TWI802966B - Vehicle motor stator structure - Google Patents

Abstract

A stator structure of a vehicle motor includes a core assembly and a plurality of coil assemblies composed of flat wires. The core assembly includes an annular portion and a plurality of tooth portions. The tooth portions extend from the annular portion in a radial direction toward a center of the core assembly. Each coil assembly is configured around a corresponding tooth portion. Each coil assembly includes a first flat wire and a plurality of second flat wires that are electrically connected in parallel. The first flat wire is radially stacked and wound around the tooth portion. The second flat wires are arranged radially adjacent to the first flat wire and are electrically connected in series to the first flat wire. The second flat wires are alternately stacked and radially wound around the tooth portion.

Description

Stator structure of automotive motor

The present invention relates to a stator structure, in particular to a stator structure of a vehicle motor.

If conventional vehicle motors use circular cross-section wires to be stacked and wound on the teeth of the iron core, if it is desired to fill up the space between the winding slots between adjacent teeth as much as possible, it usually takes a long time to process, and many The slot occupation rate of wires after coil stacking and winding is still not ideal. In view of this, motor manufacturers are actively looking for a solution to increase the slot ratio of the wires after winding, so as to improve the performance of the motor more effectively.

According to an embodiment of the present invention, a stator structure of a vehicle motor includes an iron core assembly and a plurality of coil assemblies composed of flat wires. The iron core assembly includes an annular portion and a plurality of teeth, and the teeth extend from the annular portion radially toward the center of the iron core assembly. Each coil assembly is configured on a corresponding tooth portion, and each coil assembly includes a first flat wire and a plurality of second flat wires electrically connected in parallel. The first flat wires are radially stacked and wound around the teeth. The second flat wires are disposed radially adjacent to the first flat wires and electrically connected in series to the first flat wires, and the second flat wires are alternately stacked and wound around the teeth in the radial direction.

According to another embodiment of the present invention, a stator structure of a vehicle motor includes an iron core assembly and a plurality of coil assemblies composed of flat wires. The iron core assembly includes an annular portion and a plurality of teeth, and the teeth extend from the annular portion radially toward the center of the iron core assembly. Each coil assembly is configured on a corresponding tooth portion, and each coil assembly includes a first flat wire and a plurality of second flat wires electrically connected in parallel. The first flat wires are radially stacked and wound around the teeth. The second flat wires are radially stacked and wound on the tooth portion and are radially adjacent to the first flat wires and electrically connected in series to the first flat wires. The sum of the cross-sectional radial thicknesses of each of the second flat wires is greater than the cross-sectional radial thickness of the first flat wires, wherein all the stacked second flat wires wound on the tooth portion have a cross-sectional radial thickness of The sum is smaller than the sum of the cross-sectional radial thicknesses of all the stacked first flat wires wound around the teeth.

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, and 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 in order to avoid unnecessarily limiting the invention. In the embodiments and the scope of the patent application, unless the article is specifically limited in the context, "a" and "the" can generally refer to a single or plural.

Referring to FIG. 1 , the stator structure 100 includes an iron core assembly 110 . The iron core assembly 110 includes an annular portion 112 and a plurality of tooth portions 114 , and the plurality of tooth portions 114 extend radially from the annular portion 112 toward the center 110 c of the iron core assembly 110 . An insulating winding frame 116 is sheathed around each tooth portion 114 , so that the coil wire can be better insulated from the core assembly 110 when winding. The stator structure 100 includes a plurality of coil assemblies 120 composed of flat wires, and each coil assembly 120 is disposed on a corresponding tooth portion 114 . In terms of manufacturing process, using the coil component 120 composed of flat wires to put it on the tooth portion 114 can quickly and radially stack and wind on each tooth portion 114 , reducing the man-hours spent on winding. The coil assembly 120 composed of flat wires also helps to increase the operating power of the motor stator of the vehicle.

Please refer to FIG. 2 , each coil assembly includes a first flat wire 122 and a plurality of second flat wires 124 electrically connected in parallel. The first flat wires 122 are radially stacked and wound on the tooth portion 114 from the root portion 114 c of the tooth portion 114 . The second flat wires 124 are radially adjacent to the first flat wires 122 and electrically connected in series to the first flat wires 122 . In one embodiment of the present invention, each coil assembly includes a first flat wire 122 and two second flat wires 124 electrically connected in parallel, and the two second flat wires (1241, 1242 ) are alternately stacked and wound on the tooth portion 114 in the radial direction (please also refer to FIG. 3 , the two second flat wires 1241 and 1242 are distinguished by different grayscale coloring). In other embodiments of the present invention, each coil assembly may include three or more second flat wires electrically connected in parallel. The stacked windings of the second flat wires 124 are farther away from the ring portion 112 than the stacked windings of the first flat wires 122 . The electrical configuration of the above-mentioned first and second flat wires 122 and 124 helps to reduce power loss when the stator structure is in operation. Since the first and second flat wires 122 and 124 have equal conductor cross-sectional areas, using different wire cross-sectional sizes can further increase the slot fill rate of the conductors and effectively reduce DC copper loss. In addition, the first flat wire 122 is connected in series with the second flat wire 124, and then dividing the second flat wire 124 into 1241 and 1242 can reduce the cross-sectional area of each single conductor of the copper wire near the head portion 114b of the tooth portion, thereby improving the magnetic field density. High places reduce the cross-sectional area of a single conductor, which can effectively reduce the loss of AC copper wires.

The first flat wires 122 include a first end 122a and a second end 122b, and the second flat wires 124 include a first end 124a and a second end 124b electrically connected in parallel. In one embodiment of the present invention, the position where the first end 122a of the first flat wire and the first ends 124a of the second flat wires protrude from the core assembly 110 is close to the ring portion 112, which is beneficial to free up more space. A lot of space is provided for the configuration of the ring-connecting structure (such as the ring-connecting structure 150 in FIG. 6 ). In addition, the flat wire protrudes close to the annular portion 112 and is also far away from the middle of the iron core of the motor rotor, which can reduce the inconvenience in the manufacturing process and the obstruction during the rotation of the motor. In an embodiment of the present invention, the second flat wires 124 include an extension portion 124c extending from the head 114b close to the tooth portion 114 to the first end 124a of the second flat wires for guiding and extending the second flat wires. The two flat wires 124 are wound to protrude close to the annular portion 112 . The extension portion 124c is disposed axially adjacent to the wires of the stacked layers, so as to avoid occupying the slot space between the tooth portions. In the embodiment shown in FIG. 2 , the extension portion 124c is disposed adjacent to the arc-shaped bend portion 130 of the stacked layer conductors. Using this space is beneficial to reduce or avoid the possible increase in the axial length of the core assembly 110 when the extension portion 124c is disposed. In an embodiment of the present invention, the first end 122a of the first flat wire 122 protrudes from the first side 115a of the tooth portion 114 , and the first ends 124a of the second flat wires 124 protrude from the first side 115a of the tooth portion 114 The two sides 115b, the second side 115b and the first side 115a are opposite to each other, and this configuration is beneficial to have intervals between the first end 122a of the first flat wire 122 and the first ends 124a of the second flat wires 124 to each Connect the electric phase terminal or neutral terminal to reduce mutual interference. In an embodiment of the present invention, the second end 122b of the first flat wire 122 is connected to the second ends 124b of the second flat wires 124 to form a joint (for example, a joint is formed by welding), so that The first flat wires 122 are connected in series with the parallel second flat wires 124 .

Please refer to Figure 3, in an embodiment of the present invention, each coil assembly includes a first flat wire 122 and two second flat wires (1241, 1242) electrically connected in parallel, the first and second flat The two types of flat wires 122 and 124 have different cross-sectional thicknesses and widths, and form a stepped profile adjacent to each other along the radial direction R, so as to increase the ratio of the wires to the slots and improve the operating power of the stator structure. In an embodiment of the present invention, the cross-sectional areas of the two second flat wires 124 electrically connected in parallel (that is, two flat wires (1241, 1242) filled in different gray scales in the figure) have a single cross-sectional area equal to or nearly equal to The single cross-sectional area of the first flat wire 122 is used to reduce AC power loss. In one embodiment of the present invention, the single cross-sectional width W1 of the first flat wire 122 is greater than the single cross-sectional width W2 of each second flat wire 124 , so that a stepped profile can be formed. The aforementioned cross-sectional width W1/W2 is the width in the direction perpendicular to the radial direction R.

In an embodiment of the present invention, the sum of the cross-sectional radial thicknesses of each of the second flat wires 124 (that is, the cross-sectional radial thickness T2a of the wire 1241+the cross-sectional radial thickness T2b of the wire 1242 ) is greater than that of the first flat wire 124. The cross-sectional radial thickness (T1) of a single wire 122, and the sum of the cross-sectional radial thicknesses of the second flat wires 124 wound on the teeth 114 in all stacks (T2sum along the radial direction R) is smaller than all stacks The sum of the cross-sectional radial thicknesses of the first flat wires 122 wound on the tooth portion 114 (T1sum along the radial direction R) is used to increase the ratio of the wires to occupy the slots.

In an embodiment of the present invention, the cross-sectional width W3 (thickness perpendicular to the radial direction R) of a tooth portion 114 is uniform from the root portion 114c to the head portion 114b. In one embodiment of the present invention, the tooth portion 114 includes a side surface 114a vertically connected to or nearly vertically connected to the inner ring surface 112a of the annular portion 112 at the root portion 114c of the tooth portion, so as to configure the first flat wire 122 with an approximately rectangular cross-section with the second flat wire 124 . In an embodiment of the present invention, the individual cross-sectional areas of the second flat wires 124 are equal or nearly equal to each other (for example, the single cross-sectional areas of the second flat wires 1241 and 1242 are equal or nearly equal to each other), so that The current density of each second flat wire 124 is maintained approximately equal. In other embodiments of the present invention, the individual cross-sectional areas of the second flat wires are not equal to each other, for example, the single cross-sectional areas of the second flat wires 1241 and 1242 have an integer or near-integer proportional relationship with each other.

Referring to FIG. 4 , the iron core assembly 110 has a first side 110 a and a second side 110 b opposite to each other. The first end 122 a of the first flat wire 122 and the first ends 124 a of the second flat wires 124 respectively protrude from the first side 110 a of the iron core assembly 110 . The second ends 122b of the first flat wires 122 and the second ends 124b of the second flat wires 124 are connected to each other to form a junction located on the second side 110b of the core assembly 110, which is beneficial to the second end 124b of the first flat wires 122. The end 122b is connected to the second ends 124b of the second flat wires 124 (for example, a joint is formed by welding). The first ends ( 122 a , 124 a ) and the second ends ( 122 b , 124 b ) of the flat wires are arranged on opposite sides of the iron core assembly 110 , which also facilitates the arrangement of the winding electrodes of the stator structure. For example, the first end 122a of the first flat wire is used to connect the electrical phase end, and the first end 124a of the second flat wire is used to connect the electrical neutral end; The neutral end, the first end 124a of the second flat wire is used to connect to the electric phase end.

Please refer to FIG. 5 and FIG. 6 at the same time, the stator structure 100 further includes an insulating ring cover 140 and a plurality of ring connection structures 150 . The insulating annular cover 140 covers the annular portion 112 adjacent to the core assembly 110 and the coil assemblies 120 to insulate and isolate the annular connection structures 150 and the coil assemblies 120 . In an embodiment of the present invention, the insulating ring cover 140 has a plurality of through holes 140a, and each through hole 140a can provide the first end 122a of the first flat wire 122 and the first ends of the second flat wires 124 124a crosses the salient. In an embodiment of the present invention, the insulating annular cover 140 has a groove area 140b, so that the ring-shaped wiring structures 150 are coaxially disposed in the groove area 140b. In the embodiment of the present invention, the ring connection structure 150 has a plurality of pins 150a, so as to be respectively connected to the first ends (122a, 124a) of the flat wires. The pins 150a cooperate with the ring connection structure 150 and are connected to the electrical neutral end or the electrical phase end by the connecting plate 150b. In an embodiment of the present invention, the insulating ring cover 140 has a plurality of notches 140c for respectively accommodating a plurality of connection plates 150b of the ring connection structure 150 to connect the electrical neutral end or the electrical phase end.

The stator structure of the vehicle motor of the present invention uses two types of flat wires with different cross-sectional thicknesses and widths to form a stepped profile adjacent to each other in the radial direction, thereby increasing the ratio of the wires to the slots. The two types of flat wires include a first flat wire electrically connected in series to a plurality of second flat wires electrically connected in parallel. The second flat wires are radially adjacently stacked on the first flat wires, and alternately stacked and wound on the tooth portion in the radial direction. The sum of the cross-sectional radial thicknesses of each of the second flat wires is greater than the cross-sectional radial thickness of the first flat wires, and the cross-sectional radial thickness of all the second flat wires stacked and wound on the tooth portion The sum is smaller than the sum of the cross-sectional radial thicknesses of all the stacked first flat wires wound around the teeth. With the configuration of the above two flat wires, the ratio of the wires to the slots can be better improved, the stator operation loss can be reduced, and the operation performance of the stator structure of the vehicle motor can be improved.

Although the present invention has been disclosed above in terms of implementation, it is not intended to limit the present invention. Any skilled person can make various changes and modifications without departing from the spirit and scope of the present invention. Therefore, the protection of the present invention The scope shall be defined by the appended patent application scope.

100: Stator structure 110: core assembly 110a: first side 110b: second side 110c: ring center 112: Iron core annular part 112a: Inner ring surface 114: iron core teeth 114a: side surface 114b: Tooth head 114c: tooth root 115a: the first side of the tooth 115b: the second side of the tooth portion 116: winding frame 120: coil assembly 122: the first flat wire 122a: the first end of the first flat wire 122b: the second end of the first flat wire 124: the second flat wire 1241: Second flat wire 1242: Second flat wire 124a: the first end of the second flat wire 124b: the second end of the second flat wire 124c: second flat wire extension 130: arc bend 140: insulating ring cover 140a: through hole 140b: Groove area 140c: Gap 150: ring knot structure 150a: Pin 150b: connecting plate T1: section radial thickness T2a: section radial thickness T2b: section radial thickness T1sum: total T2sum: total W1: section width W2: section width W3: section width R: Radial

Fig. 1 is a perspective view showing the structure of a motor stator for a vehicle according to an embodiment of the present invention; Figure 2 is a three-dimensional view of a stator structure of an embodiment of the present invention with a coil assembly disposed on the teeth; Fig. 3 is a cross-sectional view of a stator structure of an embodiment of the present invention with a coil assembly arranged at the teeth; Fig. 4 is a side view showing the stator structure of a vehicle motor according to an embodiment of the present invention; Fig. 5 is a perspective view showing the stator structure of Fig. 1 with an insulating annular cover added; and FIG. 6 is a perspective view of the stator structure in FIG. 5 with the ring-connected structure added.

Domestic deposit information (please note in order of depositor, date, and number) none Overseas storage information (please note in order of storage country, institution, date, and number) none

110: core assembly

112: Iron core annular part

114: iron core teeth

114b: Tooth head

114c: tooth root

115a: the first side of the tooth

115b: the second side of the tooth portion

120: coil assembly

122: the first flat wire

122a: the first end of the first flat wire

122b: the second end of the first flat wire

124: the second flat wire

1241: Second flat wire

1242: Second flat wire

124a: the first end of the second flat wire

124b: the second end of the second flat wire

124c: second flat wire extension

130: arc bend

Claims (20)

A stator structure of a vehicle motor, comprising: an iron core assembly, including an annular portion and a plurality of teeth, the teeth extending from the annular portion radially toward the core of the iron core assembly; and a plurality of coil components composed of flat wires, each of which is arranged on a corresponding tooth portion, and each of the coil components includes: a first flat wire, radially stacked and wound on the tooth portion; and a plurality of second flat wires electrically connected in parallel, arranged radially adjacent to the first flat wires and electrically connected in series to the first flat wires, the second flat wires are alternately stacked and wound radially on the tooth. The stator structure according to claim 1, wherein the sum of the cross-sectional areas of each of the second flat wires is equal to or nearly equal to the cross-sectional area of the first flat wires. The stator structure as described in Claim 1, wherein the cross-sectional areas of each of the second flat wires are: equal or nearly equal to each other; or not equal to each other; or have an integer or near integer ratio to each other. The stator structure according to claim 1, wherein the stacked windings of the second flat wires are farther away from the annular portion than the stacked windings of the first flat wires. The stator structure according to claim 1, wherein the cross-sectional width of the first flat wire is greater than the cross-sectional width of each of the second flat wires. The stator structure as claimed in claim 1, wherein the sum of the cross-sectional radial thicknesses of each of the second flat wires is greater than the cross-sectional radial thickness of the first flat wires, wherein all stacked wires are wound on the tooth portion The sum of the cross-sectional radial thicknesses of the second flat wires is smaller than the sum of the cross-sectional radial thicknesses of all the first flat wires stacked and wound on the teeth. The stator structure as claimed in claim 1, wherein the tooth portion includes a side surface vertically connected to the root of the tooth portion or nearly vertically connected to the inner ring surface of the annular portion. The stator structure according to claim 1, wherein the first flat wires include a first end and a second end, wherein the second flat wires include first ends and second ends electrically connected in parallel, wherein the The positions where the first ends of the first flat wires and the first ends of the second flat wires protrude from the core assembly are close to the ring portion. The stator structure as claimed in claim 8, wherein the second flat wires include an extension extending from the head near the tooth portion to the first end of the second flat wires. The stator structure as claimed in claim 8 or 9, wherein the first end of the first flat wire and the first ends of the second flat wires respectively protrude from the first side of the iron core assembly, the iron core assembly A second side is opposite to the first side. The stator structure according to claim 10, wherein the second ends of the first flat wires and the second ends of the second flat wires are connected to each other to form a junction, and the junction is located close to the core assembly. second side. The stator structure as claimed in item 8, wherein the first end of the first flat wire protrudes from the first side of the tooth portion, wherein the first ends of the second flat wires protrude from the second side of the tooth portion side, the second side and the first side are opposite to each other. A stator structure of a vehicle motor, comprising: an iron core assembly, including an annular portion and a plurality of teeth, the teeth extending from the annular portion radially toward the core of the iron core assembly; and a plurality of coil components composed of flat wires, each of which is arranged on a corresponding tooth portion, and each of the coil components includes: a first flat wire, radially stacked and wound on the tooth portion; And a plurality of second flat wires electrically connected in parallel are stacked and wound radially on the tooth portion, and these second flat wires are arranged radially adjacent to the first A flat wire electrically connected in series to the first flat wire, wherein the sum of the cross-sectional radial thicknesses of each of the second flat wires is greater than the cross-sectional radial thickness of the first flat wire, wherein all stacked windings The sum of the cross-sectional radial thicknesses of the second flat wires on the tooth portion is smaller than the sum of the cross-sectional radial thicknesses of all the first flat wires stacked and wound on the tooth portion. The stator structure according to claim 13, wherein the first flat wire and the second flat wire are radially adjacent to form a stepped profile, wherein the sum of the cross-sectional areas of each of the second flat wires is equal to Or nearly equal to the cross-sectional area of the first flat wire. The stator structure according to claim 13, wherein the cross-sectional areas of each of the second flat wires are: equal or nearly equal to each other; or not equal to each other; or have an integer or near integer ratio to each other. The stator structure according to claim 13, wherein the first flat wires include a first end and a second end, wherein the second flat wires include first ends and second ends electrically connected in parallel, wherein the The positions where the first ends of the first flat wires and the first ends of the second flat wires protrude from the core assembly are close to the ring portion. The stator structure as claimed in claim 16, wherein the second flat wires include an extension extending from the head near the tooth portion to the first end of the second flat wires. The stator structure as claimed in claim 13, wherein the first end of the first flat wire and the first ends of the second flat wires respectively protrude from the first side of the iron core assembly, and the iron core assembly includes a The second side and the first side are opposite to each other, the second end of the first flat wire and the second ends of the second flat wires are connected to each other to form a junction, and the junction is located close to the core assembly. second side. The stator structure as claimed in claim 13 further comprises an insulating annular cover covering the annular portion adjacent to the iron core assembly, and the insulating annular cover has a plurality of through holes for the first flat wires. The end protrudes through the first ends of the second flat wires. The stator structure as described in Claim 19 further includes a plurality of ring-shaped connection structures coaxially arranged on the insulating ring-shaped cover, each of the ring-shaped connection structures is used to connect at least one of the first flat wires of the coil assembly The first end or the first ends of the second flat wires.

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