin-shaped wire is shown in the drawing.

The motor stator 100 a includes a plurality of hairpin-shaped wires 120 and a plurality of hairpin-shaped wires 130. Each hairpin conductor 120 has a U-bend 120a and two legs 120b and 120c. The U-bend is connected between the two legs 120b and 120c. Each leg 120b is inserted into the innermost layer of the slots from the insertion side 110a of the iron core 110, and protrudes from the extension side 110b of the iron core 110, is bent in the direction 115a, and extends a distance across the slot. Each leg 120c is inserted into the secondary inner layer of the slots from the insertion side 110a of the iron core 110, and protrudes from the extension side 110b of the iron core 110, is bent in the direction 115b, and extends a distance across the groove.

In this example, the distance between each foot 120b in the innermost layer of the slot is greater than the distance between each foot 120c in the second inner layer of the slot. Each leg 120b is connected to the adjacent leg 120c to form a winding. For example, the leg 120b of the hairpin conductor 120 (1) and the leg 120c of the adjacent hairpin conductor 120 (2) are connected to the extended side 110b of the iron core 110 to The windings are formed in the innermost layer and the second inner layer of the slot.

Each hairpin-shaped wire 130 has a U-shaped bend 130a and two legs 130b and 130c. The U-shaped bend 130a is connected between the two legs 130b and 130c. Each leg 130b is inserted into the sub-outer layers of the slots 112 from the insertion side 110a of the iron core 110, and protrudes from the extension side 110b of the iron core 110, is bent in the direction 115a, and extends a distance across the groove. Each leg 130c is inserted into the outermost layer of the slots 112 from the insertion side 110a of the iron core 110, and protrudes from the extension side 110b of the iron core 110, is bent in the direction 115b, and extends a distance across the groove.

In this example, the distance between each leg 130c and the outermost layer of the slot is greater than the distance between each leg 130b and the next outer layer of the slot. Each leg 130b is connected to the adjacent leg 130c to form a winding. For example, the leg 130b of the hairpin conductor 130 (1) and the leg 130c of the adjacent hairpin conductor 130 (2) are connected to the extended side 110b of the iron core 110 to The windings are formed on the outermost layer and the second outer layer of the slot.

In this embodiment, as shown in FIG. 4A, the distance between each foot 120b at the innermost level of the slot and the distance between each foot 130c at the outermost level of the slot may be a length of 3.5 slots. The cross-slot distance of each leg 120c in the sub-inner layer of the slot and the sub-slot distance of each leg 130b in the sub-outer layer of the slot may be a length of 2.5 slots, but this case is not limited to this.

Please also refer to Figure 4B. It can be known from the figure that when the cross-slot distance DB of the hairpin-shaped wire is smaller than the cross-slot distance DA, the effect that the gap Tb of its corresponding inclined portion is greater than Ta is generated.

In this embodiment, since the distance between each foot 120b at the innermost level of the slot is greater than the distance between each foot 120c at the second inner level of the slot, and each leg 130c is at the most inner level of the slot. The cross-slot distance of the outer layer is greater than the cross-slot distance of each foot 130b in the sub-outer layer of the slot, so that the gap between the innermost layer and the outermost conductor's inclined portion (such as Ta) is smaller than that of the second inner-layer and the outer-secondary conductor. Gap (for example, Tb). The design of the motor stator 100a ensures that the difficult-to-measure clearance between the inclined portion of the secondary inner layer and the secondary outer layer wire (for example, Tb) is greater than the minimum safety insulation design requirement. In other words, since the gap between the innermost and outermost conductors (eg, Ta) is smaller than the gap between the inner and outer outer conductors (such as Tb), it is important to confirm that the innermost conductors and the outermost conductors are between each other. When there is no short circuit (that is, they are insulated from each other), the secondary inner conductors and the secondary outer conductors can also ensure that there is no short circuit at the same time, so the reliability of the product can be improved.

The directions 115a and 115b described above are circumferential directions opposite to each other, for example, clockwise or counterclockwise.

In this example, the size of the hairpin-shaped wire 120 and the size of the hairpin-shaped wire 130 are substantially equal, but not limited thereto.

In this example, each of the hairpin conductors 120 and 130 is covered with an insulation layer. For example, as shown in FIG. 4A, the hairpin conductor 120 is covered with an insulation layer 120d, and The ends of the two legs are exposed from the insulating layer to thereby be electrically connected to each other. For example, the ends 120e and 120f of the two legs of the hairpin conductor 120 are exposed from the insulating layer 120d to form an electrical connection by soldering. In addition, except that the ends of each hairpin-shaped wire are bare, the rest is covered by an insulating layer to achieve electrical insulation, so as to avoid short-circuits caused by contact between hairpin-shaped wires of different windings.

In this example, as shown in FIG. 5, the vertical distance VD between each leg 120b of the hairpin conductor 120 and the adjacent leg 120c protruding from the end surface of the iron core 110 is equal, and the distance between the hairpin conductor 130 and the hairpin conductor 130 is the same. The vertical distance VD of the connecting end of each leg 130b and the adjacent leg 130c protruding from the end surface of the iron core 110 is equal, but not limited thereto.

In other examples, when each slot can accommodate more than four layers of wires (such as six or eight layers), other hairpin-shaped wires can be arranged between the sub-inner layer and sub-outer layer of each slot to The connection forms more windings.

Please refer to FIGS. 6 to 8. FIG. 6 is a perspective view illustrating a motor stator and a hairpin conductor according to another embodiment of the present invention. FIG. 7 is a motor stator and a hairpin conductor according to FIG. 6. Bottom view; Figure 8 is a side view of the motor stator and hairpin conductors of Figure 6. The motor stator 100b includes an iron core 110 and a plurality of hairpin-shaped wires inserted thereon. In order to clearly illustrate the insertion core, bending and connection of the hairpin-shaped wire, only part of the hairpin-shaped wire is shown in the drawing. The motor stator 100b differs from the motor stator 100a mainly in that the cross-slot distance of the hairpin conductor on the extended side of the iron core is different.

The motor stator 100b includes a plurality of hairpin-shaped wires 120 and a plurality of hairpin-shaped wires 130. Each hairpin conductor 120 has a U-bend 120a and two legs 120b and 120c. The U-bend 120a is connected between the two legs 120b and 120c. Each leg 120b is inserted into the innermost layer of the slots from the insertion side 110a of the iron core 110, and protrudes from the extension side 110b of the iron core 110, is bent in the direction 115a, and extends a distance across the slot. Each leg 120c is inserted into the secondary inner layer of the slots from the insertion side 110a of the iron core 110, and protrudes from the extension side 110b of the iron core 110, is bent in the direction 115b, and extends a distance across the groove.

In this example, the cross-slot distance of each foot 120b in the innermost layer of the slot is smaller than the cross-slot distance of each foot 120c in the second inner layer of the slot. Each leg 120b is connected to the adjacent leg 120c to form a winding. For example, the leg 120b of the hairpin conductor 120 (1) and the leg 120c of the adjacent hairpin conductor 120 (2) are connected to the extended side 110b of the iron core 110 to The windings are formed in the innermost layer and the second inner layer of the slot.

Each hairpin-shaped wire 130 has a U-shaped bend 130a and two legs 130b and 130c. The U-shaped bend 130a is connected between the two legs 130b and 130c. Each leg 130b is inserted into the sub-outer layers of the slots 112 from the insertion side 110a of the iron core 110, and protrudes from the extension side 110b of the iron core 110, is bent in the direction 115a, and extends a distance across the groove. Each leg 130c is inserted into the outermost layer of the slots 112 from the insertion side 110a of the iron core 110, and protrudes from the extension side 110b of the iron core 110, is bent in the direction 115b, and extends a distance across the groove.

In this example, the distance between each leg 130c and the outermost layer of the slot is smaller than the distance between each leg 130b and the next outer layer of the slot. Each leg 130b is connected to the adjacent leg 130c to form a winding. For example, the leg 130b of the hairpin conductor 130 (1) and the leg 130c of the adjacent hairpin conductor 130 (2) are connected to the extended side 110b of the iron core 110 to The windings are formed on the outermost layer and the second outer layer of the slot.

As can be seen from FIG. 4B, when the cross-slot distance DB of the hairpin-shaped wire is smaller than the cross-slot distance DA, the effect that the gap Tb of its corresponding inclined portion is greater than Ta is generated.

In this embodiment, the distance across the slot (eg, DB) of each foot 120b in the innermost layer of the slot is less than the distance across the slot (eg DA) of each foot 120c in the second inner layer of the slot, and each The cross-slot distance (for example, DB) of one leg 130c at the outermost layer of the slot is smaller than the cross-slot distance (for example, DA) of each leg 130b at the second outer layer of the slot, so as to generate the inclined parts of the innermost and outermost wires. The gap (for example, Tb) is larger than the gap (for example, Ta) in the inclined portion of the sub-inner layer and the sub-outer layer. The design of the motor stator 100b is suitable for use in an oil cooling system. Because the gap between the innermost and outermost inclined wires is larger than the gap between the inner and outer outer wires, when the cooling oil is input, it can effectively reduce the resistance of the outer wires to the cooling oil flow. In other words, the cooling oil can effectively enter the inner wires (for example, the sub-inner layer and the sub-outer layer wires), thereby improving the contact effect between the inner layer wires and the cooling oil, and obtaining better conductor heat dissipation efficiency.

The directions 115a and 115b described above are circumferential directions opposite to each other, for example, clockwise or counterclockwise.

In this example, as shown in FIG. 7, each of the hairpin conductors 120 and 130 is covered with an insulation layer. For example, the hairpin conductor 130 is covered with an insulation layer 130d, and two The ends of the legs are exposed from the insulation layer to thereby be electrically connected to each other. For example, the ends 130e and 130f of the two legs of the hairpin conductor 130 are exposed from the insulation layer 130d to form an electrical connection by soldering. In addition, except that the ends of each hairpin-shaped wire are bare, the rest is covered by an insulating layer to achieve electrical insulation, so as to avoid short-circuits caused by contact between hairpin-shaped wires of different windings.

In this example, the vertical distance VD between the connecting end of each leg 120b of the hairpin conductor 120 and the adjacent leg 120c protruding from the end surface of the iron core 110 is equal, and each leg 130b of the hairpin conductor 130 is in close contact with the adjacent The vertical distance VD of the connecting end of the leg 130c protruding from the end surface of the iron core 110 is equal (refer to FIG. 8), but it is not limited thereto.

In some examples, each leg 120b of the hairpin conductor 120 and each leg 130b of the hairpin conductor 130 are bent in the same direction (for example, direction 115a) after protruding from the extended side 110b. Synchronize execution to speed up processes and reduce man-hours. Similarly, each leg 120c of the above-mentioned hairpin-shaped wire 120 and each leg 130c of the hair-pin-shaped wire 130 are bent in the same direction (for example, direction 115b) after protruding from the extended side 110b, and can also be performed simultaneously. To speed up the process and reduce man-hours.

Please refer to FIGS. 9A, 9B, 10A, 10B, and 11 for a schematic diagram showing a connection manner of one phase winding of the three-phase motor stator 100a described above. In FIG. 9A, after the pin 130b of the hairpin-shaped wire 130 (1) passes through the slot (for example, the second outer layer of the slot), it protrudes from the extension side 110b of the iron core 110, bends in the direction 115a, and extends a span. Slot distance D3. After passing through the slot (for example, the outermost layer of the slot), the foot 130c of the hairpin-shaped wire 130 (2) protrudes from the extension side 110b of the iron core 110, bends in the direction 115b, and extends across a slot. Distance D4. Therefore, the foot 130b of the hairpin-shaped wire 130 (1) is connected to the foot 130c of the hairpin-shaped wire 130 (2) next to the extended side 110b of the iron core 110, and the hairpin shape of the outermost layer and the second outer layer of the slot is connected. The wires 130 (1), 130 (2), ... are connected to each other in the above manner to form a winding that surrounds an iron core (such as the iron core 110 in FIG. 1), such as the winding 130 'in FIG. 9B. Similarly, in the slot next to the adjacent winding 130 ', another winding 130 "around the core can be formed by the above-mentioned method.

In this embodiment, the cross-slot distance D4 (for example, 3.5 slot pitch) is greater than the cross-slot distance D3 (for example, 2.5 slot pitch), but is not limited thereto.

Next, please refer to (a) in FIG. 11 together. Because the windings 130 'and 130 "are different from each other by a slot position, if the two windings are to be connected, a hairpin of a different size from the hairpin-shaped wire 130 must be used. Clip-shaped wire 130SP. As shown in FIG. 11 (a), one of the legs of the hairpin conductor 130P is inserted into the next outer layer of the slot, protruding to the side of the extension and bent to extend a distance D3 across the slot, and then the tail foot 1302 'of the winding 130' connection. In addition, the other leg of the hairpin-shaped wire 130P is inserted into the outermost layer of the slot, protruding from the extension side and bent to extend a span of a distance D4, and then connected to the first leg 1301 "of the winding 130", so that the The windings 130 'and 130 "are connected. In this embodiment, the size of the hairpin-shaped wire 130SP (for example, a distance between five slots) is smaller than the size of the hairpin-type wire 130 (for example, a distance between six slots), but the present invention is not limited thereto.

In this embodiment, the motor stator 100a includes a terminal wire 132 (as shown in FIG. 1) as a connection terminal of one phase of the three-phase winding, and one end thereof on the insertion side 110a is used to connect to an electrical phase terminal ( One of the U-phase, V-phase, and W-phase) is located at one end of the extended side 110b and is connected to the winding 130 '. In this embodiment, as shown in FIG. 11 (a), the terminal wire 132 is inserted into the outermost layer of the slot, and the protruding extension side is bent to extend a distance D4 across the slot, and then connected to the first leg 1301 'of the winding 130' .

In this embodiment, the trailing leg 1302 "of the winding 130" is connected to the windings inserted into the inner and inner layers through another hairpin-shaped wire 140 (as shown in Fig. 11 (b)). This will be detailed later.

Please refer to Figures 10A and 10B. In FIG. 10A, after the foot 120b of the hairpin conductor 120 (1) passes through the slot (for example, the innermost layer of the slot), it protrudes from the extension side 110b of the iron core 110, bends in the direction 115a, and extends Crossing the distance D1, the foot 120c of the hairpin-shaped wire 120 (2) passes through the slot (for example, the second inner layer of the slot), protrudes from the extension side 110b of the core 110, and bends and extends in the direction 115b. Distance across the slot D2. Therefore, the foot 120b of the hairpin conductor 120 (1) is connected to the foot 120c of the hairpin conductor 120 (2) adjacent to the extended side 110b of the iron core 110, and the hairpins located at the innermost layer and the sub-inner layer of the slot are connected. The clip-shaped wires 120 (1), 120 (2),... Can be connected to each other by the above-mentioned methods to form a winding, such as the winding 120 'shown in FIG. 10B. Similarly, in the slot next to the adjacent winding 120 ', another winding 120 "surrounding the core can be formed by the above-mentioned method.

In this embodiment, the cross-slot distance D1 (for example, 3.5 slot pitch) is greater than the cross-slot distance D2 (for example, 2.5 slot pitch), but it is not limited thereto.

Next, please refer to (c) in FIG. 11. Similar to the windings 130 ′ and 130 ″, to connect the windings 120 ′ and 120 ″, a hairpin conductor 120SP with a different size from the hairpin conductor 120 is required. As shown in FIG. 11 (c), one of the legs of the hairpin conductor 120P is inserted into the innermost layer of the slot, protruding from the extension side and bent to extend a distance D1 across the slot, and then the tail foot 1202 of the winding 120 ' 'connection. In addition, the other pin of the hairpin conductor 120P is inserted into the slot's inner layer, protruding from the extension side and bent to extend a distance D2 across the slot, and then connected to the first leg 1201 "of the winding 120", thereby Connect the windings 120 'and 120' '. In this embodiment, the size of the hairpin-shaped wire 120SP (for example, a distance between five slots) is smaller than the size of the hairpin-type wire 120 (for example, a distance between six slots), but the present invention is not limited thereto.

In this embodiment, the motor stator 100a includes a neutral wire 122 (as shown in FIG. 1) as the electric neutral terminal of the three-phase winding, which is located at one end of the insertion side 110a for connecting to an electric neutral terminal One end of the extension side 110b is used to connect to the winding 120 ". In this embodiment, as shown in FIG. 11 (c), the neutral wire 122 is inserted into the innermost layer of the slot, and it protrudes from the extension side Bend and extend a distance D1 across the slot, and then connect to the tail 1202 "of the winding 120".

In this embodiment, the motor stator 100a further includes a hairpin-shaped wire 140 for connecting the windings 130 'and 130 "connected to the terminal wire 132 and the windings 120' and 120" connected to the neutral wire 122. As shown in Figure 11 (b), one of the pins of the hairpin wire 140 is inserted into the next outer layer of the slot, and the protruding extension side is bent and extended a distance D3 across the slot, and then is inserted into the outermost winding 130 of the slot. "Tail foot 1302" connected. In addition, the other foot of the hairpin-shaped wire 140 is inserted into the inner layer of the slot, the protruding side is bent and extended a distance D2 across the slot, and then the first leg 1201 'of the winding 120' inserted into the innermost layer of the slot. connection. Thereby, the entire one-phase winding of the motor stator 110a can be completed. In this embodiment, the size of the hairpin-shaped wire 140 may be the same as the size of the hairpin-shaped wires 120 and 130 (for example, the distance between six slots), but the present invention is not limited thereto. On the other hand, the cross-slot distance D2 and the cross-slot distance D3 of the two legs of the hairpin-shaped wire 140 are the same, but not limited thereto.

In this embodiment, the cross-slot distance D1 of the wire inserted in the innermost layer is the same as the cross-slot distance D4 of the wire inserted in the outermost layer, and the cross-slot distance D2 of the wire inserted in the second inner layer is the same as The cross-slot distance D3 of the wires of the second outer layer is the same, and the cross-slot distance D1 is greater than the cross-slot distance D2, and the cross-slot distance D4 is greater than the cross-slot distance D3. As a result, the gap between the inclined parts of the innermost and outermost conductors is smaller than the gap between the inclined parts of the inner and outer conductors (see Figure 4B), which can ensure the difficult measurement of the inclined parts of the inner and outer conductors. The gap is greater than the minimum safety insulation design requirement. In other words, since the gap between the inclined parts of the innermost and outermost wires is smaller than the gap between the inclined parts of the inner and outer conductors, it is confirmed that there is no short circuit between the innermost wires and the outermost wires (that is, insulated from each other). When this happens, the secondary inner conductors and the secondary outer conductors can also ensure that there is no short circuit at the same time, so the reliability of the product can be improved.

It is worth mentioning that in this embodiment, with the exception of the hairpin-shaped wire 140, the two legs of the remaining hairpin-shaped wire comply with the unequal distance relationship across the slot. This can satisfy the aforementioned effects.

It can be understood that, the embodiment in FIGS. 9A-11 described above is an example of a connection manner of one phase winding of a three-phase motor. Similarly, the windings of the remaining two phases are formed using the same connection method. It should be noted that when the individual single-phase windings are completed (that is, the U-phase, V-phase, and W-phase windings are completed in the above manner), the neutral wires 122 of the respective single-phase windings will be connected together on the insertion side for common Connect the electrical neutral terminal, as shown in Figure 1, to complete the winding structure of the three-phase motor.

Please refer to FIGS. 12A, 12B, 13A, 13B, and 14 which are schematic diagrams showing a connection manner of one phase winding of the three-phase motor stator 100b described above. In FIG. 12A, after the foot 130b of the hairpin-shaped wire 130 (1) passes through the slot (for example, the second outer layer of the slot), it protrudes from the extension side 110b of the iron core 110, bends in the direction 115a, and extends a span. Slot distance D3. After passing through the slot (for example, the outermost layer of the slot), the foot 130c of the hairpin-shaped wire 130 (2) protrudes from the extension side 110b of the iron core 110, bends in the direction 115b, and extends across a slot. Distance D4. Therefore, the foot 130b of the hairpin-shaped wire 130 (1) is connected to the foot 130c of the hairpin-shaped wire 130 (2) next to the extended side 110b of the iron core 110, and the hairpin shape of the outermost layer and the second outer layer of the slot is connected. The wires 130 (1), 130 (2),..., Are connected to each other in the above manner to form a winding that surrounds an iron core (such as the iron core 110 in FIG. 1), such as the winding 130 ′ in FIG. 12B. Similarly, in the slot next to the adjacent winding 130 ', another winding 130 "around the core can be formed by the above-mentioned method.

In this embodiment, the span-to-slot distance D3 (for example, 3.5 slot pitch) is greater than the span-to-slot distance D4 (for example, 2.5 slot pitch), but is not limited thereto.

Please refer to (a) of FIG. 14 together. Because the windings 130 ′ and 130 ″ are separated by one slot, if you want to connect the two windings, you need to use a hairpin with a different size from the hairpin conductor 130. Clip-shaped wire 130SP. As shown in FIG. 14 (a), one of the legs of the hairpin conductor 130P is inserted into the next outer layer of the slot, protrudes from the extended side and is bent to extend a distance D3 across the slot, and then is connected to the tail leg 1302 'of the winding 130' connection. In addition, the other leg of the hairpin-shaped wire 130P is inserted into the outermost layer of the slot, protruding from the extension side and bent to extend a span of a distance D4, and then connected to the first leg 1301 "of the winding 130", so that the The windings 130 'and 130 "are connected. In this embodiment, the size of the hairpin-shaped wire 130SP (for example, a distance between five slots) is smaller than the size of the hairpin-type wire 130 (for example, a distance between six slots), but the present invention is not limited thereto.

In this embodiment, the motor stator 100b includes a terminal wire 132 as one of the three-phase winding connection ends, and one end on the insertion side is used to connect to an electrical phase end (U-phase, V-phase, W-phase One of the phases) is connected to the winding 130 'at one end on the extension side. In this embodiment, as shown in FIG. 14 (a), the terminal wire 132 is inserted into the outermost layer of the slot, and the protruding extension side is bent to extend a distance D4 across the slot, and then connected to the first leg 1301 'of the winding 130' .

In this embodiment, the tail 1302 "of the winding 130" is connected to the winding inserted into the inner and inner layers through another hairpin-shaped wire 140 (as shown in Fig. 14 (b)). This section will be detailed later.

Please refer to Figures 13A and 13B. In FIG. 13A, after the pins 120b of the hairpin conductor 120 (1) pass through the slot (for example, the innermost layer of the slot), they protrude from the extension side 110b of the iron core 110, are bent in the direction 115a, and extend Crossing the distance D1, the foot 120c of the hairpin-shaped wire 120 (2) passes through the slot (for example, the second inner layer of the slot), protrudes from the extension side 110b of the core 110, and bends and extends in the direction 115b. Distance across the slot D2. Therefore, the foot 120b of the hairpin conductor 120 (1) is connected to the foot 120c of the hairpin conductor 120 (2) adjacent to the extended side 110b of the iron core 110, and the hairpins located at the innermost layer and the sub-inner layer of the slot are connected. The clip-shaped wires 120 (1), 120 (2),... Can be connected to each other through the above-mentioned methods to form a winding, such as the winding 120 'shown in FIG. 13B. Similarly, in the slot next to the adjacent winding 120 ', another winding 120 "surrounding the core can be formed by the above-mentioned method.

In this embodiment, the cross-slot distance D2 (for example, 3.5 slot pitch) is greater than the cross-slot distance D1 (for example, 2.5 slot pitch), but it is not limited thereto.

Next, please refer to (c) of FIG. 14 similarly to the windings 130 ′ and 130 ″. To connect the windings 120 ′ and 120 ″, a hairpin conductor 120SP with a different size from the hairpin conductor 120 is required. As shown in FIG. 14 (c), one of the legs of the hairpin conductor 120P is inserted into the innermost layer of the slot, protruding from the extension side and bent to extend a distance D1 across the slot, and then the tail foot 1202 of the winding 120 ' 'connection. In addition, the other pin of the hairpin conductor 120P is inserted into the slot's inner layer, protruding from the extension side and bent to extend a distance D2 across the slot, and then connected to the first leg 1201 "of the winding 120", thereby Connect the windings 120 'and 120' '. In this embodiment, the size of the hairpin-shaped wire 120SP (for example, a distance between five slots) is smaller than the size of the hairpin-type wire 120 (for example, a distance between six slots), but the present invention is not limited thereto.

In this embodiment, the motor stator 100b includes a neutral wire 122 as an electrical neutral end of the three-phase winding. One end on the insertion side is used to connect to an electrical neutral end, and one end on the extension side is It is used to connect with the winding 120 ". In this embodiment, as shown in Fig. 14 (c), the neutral conductor 122 is inserted into the innermost layer of the slot, and the protruding extension side is bent to extend a span distance D1, and then Connected to the tail foot 1202 "of the winding 120".

In this embodiment, the motor stator 100b further includes a hairpin-shaped wire 140 for connecting the windings 130 'and 130 "connected to the terminal wire 132 and the windings 120' and 120" connected to the neutral wire 122. As shown in FIG. 14 (b), one of the pins of the hairpin wire 140 is inserted into the next outer layer of the slot, and the protruding side is bent and extended a distance D3 across the slot, and then is inserted into the outermost winding 130 of the slot. "Tail foot 1302" connected. In addition, the other foot of the hairpin-shaped wire 140 is inserted into the inner layer of the slot, the protruding side is bent and extended a distance D2 across the slot, and then the first leg 1201 'of the winding 120' inserted into the innermost layer of the slot. connection. Thereby, the entire one-phase winding of the motor stator 110a can be completed. In this embodiment, the size of the hairpin-shaped wire 140 may be the same as the size of the hairpin-shaped wires 120 and 130 (for example, the distance between six slots), but the present invention is not limited thereto. On the other hand, the cross-slot distance D2 and the cross-slot distance D3 of the two legs of the hairpin-shaped wire 140 are the same, but not limited thereto.

In this embodiment, the cross-slot distance D1 of the wire inserted in the innermost layer is the same as the cross-slot distance D4 of the wire inserted in the outermost layer, and the cross-slot distance D2 of the wire inserted in the second inner layer is the same as The cross-slot distance D3 of the wires of the second outer layer is the same, and the cross-slot distance D1 is less than the cross-slot distance D2, and the cross-slot distance D4 is less than the cross-slot distance D3. As a result, the gap between the inclined parts of the innermost and outermost wires is greater than the gap between the inclined parts of the inner inner and outer wires. The design of the motor stator 100b is suitable for use in an oil cooling system. Because the gap between the innermost and outermost inclined wires is larger than the gap between the inner and outer outer wires, when the cooling oil is input, it can effectively reduce the resistance of the outer wires to the cooling oil flow. In other words, the cooling oil can effectively enter the inner wires (for example, the sub-inner layer and the sub-outer layer wires), thereby improving the contact effect between the inner layer wires and the cooling oil, and obtaining better conductor heat dissipation efficiency.

It is worth mentioning that in this embodiment, with the exception of the hairpin-shaped wire 140, the two legs of the remaining hairpin-shaped wire comply with the unequal distance relationship across the slot. This can satisfy the aforementioned effects.

It can be understood that, the above-mentioned embodiment of FIGS. 12A-14 is an example of a connection manner of one phase winding of a three-phase motor. Similarly, the windings of the remaining two phases are formed using the same connection method. It should be noted that when the individual single-phase windings are completed (that is, the U-phase, V-phase, and W-phase windings are completed in the above manner), the neutral wires 122 of the respective single-phase windings will be connected together on the insertion side. This completes the winding structure of the three-phase motor.

Please refer to FIG. 15, which illustrates a method 200 for forming a motor stator according to an embodiment of the present invention.

In step 202 (refer to FIG. 2 at the same time), an iron core 110 having a plurality of slots 112 is provided. The iron core 110 has an insertion side 110a and an extension side 110b opposite to the insertion side. Each slot 112 has an innermost layer 112a, a first inner layer 112b, a first outer layer 112c, and an outermost layer 112d in a radial direction 114 of the iron core 110.

In step 204 (please refer to FIGS. 3 to 8 at the same time), insert a plurality of first winding hairpin-shaped wires (for example, hairpin-shaped wires 120) into the slots. Each leg 120b of the hairpin conductor 120 is inserted into the innermost layer of the slots from the insertion side 110a of the iron core 110, and protrudes from the extended side 110b of the iron core 110. Each leg 120c of the hairpin conductor 120 is inserted from the insertion side 110a of the iron core 110 into the secondary inner layers of the slots, and protrudes from the extension side 110b of the iron core 110.

In step 206 (please refer to FIGS. 3 to 8 at the same time), insert a plurality of second winding hairpin conductors (for example, hairpin conductor 130) into the slots. Each leg 130b of the hairpin-shaped wire 130 is inserted into the secondary outer layers of the slots 112 from the insertion side 110a of the iron core 110, and protrudes from the extended side 110b of the iron core 110. Each leg 130c is inserted into the outermost layer of the slots 112 from the insertion side 110a of the iron core 110, and protrudes from the extended side 110b of the iron core 110. It should be noted that Figures 3 to 8 listed above are examples of the arrangement of one phase winding of a three-phase motor. In steps 204 to 206, inserting a plurality of first winding hairpin conductors and a plurality of second winding hairpin conductors refer to each of the first winding hairpin conductors and the second winding hairpins of each phase winding of the three-phase winding. The clip wires are inserted into the corresponding slots.

In step 208, bend each leg 120b in the direction 115a and extend a span distance D1, bend each leg 120c in the direction 115b and extend a span distance D2; bend each leg 130b in the direction 115a and extend For a cross-slot distance D3, bend each leg 130c in the direction 115b and extend a cross-slot distance D4. In the above embodiment of the motor stator 100a, the slot-to-slot distance D1 is the same as the slot-to-slot distance D4, the slot-to-slot distance D2 is the same as the slot-to-slot distance D3, and the slot-to-slot distance D1 is greater than the slot-to-slot distance D2, and the slot-to-slot distance D4 is greater than the slot-to-slot Distance D3. In the above embodiment of the motor stator 100b, the slot-to-slot distance D1 is the same as the slot-to-slot distance D4, the slot-to-slot distance D2 is the same as the slot-to-slot distance D3, and the slot-to-slot distance D1 is smaller than the slot-to-slot distance D2, and the slot-to-slot distance D4 is smaller than the slot-to-slot Distance D3.

In step 210, please refer to Figs. 1, 11, and 14, in addition to the hairpin conductors 120 and 130, the neutral conductor 122 and the terminal conductor 132 are also inserted, so that the conductors are arranged in all the slots of the iron core 110, and Bent neutral wires 122 and terminal wires 132 protrude from the extended side. As shown in FIG. 11 (c) and FIG. 14 (c), the neutral wire 122 is inserted into the innermost layer of the slot, and the protruding extension side 110b thereof is bent to extend a distance D1 across the slot. As shown in FIG. 11 (a) and FIG. 14 (a), the terminal lead 132 is inserted into the outermost layer of the slot, and the protruding extension side 110b thereof is bent to extend a distance D4 across the slot.

Similarly, in step 210, inserting the neutral conductor 122 and the terminal conductor 132 refers to inserting the neutral conductor 122 and the terminal conductor 132 of the three-phase winding into corresponding slots, so that all the conductors are arranged in the All slots.

In some examples, bending each leg 120b, bending each leg 130b, and bending the neutral wire 112 in the same direction 115a can be performed simultaneously to speed up the process and reduce man-hours; bending each leg 120c, Bending each leg 130c and bending terminal wire 132 in the same direction 115b can be performed simultaneously to speed up the process and reduce man-hours. Specifically, the first winding hairpin conductor (for example, hairpin conductor 120), the second winding hairpin conductor (for example, hairpin conductor 130), the neutral conductor 122, and the terminal conductor 132 are inserted into each corresponding After the slots are arranged in all slots, each leg of the first winding hairpin conductor 120b, each leg of the second winding hairpin conductor 130b, and the neutral conductor 122 are simultaneously bent, and the bending is performed simultaneously. Fold each leg 120c of the first winding hairpin conductor, each leg 130c of the second winding hairpin conductor, and the terminal conductor 132. In step 212, at the ends of all the above-mentioned wires, the first winding hairpin-shaped wire (such as hairpin-shaped wire 120), the second winding hairpin-shaped wire (such as hairpin-shaped wire 130), and the neutral wire 122 And terminal wires 132. Specifically, the close ends of the hairpin wires 120 are connected to form a first winding, and the close ends of the hairpin wires 130 are connected to form a second winding. For example, referring to FIGS. 9A, 10A, 12A, and 13A, the ends of the legs 130b of the hairpin conductor 130 (1) and the ends of the legs 130c of the immediately adjacent hairpin conductor 130 (2) are on the extended side 110b of the iron core 110. Connection, and so on; the foot 120b of the hairpin conductor 120 (1) is connected to the foot 120c of the hairpin conductor 120 (2) adjacent to the extended side 110b of the iron core 110, and so on. In addition, as shown in FIG. 11 (c) and FIG. 14 (c), the end of the neutral conductor 122 is connected to the end of the tail foot 1202 "of the first winding; as shown in Fig. 11 (a) and Fig. 14 ( As shown in a), the end of the terminal wire 132 is connected to the end of the first leg 1301 'of the second winding. In summary, the connection of various types of wires on the extension side is configured as "the end of the wire protruding from the innermost layer of the slot" Connected with the end of the wire protruding from the inner layer of the slot "and" connected with the end of the wire protruding from the slot's outer layer and the end of the wire protruding from the outermost layer of the slot ", finally forming a three-phase motor as shown in Figure 1 Stator winding structure.

In summary, the present invention utilizes hairpin-shaped wires to protrude the extended side of the iron core and bend them at different distances between the innermost layer, sub-inner layer, sub-outer layer, and outermost layer. This improves the heat dissipation efficiency of the conductor and ensures The lead gap meets the requirements for safe insulation design.

Although the present invention has been disclosed as above in the embodiments, it is not intended to limit the present invention. Any person skilled in the art can make various modifications and retouches without departing from the spirit and scope of the present invention. Therefore, the protection of the present invention The scope shall be determined by the scope of the attached patent application.

In order to make the above and other objects, features, advantages, and embodiments of the present invention more comprehensible, the description of the attached symbols is as follows:

100‧‧‧Motor stator

100a‧‧‧Motor stator

100b‧‧‧motor stator

110‧‧‧ iron core

110a‧‧‧ Insertion side

110b‧‧‧Extended side

110c‧‧‧ inside

110d‧‧‧outside

112‧‧‧slot

112a‧‧‧ innermost layer

112b‧‧‧times inner layer

112c‧‧‧th outer layer

112d‧‧‧ outermost

114‧‧‧

115‧‧‧ circumferential direction

115a‧‧‧direction

115b‧‧‧direction

120‧‧‧hairpin wire

120 （1） ‧‧‧hairpin wire

120 （2） ‧‧‧hairpin shaped wire

120 （3） ‧‧‧hairpin shaped wire

120SP‧‧‧hairpin wire

120a‧‧‧U-shaped bend

120b‧‧‧foot

120c‧‧‧foot

120d‧‧‧Insulation

120e‧‧‧end

120f‧‧‧ end

120’‧‧‧winding

1201’‧‧‧ head and feet

1202’‧‧‧ tail

120 ”‧‧‧winding

1201 "‧‧‧head

1202 "‧‧‧Tail feet

122‧‧‧ Neutral Conductor

130‧‧‧hairpin wire

130 （1） ‧‧‧hairpin shaped wire

130 （2） ‧‧‧hairpin shaped wire

130 （3） ‧‧‧hairpin shaped wire

130SP‧‧‧hairpin wire

130a‧‧‧U-shaped bend

130b‧‧‧ feet

130c‧‧‧ feet

130d‧‧‧insulation layer

130e‧‧‧ end

130f‧‧‧ end

130’‧‧‧winding

1301’‧‧‧ head and feet

1302’‧‧‧ tail

130 ”‧‧‧winding

1301 "‧‧‧head

1302 "‧‧‧Tail feet

132‧‧‧ terminal wire

140‧‧‧hairpin wire

D1‧‧‧Span distance

D2‧‧‧Span distance

D3‧‧‧Span distance

D4‧‧‧Span distance

VD‧‧‧Vertical distance

200‧‧‧ Method

202 ～ 212‧‧‧step

In order to make the above and other objects, features, advantages, and embodiments of the present invention more comprehensible, the description of the drawings is as follows: FIG. 1 is a perspective view showing a motor stator according to an embodiment of the present invention; FIG. 2 is a perspective view showing an iron core of a motor stator according to an embodiment of the present invention; FIG. 3 is a perspective view showing a motor stator and a hairpin-shaped wire according to an embodiment of the present invention; FIG. 4A is a drawing FIG. 3 is a bottom view of the motor stator and the hairpin-shaped wire in FIG. 3; FIG. 4B is a schematic diagram showing the relationship between the cross-slot distance of the hairpin-shaped wire and the clearance of the inclined portion according to an embodiment of the present invention; FIG. 3 is a side view of a motor stator and a hairpin conductor in FIG. 3; FIG. 6 is a perspective view of a motor stator and a hairpin conductor in accordance with another embodiment of the present invention; FIG. Figure 8 is a bottom view of the motor stator and hairpin conductors; Figure 8 is a side view of the motor stator and hairpin conductors of Figure 6; Figures 9A, 9B, 10A, 10B, and 11 are drawings according to the present invention A hairpin-shaped wire connector of an embodiment Figures 12A, 12B, 13A, 13B, and 14 show a schematic view of a hairpin-shaped wire connection method according to another embodiment of the present invention; and Figure 15 is a diagram showing a method according to an embodiment of the present invention How to form a motor stator.

Claims (20)

A motor stator includes: an iron core having a plurality of slots, the iron core having an insertion side and an extension side opposite to the insertion side, wherein each of the slots is in a radial direction with respect to the iron core It has an innermost layer, an inner layer, an outer layer and an outermost layer; a plurality of hairpin-shaped wires are arranged to be inserted into the slots from the insertion side and protrude from the extension side and are bent in the circumferential direction of the iron core And extending a span distance, wherein the hairpin conductors are connected at the extension side to form a winding structure, and the hairpin conductors inserted into the innermost layer extend a first span distance different from the The hairpin conductors of the second inner layer extend a second span distance, and the hairpin conductors of the second outer layer extend a third span distance different from the hairpins of the outermost layer. A fourth cross-slot distance is extended by the shaped wire, wherein the first cross-slot distance is the same as the fourth cross-slot distance, and the second cross-slot distance is the same as the third cross-slot distance. The motor stator according to item 1 of the patent application scope, wherein the first spanning slot distance is greater than the second spanning slot distance, and the fourth spanning slot distance is greater than the third spanning slot distance. The motor stator according to item 1 of the patent application scope, wherein the first spanning slot distance is smaller than the second spanning slot distance, and the fourth spanning slot distance is smaller than the third spanning slot distance. The motor stator according to item 1 of the application, wherein the hairpin conductors include a plurality of first winding hairpin conductors, and the first winding hairpin conductors have a first leg and a second leg, Respectively disposed in the innermost layer and the secondary inner layer of the slots, and bent and extended respectively in the first direction and the second direction to extend the first cross-slot distance and the second cross-slot distance, each of which The first leg is connected to the second leg immediately adjacent to form a first winding, wherein the hairpin conductors further include a plurality of second winding hairpin conductors, and the second winding hairpin conductors have a third pin And a fourth pin, which are respectively disposed on the outer layer and the outermost layer of the slots, and are bent in the third direction and the fourth direction and extend the third cross-slot distance and the fourth cross-slot distance, respectively, Each of the third pins is connected to the immediately adjacent fourth pin to form a second winding. The motor stator according to item 4 of the scope of patent application, further comprising: at least one neutral wire for connecting an electrical neutral terminal; and at least one terminal wire for connecting at least one electrical phase terminal; The first winding hairpin conductors, the second winding hairpin conductors, the at least one neutral conductor and the at least one terminal conductor are all disposed in the slots, and are protruded and bent at the extension side and The ends of the wires are connected to form a three-phase motor stator winding structure, wherein the connections at the ends of the wires are configured as follows: the ends of the wires protruding from the innermost layer are connected to the ends of the wires protruding from the inner layer next to it. ; And the end of the wire protruding from the outer layer is connected to the end of the wire protruding from the outermost layer next to it. The motor stator according to item 4 of the scope of patent application, wherein the first direction is the same circumferential direction as the third direction, and the second direction is the same circumferential direction as the fourth direction. The motor stator according to item 4 of the scope of the patent application, wherein the sum of the distance between the first span slot and the second span slot of each of the first winding hairpin conductors is equal to each of the second winding slots The sum of the distance between the third span of the clip-shaped wire and the distance between the fourth span. The motor stator according to item 4 of the scope of the patent application, wherein each of the first leg of the first winding hairpin conductor and the adjacent end of the second leg protrudes from the end face of the iron core at a vertical distance equal. The motor stator according to item 4 of the scope of patent application, wherein each of the first leg of the second winding hairpin conductors and the immediately adjacent connecting end of the second leg protrudes from the end face of the iron core at a vertical distance from each other. equal. A motor stator includes: an iron core having a plurality of slots, the iron core having an insertion side and an extension side opposite to the insertion side, wherein each of the slots is defined from the inside to the outside with respect to the core The first layer, the second layer, the third layer, and the fourth layer are provided. Each of the first hairpin-shaped wires has a first pin and a second pin. A foot is inserted into the first layer of the slots from the insertion side and protrudes from the extension side to bend in a first direction and extend a first spanning distance, and each second foot is inserted from the insertion side The second layer of the slots protrudes from the extension side to bend in a second direction and extend a second spanning distance, wherein the first spanning distance is different from the second spanning distance, each of The first pin is connected to the second pin immediately adjacent to form a first winding; and a plurality of second hairpin-shaped wires, each of the second hairpin-shaped wires has a third pin and a fourth pin, the The third foot is inserted into the third layer of the slots from the insertion side and protrudes from the extension side in a third direction And extend a third span distance, and the fourth foot is inserted into the fourth layer of the slots from the insertion side and protrudes from the extension side in a fourth direction to bend and extend a fourth span distance, The third span-to-slot distance is different from the fourth span-to-slot distance, and each of the fourth legs is connected to the immediately adjacent third leg to form a second winding. The motor stator according to item 10 of the scope of patent application, wherein the sizes of the first hairpin conductors are equal to the sizes of the second hairpin conductors. According to the motor stator of claim 10, the first direction is the same circumferential direction as the third direction, and the second direction is the same circumferential direction as the fourth direction. The motor stator according to item 10 of the scope of patent application, wherein each of the first and second hairpin conductors is covered with an insulating layer, and the ends of the two legs of each hairpin conductor are from the Bare insulation. A method for forming a motor stator includes: providing an iron core having a plurality of slots, the iron core having an insertion side and an extension side opposite to the insertion side, wherein each of the slots is opposite to the iron The core has an innermost layer, an inner layer, an outer layer and an outer layer in the radial direction; inserting a plurality of first winding hairpin conductors into the slots so that the first winding hairpin conductors A first foot and a second foot are respectively inserted into the innermost layer and the secondary inner layer of the slots from the insertion side and protrude from the extension side; inserting a plurality of second winding hairpin-shaped wires to the plugs In the slot, a third leg and a fourth leg of one of the second winding hairpin conductors are respectively inserted from the insertion side into the secondary outer layer and the outermost layer of the slots and protrude from the extension side; A first foot is bent in a first direction to extend a distance across a slot; each second foot is bent in a second direction to extend a distance across a slot; each of the Bending the third foot in a third direction to extend a third spanning distance; and Each of the fourth feet is bent in a fourth direction to extend a fourth span distance, wherein the first span distance is different from the second span distance, and the third span distance is different from the fourth span. The slot distance, and the first span slot distance are the same as the fourth span slot distance, and the second span slot distance is the same as the third span slot distance. The method according to item 14 of the scope of patent application, wherein the first direction is the same circumferential direction as the third direction, and the second direction is the same circumferential direction as the fourth direction. The method according to item 14 of the scope of patent application, wherein the first spanning distance is greater than the second spanning distance, and the fourth spanning distance is greater than the third spanning distance. The method according to item 14 of the scope of patent application, wherein the first spanning distance is smaller than the second spanning distance, and the fourth spanning distance is smaller than the third spanning distance. The method according to item 14 of the scope of patent application, further comprising: synchronously performing the steps of bending each of the first foot and bending each of the third foot; and simultaneously performing the bending of each of the second foot and the bend Fold each step of the fourth leg. The method according to item 14 of the scope of patent application, further comprising: connecting each of the first leg and the immediately adjacent second leg to form a first winding; and connecting each of the third leg and the immediately adjacent fourth part Feet to form a second winding. The method according to item 14 of the scope of patent application, further comprising: inserting at least one neutral wire and at least one terminal wire so that the first winding hairpin-shaped wire, the second winding hairpin-shaped wire, the at least one The conductive wire and the at least one terminal wire are arranged in all the slots, wherein the at least one neutral wire is used to connect an electrical neutral terminal, and the at least one terminal wire is used to connect at least one electrical phase terminal; Fold the end of the at least one neutral conductor; bend the end of the at least one terminal conductor; connect the first winding hairpin conductor, the second winding hairpin conductor, the at least one middle at the end of the conductor The conductive wire is connected to the at least one terminal wire, wherein the connection at the end of the wire is configured to: connect the end of the wire protruding from the innermost layer with the end of the wire protruding from the secondary inner layer; and project from the secondary outer layer The ends of the wires are connected to the ends of the wires protruding from the outermost layer.