WO2019062897A1 - 定子组件和具有其的电机和车辆 - Google Patents

定子组件和具有其的电机和车辆 Download PDF

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Publication number
WO2019062897A1
WO2019062897A1 PCT/CN2018/108591 CN2018108591W WO2019062897A1 WO 2019062897 A1 WO2019062897 A1 WO 2019062897A1 CN 2018108591 W CN2018108591 W CN 2018108591W WO 2019062897 A1 WO2019062897 A1 WO 2019062897A1
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WO
WIPO (PCT)
Prior art keywords
stator
line
phase
winding
star
Prior art date
Application number
PCT/CN2018/108591
Other languages
English (en)
French (fr)
Inventor
陈晓平
陈园辉
游斌
Original Assignee
比亚迪股份有限公司
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Publication of WO2019062897A1 publication Critical patent/WO2019062897A1/zh

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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • H02K3/28—Layout of windings or of connections between windings
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • H02K3/12—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors arranged in slots
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/46—Fastening of windings on the stator or rotor structure
    • H02K3/50—Fastening of winding heads, equalising connectors, or connections thereto
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K2203/00—Specific aspects not provided for in the other groups of this subclass relating to the windings
    • H02K2203/06—Machines characterised by the wiring leads, i.e. conducting wires for connecting the winding terminations

Definitions

  • the present disclosure relates to the field of electrical machinery, and more particularly to a stator assembly and a motor and vehicle therewith.
  • the neutral line connects two connection parts two by two U-shaped lines, which causes the intermediate welding part to be thick, takes up a large space, and is welded. Performance is difficult to guarantee.
  • the present disclosure is intended to address at least one of the technical problems existing in the prior art. To this end, the present disclosure proposes a stator assembly in which the star point line and the neutral line are simply connected and occupy less space.
  • a second aspect of the present disclosure is to provide a motor having the above stator assembly.
  • a third aspect of the present disclosure is to propose a vehicle having the above electric machine.
  • a stator assembly includes: a cylindrical stator core having a plurality of stator slots spaced apart in a circumferential direction of the stator core; a stator winding including a plurality of stator windings a conductor segment, each of the conductor segments including an in-slot portion disposed in the stator slot, a first end and a second end disposed outside the stator core, the in-slot portion being coupled to the first end And the second end of the plurality of conductor segments forming a soldering end, wherein the star-point lines of each phase of the stator winding are located on the soldering end; a neutral line, the neutral line The welded end of the stator winding is circumferentially wound and is directly connected to the star point line of each phase.
  • the stator assembly of the present disclosure by providing a neutral line and directly connecting the star point lines of the respective phases to the neutral line, the welded portion is reduced and the neutral line and the star point line are reduced as compared with the related art.
  • the connection is more stable, and the connection structure between the star point and the neutral line is simplified, the welding portion is reduced, the axial and radial space of the stator assembly occupied thereby is reduced, and the structure is compact, so that the space occupied by the casing and the end cover of the motor is occupied. Minimize and meet the requirements for motor miniaturization.
  • FIG. 1 is a schematic view of a stator assembly in which a line end of a star point line extends upward in accordance with an embodiment of the present disclosure
  • FIG. 2 is a schematic view of a stator assembly in which a wire end of a star point line is bent outward according to an embodiment of the present disclosure
  • Figure 3 is a schematic view showing the star point line and the neutral line shown in Figure 2;
  • FIG. 4 is a schematic illustration of a stator assembly in which a neutral line has an antennae, in accordance with an embodiment of the present disclosure
  • FIG. 5 is a schematic diagram of a star point line and a neutral line connection of a stator assembly according to an embodiment of the present disclosure, wherein the motor is three-phase and each phase is one way, and the neutral line is an antenna type;
  • FIG. 6 is a schematic view of a stator assembly in which the antennae of the neutral line are in a straight line, in accordance with an embodiment of the present disclosure
  • FIG. 7 is a schematic view of a stator core in a stator assembly in accordance with an embodiment of the present disclosure
  • FIG. 8 is a schematic illustration of a U-shaped conductor segment in a stator assembly in accordance with an embodiment of the present disclosure
  • FIGS. 9a-9d are schematic illustrations of first to fourth U-shaped conductor segments employed in winding a stator assembly in accordance with an embodiment of the present disclosure
  • FIG. 10 is a schematic diagram of a stator assembly as an initial arrangement, with an 8-pole 48-slot 3 phase as an example, in accordance with an embodiment of the present disclosure
  • FIG. 11 is a schematic view showing the winding manner of the stator assembly of FIG. 10, wherein the U-phase 1 road is taken as an example;
  • FIG. 12 is a final stator assembly in which the stator assembly of FIG. 10 is processed to form a 2-way wiring manner;
  • Figure 13 is a final stator assembly of the stator assembly of Figure 10 after being processed to form a 1-way connection;
  • FIG. 14 is a schematic view of a motor in accordance with an embodiment of the present disclosure.
  • 15 is a schematic diagram of a vehicle in accordance with an embodiment of the present disclosure.
  • the neutral line 3 The neutral line 3, the curved connecting member 31, the antenna angle 32, the first connecting portion 321, the second connecting portion 322, the curved portion 323, and the escape space 5.
  • connection In the description of the present disclosure, it should be noted that the terms “installation”, “connected”, and “connected” are to be understood broadly, and may be fixed or detachable, for example, unless otherwise explicitly defined and defined. Connected, or integrally connected; can be mechanical or electrical; can be directly connected, or indirectly connected through an intermediate medium, can be the internal communication of the two components.
  • Connected, or integrally connected can be mechanical or electrical; can be directly connected, or indirectly connected through an intermediate medium, can be the internal communication of the two components.
  • the specific meanings of the above terms in the present disclosure can be understood in the specific circumstances by those skilled in the art.
  • stator assembly 100 in accordance with an embodiment of the present disclosure is described below with reference to FIGS.
  • the m-phase motor is used as a three-phase motor as an example.
  • the m-phase motor is a technical solution of other phase motors after reading the following technical solutions, and therefore will not be described here. .
  • a stator assembly 100 of an embodiment of the present disclosure includes a stator core 1, a stator winding 2, and a neutral wire 3.
  • the stator core is cylindrical, and the stator core 1 has a plurality of stator slots; the stator slots are formed on the inner peripheral wall of the stator core 1 and are axially aligned (for example, as shown in FIG. 1) The direction) penetrates the stator core 1, and a plurality of stator slots are spaced apart in the circumferential direction of the stator core 1, and the depth direction of the stator slots coincides with the radial direction of the stator core.
  • Each stator slot 11 has a plurality of slot layers therein. Specifically, after the stator windings are inserted into the stator slots 11, the stator slots have a plurality of layers formed by stator windings.
  • the slot layers include The respective layers a, b, c, d, e, and f are arranged in each of the stator slots 11 in the radial direction of the stator core 1 in the innermost layer, and in the outermost layer, in the outer layer.
  • Floor The respective layers a, b, c, d, e, and f are arranged in each of the stator slots 11 in the radial direction of the stator core 1 in the innermost layer, and in the outermost layer, in the outer layer.
  • the rotor of the three-phase machine includes eight poles, and correspondingly, the total number of stator slots disposed on the stator core is 48.
  • stator winding 2 comprising a plurality of conductor segments 21, each conductor segment 21 comprising an in-slot portion disposed in a stator slot of the stator core, a first end and a second end disposed outside the stator core, The inner portion of the slot is connected between the first end and the second end, the second end of the plurality of conductor segments 21 forms a soldering end 23, and the star-point lines 24 of the phases of the stator winding 2 are all located on the soldering end 23.
  • each conductor segment 21 includes: an in-slot portion (for example, a first in-slot portion 212 and a second in-slot portion 213 described hereinafter) and a bent portion, wherein the inner portion of the groove is disposed in the stator In the groove, the bent portion is connected to the inner portion of the groove, and after the inner portion of the groove passes through the stator groove, the end portion of the inner portion of the groove (for example, the upper end portion of the inner portion of the groove shown in FIG. 1) exceeds the stator core 1, and the inner portion of the groove exceeds
  • the end of the stator core 1 forms the welded end 23 of the stator winding 2.
  • the star-point lines of the phases of the stator winding 2 are all located on the welding end 23, that is to say, the respective star-point lines 24 of the stator winding 2 are taken out from the welding end 23 and connected by the neutral line 3.
  • the neutral wire 3 surrounds the welding end 23 of the stator winding 2 in the circumferential direction of the stator core, whereby the distance between the star point line 24 and the neutral line 3 can be reduced, facilitating the neutral line 3 and the welding end 23
  • the star point line 24 is connected.
  • the neutral line 3 is connected to the star point line 24 of each phase. That is to say, each phase star line 24 is connected to the neutral line 3, respectively. In this way, the connection position of each star point line 24 and the neutral line 3 can be made small, and the connection mode is simpler.
  • the star point line 24 of each phase of the stator winding 2 is directly connected to the neutral line 3. That is to say, the star point lines 24 are all directly connected to the neutral line 3, and the plurality of star point lines 24 are connected together by being connected with the neutral line 3, instead of being indirectly connected to the neutral line 3 through the intermediate transitional link.
  • the neutral line 3 directly connects all the star point lines 24 in the stator winding 2, which reduces the welding position and makes the connection between the neutral line and the star point line more stable. Thereby, the connection is convenient, simple and quick.
  • each of the star-point lines 24 in each of the stator windings 2 is directly soldered to the neutral line 3, respectively.
  • stator assembly 100 of the present disclosure is described below.
  • the stator assembly 100 of the present embodiment is used for a three-phase motor
  • the stator winding 2 of the three-phase motor is a three-phase winding: a U-phase winding, a V-phase winding, and a W-phase winding, in each phase winding.
  • the number of parallel branches is 2, that is, 2 channels are connected in parallel.
  • the number of parallel branches of each phase winding can also be 1, 3, 4 or more and so on. In the following, only the number of parallel branches of each phase winding is 2 as an example. Those skilled in the art can clearly understand that the number of parallel branches of each phase winding is 1, 3, 4 or 5 after reading the following technical solutions. Program, so I will not go into details here.
  • each of each phase winding is a lead line 25 and the other end is a star point line 24, that is, the stator winding 2 has a total of six lead lines 25 And six star point lines 24, the lead line 25 is used for electrical connection with an external circuit, and the star point lines are connected by a connection.
  • the six lead wires 25 of the three-phase winding are respectively: a U-phase one-way lead line 25a, a U-phase two-way lead-out line 25b, a V-phase one-way lead-out line 25c, and a V-phase two-way lead-out line 25d,
  • the six star-point lines 24 of the three-phase winding are: U-phase one-way star point line a, U-phase two-way star point line b, V-phase one-way star point line c, V-phase two-way star point line d, W-phase one-way star Dotted line e, W phase two way star point line f.
  • the six star-point lines 24 are respectively connected to the neutral line 3, that is, the star-point lines 24 of each of the respective phases are respectively connected to the neutral line 3.
  • the neutral line has a UV connection line connecting the neutral point connection portion of the U-phase winding and the neutral point connection portion of the V-phase winding, and a neutral point connection portion and a W-phase winding of the V-phase winding.
  • the VW connection line connected by the point connection portion, the neutral line in the above technology is that the two connection parts are respectively connected by two U-shaped lines, which causes the intermediate welding portion to be thick and takes up a large space, and Welding performance is difficult to guarantee.
  • the axial and radial space of the stator assembly 100 occupied by the connection portion of the neutral line 3 and the star point line 24 can be reduced, making the structure more compact.
  • the connection method is simple, which is convenient for mass production.
  • the neutral line is respectively composed of two line U-shaped lines.
  • the connecting points of the three star point lines are connected two by two, thereby simplifying the connection structure of the star point line 24 and the neutral line 3, reducing the welded portion and reducing the axial and radial space of the occupied stator assembly 100,
  • the compact structure minimizes the space occupied by the casing and the end cover of the motor, and achieves the requirement of miniaturization of the motor, so that the connection between the neutral line and the star point line is more stable.
  • the conductor segments 21 are non-circular in cross section.
  • the cross section of the conductor segment 21 is rectangular in shape which is perpendicular to the plane of the length of the conductor segment.
  • the cross section of the conductor segment 21 perpendicular to its longitudinal direction is rectangular, whereby the groove fullness of the coil in the stator slot can be increased, that is, by setting the cross section of the conductor segment 21 to a rectangular shape, the stator of the same volume Within the slot, more conductor segments 21 can be placed, thereby making the arrangement of the plurality of conductor segments 21 within the stator slots more compact.
  • the cross section of the conductor segment 21 perpendicular to its length may also be other shapes such as a trapezoid or the like.
  • the conductor segment 21 can be a U-shaped conductor segment, the U-shaped conductor segment including a first in-slot portion and a second in-slot portion disposed in the stator slot, the first end being connected to the first slot a U-shaped bent portion of the portion and the inner portion of the second groove; the U-shaped bent portion of the plurality of U-shaped conductor segments forms a hairpin end of the stator winding, and the second end portion of the first groove inner portion and the second groove inner portion Forming the welded end of the stator winding.
  • the U-shaped conductor segments 21 each include a U-shaped bent portion 211, a first in-slot portion 212, and a second in-slot portion 213, wherein the first in-slot portion 212 and the second in-slot portion
  • the portion 213 is disposed in the stator slot, and the first in-slot portion 212 and the second in-slot portion 213 are respectively coupled to the U-shaped bent portion 211, and the first in-slot portion 212 and the second in-slot portion 213 pass through the stator slot The rear end thereof is beyond the stator core 1.
  • FIG. 1 As shown in FIG.
  • the lower end of the first in-slot portion 212 and the lower end of the second in-slot portion 213 are both connected to the U-shaped bent portion 211, and the upper end of the first in-slot portion 212 and the second in-slot portion 213 are The upper end passes through the stator slots and protrudes from the axial end of the stator core 1 (for example, the upper end of the stator core 1 shown in Fig. 1) to facilitate connection of the plurality of conductor segments 21.
  • one end of the U-shaped bent portion 211 of the plurality of conductor segments 21 is the card-issuing end 22 of the stator winding 2, and one end of the end portion of the first in-slot portion 212 and the second in-slot portion 213 is referred to as a stator winding 2
  • the multiplexed star dotted lines in each phase can be individually connected to the neutral line.
  • the multi-channel star points in each phase can also be connected and connected to the neutral line.
  • the multiple dotted lines in each phase can be directly welded or welded through the connecting strips.
  • the line ends of the multi-way star point lines in each phase extend vertically upward, and the line ends of the multi-way star point lines in each phase are welded and connected, and then welded to the neutral line.
  • each phase star line 24 of the stator winding 2 is in surface contact with the neutral line 3 and is fixed by soldering.
  • connection efficiency and connection reliability can be improved.
  • the contact between the star point line and the neutral line means that one side surface of the star point line is in contact with one side surface of the neutral line to increase the contact area between the star point line and the neutral line, thereby improving Reliability of welding.
  • the surface of the star-dot line toward the neutral side is in close contact with the surface of the neutral line toward the side of the star-point line and then welded together.
  • the line ends of the star-point lines 24 of the stator windings 2 extend axially outward (eg, in the upward direction shown in FIG. 1) along the stator core and form an axial direction.
  • the protruding portion 241 is connected to the axially protruding portion 241, respectively.
  • the axial projection 241 exceeds the end of the welding end 23 by a predetermined distance equal to or larger than the dimension of the neutral wire 3 in the axial direction of the stator core 1 (for example, the up and down direction described in the drawing).
  • the predetermined distance is greater than the distance of the neutral wire 3 in the axial direction of the stator core 1.
  • the dimension of the neutral wire 3 in the axial direction of the stator core 1 means the height or size of the neutral wire 3 in the axial direction along the stator core 1.
  • the more neutral line is welded to the radially outer surface of the axial projection 241. Simplified structure for easy soldering and reduced footprint in the radial direction.
  • the line end of the star point line 24 extends upward and the upper end surface thereof is higher than the upper end surface of the soldering end 23, and the upper end surface of the star point line 24 is The distance between the upper end faces of the welding ends 23 is not less than the height of the neutral wire 3 in the up and down direction.
  • the outermost line and the neutral line 3 on the welded end 23 can be along the stator core 1. Axial spacing to avoid interference.
  • the neutral wire 3 can be welded to the end of the line end of the star point line 24, and can also be connected to the middle portion of the line end, which is not much different for the electrical connection effect.
  • phase lead wires 25 of the stator windings are located at the outermost layer in the radial direction of the stator windings.
  • each phase star line 24 of the stator winding is located in the radially outer outer layer, that is, the star point line 24 is located in the secondary outer layer of the stator winding 2 in the radial direction of the stator core 1.
  • the lead-out position of the star-point line and the lead-out position of the lead-out line depend on the winding manner of the stator winding.
  • the specific winding method adopted by the stator assembly of the present embodiment will be specifically described below.
  • the respective star-point lines are located in the stator winding.
  • the secondary outer layer, each phase lead line is located at the outermost layer of the stator winding.
  • the star-point lines of each phase can be located at the outermost layer of the stator winding.
  • the line ends of the respective star-shaped dotted lines 24 of the stator winding 2 may extend outward in the radial direction of the stator core 1 and be bent at a predetermined angle to form a radial direction.
  • the protruding portion 242 is connected to the radial protrusion 242, respectively.
  • each phase when each phase includes a plurality of star point lines, the line ends of the plurality of star point lines in each phase may extend outward in the radial direction of the stator core 1 and bend the predetermined angle and after the welding connection, Welding with the neutral wire.
  • the neutral wire 3 it is convenient for the neutral wire 3 to avoid the outermost line on the welding end 23 in the radial direction of the stator core 1 to avoid interference.
  • the radial protrusion 242 exceeds a predetermined distance of the outermost layer of the winding of the welding end, and the predetermined distance is greater than or equal to the dimension of the neutral line in the radial direction of the stator core.
  • the predetermined distance is greater than the dimension of the neutral wire in the radial direction of the stator core.
  • the dimension of the neutral wire in the radial direction of the stator core means the thickness dimension of the neutral wire in the radial direction of the stator core.
  • the neutral line is welded to the radially outer surface of the radial projection 242.
  • the structure is simplified, the welding is facilitated, and the space in the axial direction is reduced.
  • the angle of the star-point line 24 of each phase of the stator winding is extended from 60 degrees to 150 degrees.
  • the angle at which the star-point line 24 of each phase of the stator winding is bent outward is 90 degrees.
  • the neutral line 3 may be formed in a curved line segment shape.
  • the curved line-shaped neutral line 3 may be substantially parallel to the circumferential direction of the stator core 1 to facilitate the connection of the neutral line 3 with a plurality of star-point lines 24 circumferentially spaced along the stator core 1.
  • the cross section of the neutral line 3 perpendicular to its longitudinal direction may be circular; the cross section of the neutral line 3 perpendicular to its length may also be rectangular, as shown in FIG.
  • the present disclosure is not limited thereto, and the cross section of the neutral line 3 perpendicular to the longitudinal direction thereof may also be other shapes such as an oblate shape, a polygonal shape, or the like.
  • the neutral line 3 can include an arcuate connector 31 and a plurality of antennas 32 that are respectively coupled to respective phase-point lines 24 of the stator windings. Thereby, the arcuate connector 31 can be prevented from interfering with the outermost winding of the soldering end 23.
  • the curved connector 31 has a gap between the radial direction and the radially outermost winding on the welding end 23. Thereby, the arcuate connecting member 31 can be further prevented from interfering with the radially outermost winding on the welding end 23.
  • the neutral line 3 may include a plurality of antennas 32 corresponding to the star point line 24 one by one, so that each antenna angle 32 is correspondingly connected to one star point line 24.
  • the winding coil has a six-way star point line 24, and the neutral line 3 for the stator assembly 100 has six antenna angles 32, as shown in the figure. 4 is shown.
  • the winding coil has three star-point lines 24, and at this time, three antennas 32 may be provided on the center line of the stator assembly 100, as shown in FIG. Shown.
  • each of the antennas 32 may include a first connecting section 321, a second connecting section 322 and a curved section 323.
  • the curved section 323 is connected between the first connecting section 321 and the second connecting section 322.
  • the connecting section 321 is connected to the curved connecting piece 31, and the second connecting section 322 is welded to the line end of the star point line 24.
  • the first connecting section 321 and the second connecting section 322 are smoothly transitioned through the curved section 323.
  • the antenna 32 extends from the upper surface of the arcuate connector 31, and both the first connecting segment 321 and the second connecting segment 322 extend upward. That is, the first connecting section 321 is connected to the upper surface of the curved connecting member 31 and extends upward, the curved section 323 is connected to the upper end of the first connecting section 321, and the lower end of the second connecting section 322 is connected to the curved section 323. Extend upwards.
  • first connecting portion 321 of the antenna 32 may also extend inwardly from the radially inner surface of the curved connecting member 31, and the second connecting portion 322 extends upward and outward (upward) along the axial direction of the stator core 1.
  • the extended star point line 24 is welded.
  • the first connecting section 321 is coupled to the inner surface of the curved connecting member 31 and extends radially inward
  • the second connecting section 322 extends vertically upward
  • the curved section 323 is connected to the horizontal first connecting section 321 and the vertical
  • the antenna 32 has an L shape.
  • the antenna angle 32 may also be formed in a straight line segment shape, and the antenna angle 32 extends inwardly from the radially inner surface of the curved connector 31, and the antenna angle 32 and the star point line 24 are shown. Wire end welding. The antenna 32 can be soldered to the end of the star point line 24 that is bent outward.
  • the neutral wire 3 has the antenna angle 32
  • at least a part of the antenna angle 32 extends radially inward, so that it is advantageous to weld inwardly with the wire end of the star point line 24 by using the antenna angle 32.
  • the curved connector 31 is spaced from the outermost winding of the solder end 23 to avoid interference. That is to say, when the neutral line 3 has the antenna angle 32, the adjacent two corresponding antenna angles 32 constitute a avoidance space 5, and the avoidance space 5 is adapted to accommodate the most between the adjacent two-phase star point lines 24. Outer winding.
  • the span of the neutral line in the circumferential direction of the stator core is greater than or equal to the maximum span of the respective star point lines in the circumferential direction.
  • the length of the neutral line along the circumferential direction of the stator core is not less than the distance between the two star point lines farthest from the three-phase star point line along the circumferential direction of the stator core, that is, neutral.
  • the span of the line in the circumferential direction is greater than or equal to the span of the three-phase star point line in the circumferential direction, so that the neutral line can be connected to the three-phase star point line.
  • the cross-sectional area of the neutral line perpendicular to its length direction is greater than or equal to the cross-sectional area of the star point line perpendicular to its length direction.
  • the cross-sectional area of the neutral line 3 perpendicular to the radial direction of the stator core is greater than or equal to the sum of the cross-sectional areas of the respective star-point lines 24 in each phase, and the cross-section of the star-point line 24 is Refers to the plane perpendicular to the length of the star point line 24.
  • the cross-sectional area of the neutral line 3 is greater than or equal to the cross-sectional area of the star point line 24; when the number of windings of the stator winding 2 is two
  • the cross-sectional area of the neutral line 3 is greater than or equal to the sum of the cross-sectional areas of the two paths.
  • the electrical connection between the neutral line 3 and the star point line 24 can be satisfied.
  • the magnitude of the resistance of the conductor is inversely proportional to the cross-sectional area of the conductor, and therefore, the cross-sectional area of the neutral line 3
  • the sum of the cross-sectional areas of the star-point line 24 of each channel in each phase is greater than or equal to the resistance of 24 units of the star-point line of each channel in each phase, so the neutral line 3
  • the calorific value per unit length is less than or equal to the calorific value of 24 units of the length of each star line in each phase, avoiding the problem of local overheating of the neutral line 3.
  • the neutral line 3 may be constructed as a rectangular line having a rectangular cross section. In the direction in which the neutral line 3 extends, the cross-sectional area is the same.
  • the neutral line 3 may be a press-formed copper row.
  • the neutral line 3 can also be a copper wire having a circular cross section.
  • the neutral line 3 may also be a scattered line.
  • the material of the neutral wire 3 may conform to the material of the conductor segment 21 to improve the reliability of the connection between the neutral wire 3 and the star point line 24.
  • the multiplexed star-point lines 24 in each phase are joined and then connected to the neutral line 3.
  • the multiple star-point lines 24 in each phase may be welded directly or through a connecting strip.
  • the number of parallel branches of each phase winding is two.
  • the two star point lines 24 in the same phase can be welded together, and then one of the star point lines 24 is connected.
  • the block 4 is welded and the connecting block 4 is welded to the neutral wire 3.
  • the number of winding parallel branches of the stator winding 2 is at least one, and each of the star-point lines 24 is connected to the neutral line 3 separately, for example.
  • the number of winding parallel branches of the stator winding 2 is two, the stator winding is provided with two neutral lines 3, and each neutral line 3 is connected with each phase of each star point line 24, the two neutrals
  • the wires 3 are arranged in parallel in the axial direction of the stator windings to reduce the space in the radial direction of the stator windings.
  • a motor 1000 in accordance with an embodiment of the second aspect of the present disclosure includes a stator assembly 100 in accordance with an embodiment of the first aspect of the present disclosure.
  • the motor 1000 according to an embodiment of the present disclosure improves the overall performance of the motor by providing the stator assembly 100 according to the embodiment of the first aspect of the present disclosure.
  • a vehicle 10000 according to a third aspect of the present disclosure includes a motor 1000 in accordance with an embodiment of the second aspect of the invention.
  • a vehicle according to an embodiment of the present disclosure improves the overall performance of the vehicle by providing the electric machine according to the embodiment of the second aspect of the present disclosure.
  • each stator slot 11 The six groove layers include layers a, b, c, d, e, and f arranged in sequence, in each stator slot.
  • the innermost layer in the radial direction of the stator core 1 is the a layer
  • the outermost layer is the f layer.
  • the star point line and the lead line of each U phase are different from each other by 6 stator slots, and the two channels of each phase are different in the circumferential direction by one stator slot; U phase, V phase The corresponding star point line of W differs by four stator slots in the circumferential direction; the corresponding line of U phase, V phase, and W differs by four stator slots in the circumferential direction.
  • the U-phase 1 way lead line U1A and the U-phase 2 way lead line U2A differ by 1 stator slot, and the V-phase 1 way lead line V1A and V phase
  • the two-way lead-out line V2A differs by one stator slot; the W-phase one-way lead-out line W1A and the W-phase two-way lead-out line W2A differ by one stator slot.
  • the U-phase 1 way lead line U1A and the U-phase 1 way star line U1B are different from each other by 6 stator slots, and the U-phase 2 way leads line U2A and U-phase 2 way.
  • the star-point line U2B differs by 6 stator slots; likewise, the two-way lead-out line V1A and the star-point line V1B, the lead-out line V2A, and the star-point line V2B are also different from each other by 6 stator slots; There are also six stator slots between the two-way lead line W1A and the star point line W1B, the lead line W2A, and the star point line W2B.
  • the star-point lines corresponding to the U-phase, the V-phase, and the W are different in the circumferential direction by four stator slots.
  • the first-path is taken as an example, and the star-point line U1B of the U-phase 1 road and the star point of the V-phase 1 road
  • the line V1B and the W-phase line W1B of the W-phase 1 are sequentially different from each other by 4 slots in the circumferential direction.
  • U1B is taken out from the 07-slot e-layer
  • V1B is taken out from the 03-slot e-layer
  • W1B is taken from the 47-slot e.
  • the layer is brought out.
  • U2B, V2B, and W2B of the second path are taken out from the 08-slot e-layer, the 04-slot e-layer, and the 48-slot e-layer, respectively, with 4 stator slots in between.
  • the lead lines corresponding to the U phase, the V phase, and the W are different in the circumferential direction by four stator slots.
  • the U-phase 1 lead line U1A, the V-phase 1 way lead line V1A, and the W-phase 1 way lead line W1A are sequentially different by four slots in the circumferential direction, for example, in FIG.
  • U1A is introduced from the 01-slot f layer
  • V1A is introduced from the 45-slot f-layer
  • W1A is introduced from the 41-slot f-layer.
  • the U2A, V2A, and W2A of the second path are introduced from the 02-slot f-layer, the 46-slot f-layer, and the 42-slot-f layer, respectively, with 4 stator slots in between.
  • the winding coil structure can be wound by the following winding method. As shown in FIG. 11 and FIG. 12, taking the U-phase first path as an example, the winding line is as follows:
  • the winding circuit of the U-phase second road is different from the U-phase first road by one stator slot in the circumferential direction.
  • the U-phase, V-phase, and W-phase adjacent star-point lines are different in the circumferential direction by four stator slots;
  • the lead lines corresponding to the U phase, the V phase, and the W phase are adjacent to each other by four stator slots in the circumferential direction.
  • the lead wire U1A is introduced on the welding end into the radially outermost groove layer 1f of the first groove of the initial groove, and is connected to the first groove inner portion of the first U-shaped conductor segment 2001.
  • the first U-shaped conductor segment 2001 is in the first direction
  • the layer spans six stator slots and reaches the radially outermost groove layer 43f of the 43rd groove; for example, the second direction is the direction in which the motor rotor rotates, and the first direction is the opposite direction of the motor rotating rotor.
  • a plurality of second U-shaped conductor segments 2002 are spanned and sequentially connected in a second direction, each second U-shaped conductor segment 2002 spanning six stator slots, and the second slot portion of each second U-shaped conductor segment 2002 is located
  • the groove layer is radially inward than the groove layer in which the inner portion of the first groove is located until the inner portion of the second groove is located in the radially inner inner groove layer, that is, the diameter of the groove from the 43th groove through a second U-shaped conductor segment 2002
  • the radially outer outer groove layer 1e spanning to the outermost groove layer 43f to the first groove, and the groove from the radially outer outer groove layer 1e of the first groove to the seventh groove by the next second U-shaped conductor segment 2002 7d, and so on until the radial sub-inner layer 19b of the 19th slot is reached;
  • each fourth U-shaped conductor segment 2004 spans six stator slots, and the second slot portion of each fourth U-shaped conductor segment 2004 is located
  • the groove layer is radially outward from the groove layer in which the inner portion of the first groove is located until the inner portion of the second groove is located in the radially outer outer groove layer, that is, through the fourth U-shaped conductor segment 2004 from the 19th groove
  • the radially innermost groove layer 19a spans to the radially inner inner groove layer 13b of the thirteenth groove, and passes from the radially inner inner groove layer 13b of the thirteenth groove to the groove of the seventh groove by the next fourth U-shaped conductor segment 2004 Layer 7c, and so on, until reaching the radially outer outer layer 43e of the 43rd groove;
  • the above arrangement is repeated using the first U-shaped conductor segment 2001, the second U-shaped conductor segment 2002, the third U-shaped conductor segment 2003, and the fourth U-shaped conductor segment 2004 until the second of the fourth U-shaped conductor segments 2004
  • the inner portion of the groove reaches the adjacent layer of the radially outermost groove layer of the seventh groove of the terminating groove (ie, the secondary outer groove layer 7e) and connects the star point line U1B of the phase, wherein the seventh groove of the terminating groove is at the second
  • the direction is different from the initial slot by 6 stator slots.
  • a stator assembly for an 8-pole 48-slot 3-phase motor may be optionally machined into a two-way or one-way solution based on its initial stator assembly 100.
  • the first road star lines U1B, V1B, W1B, and the second road star points U2B, V2B, and W2B of the U, V, and W phases are respectively bent outward and passed.
  • the center line 3 is welded and connected, as shown in FIG. 12, and finally the first lead wires U1A, V1A, W1A of the three phases of U, V, and W, and the second lead wires U2A, V2A, and W2A are welded and fixed by soldering terminals. Connected to an external controller interface.
  • the U2, V2, and W2A of the U, V, and W phases are stretched and bent, and the first road star line U1B of the three phases of U, V, and W, V1B and W1B are respectively welded and fixed, and the second star point lines U2B, V2B, and W2B are respectively bent outward, and are connected by the neutral wire 3 welding.
  • the first lead wires U1A, V1A, and W1A of the three phases of U, V, and W are welded and fixed by soldering terminals, and then connected to a controller interface other than the stator assembly.
  • stator winding structure of each phase is different.
  • each phase includes three paths (not shown), wherein the star points of each of the U phases
  • the difference between the line and the lead line is 9 stator slots 11, and the two sides of the U phase are different from each other by one stator slot 11 in the circumferential direction; the two sides of the V phase are different in the circumferential direction by one stator slot 11
  • the two phases of the W phase are different from each other in the circumferential direction by one stator slot 11, and the star-point lines corresponding to the U phase, the V phase, and the W are circumferentially different from each other by six stator slots 11, U phase, V phase, W
  • the corresponding lead wires are different in the circumferential direction by six stator slots 11.
  • the star point line of each phase of each phase is located in the radially outermost layer, and the lead line of each phase of each phase is located in the radial direction.
  • the outer layer of the outer layer is convenient for the introduction of the lead line, the extraction of the star point line, and the structure of the entire coil winding is simple.
  • the stator assembly 100 adopting the above winding method has a soldering point only on the soldering end, and no soldering terminal on the card issuing end, and the soldering process is simple and convenient; the coil type required for winding Less, less equipment required, easy to achieve mass production.
  • the winding method is adopted, so that the flat wire voltage difference between adjacent groove layers in the same groove is smaller than the existing solution, which can effectively reduce the risk of motor insulation breakdown and high reliability; in addition, the number of winding paths can be easily adjusted. .

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Abstract

一种定子组件和具有其的电机和车辆，定子组件包括：定子绕组(2)，所述定子绕组包括多个导体段(21)，多个导体段的所述第二端形成焊接端(23)，定子绕组(2)各相的星点线(24)均位于焊接端(23)上；中性线(3)，中性线(3)沿周向环绕定子绕组(2)的焊接端(23)，且与各相的星点线(24)直接相连。

Description

定子组件和具有其的电机和车辆
相关申请的交叉引用
本公开基于申请号为201710910210.8，申请日为2017年9月29日的中国专利申请提出，并要求该中国专利申请的优先权，该中国专利申请的全部内容在此引入本公开作为参考。
技术领域
本公开涉及电机技术领域，尤其涉及一种定子组件和具有其的电机和车辆。
背景技术
相关技术中公开了一种中性线连接方式，中性线是由两根线U形线分别将三个连接部位两两相连，这样会导致中间焊接部位较厚，占用空间较大，且焊接性能难以保证。
发明内容
本公开旨在至少解决现有技术中存在的技术问题之一。为此，本公开提出一种定子组件，所述定子组件的星点线与中性线连接简单，占用空间少。
本公开第二方面在于提出一种具有上述定子组件的电机。
本公开第三方面在于提出一种具有上述电机的车辆。
根据本公开的定子组件，包括：圆筒形的定子铁芯，所述定子铁芯上具有沿所述定子铁芯的圆周方向间隔排列的多个定子槽；定子绕组，所述定子绕组包括多个导体段，每个所述导体段包括设置在定子槽中的槽内部分、设置在所述定子铁芯外部的第一端和第二端，所述槽内部分连接在所述第一端和所述第二端之间，多个导体段的所述第二端形成焊接端，所述定子绕组各相的星点线均位于所述焊接端上；中性线，所述中性线沿周向环绕所述定子绕组的所述焊接端，且与各相的所述星点线直接相连。
根据本公开的定子组件，通过设置中性线，并将各相的星点线直接与中性线相连，由此，与相关技术相比，减少了焊接部位，使中性线与星点线的连接更加稳定，并且简化星点线与中性线的连接结构，减少焊接部位，减少其占用的定子组件的轴向和径向空间，结构紧凑，使电机的机壳和端盖占用的空间尽量减小，达到电机小型化的要求。
本公开的附加方面和优点将在下面的描述中部分给出，部分将从下面的描述中变得明显，或通过本公开的实践了解到。
附图说明
本公开的上述和/或附加的方面和优点从结合下面附图对实施例的描述中将变得明显和容易理解，其中：
图1是根据本公开实施例的定子组件的示意图，其中星点线的线端向上延伸；
图2是根据本公开实施例的定子组件的示意图，其中星点线的线端向外折弯；
图3是图2中所示的星点线与中性线连接的示意图；
图4是根据本公开实施例的定子组件的示意图，其中中性线具有触角；
图5是根据本公开实施例的定子组件的星点线与中性线连接的示意图，其中电机为三相且每相为一路，中性线为触角式；
图6是根据本公开实施例的定子组件的示意图，其中中性线的触角呈直线；
图7为根据本公开实施例的定子组件中定子铁芯的示意图；
图8为根据本公开实施例的定子组件中U形导体段的示意图；
图9a-图9d是根据本公开实施例的定子组件绕线时采用的第一至第四U形导体段的示意图；
图10为根据本公开实施例的作为初始设置的定子组件的示意图，其中以8极48槽3相为例示出；
图11为图10中的定子组件的绕线方式示意图，其中以U相1路为例示出；
图12为图10中定子组件经过加工后形成2路接线方式的最终定子组件；
图13为图10中定子组件经过加工后形成1路接线方式的最终定子组件；
图14为根据本公开实施例的电机的示意图；
图15为根据本公开实施例的车辆的示意图。
附图标记：
定子组件100，
定子铁芯1，
定子绕组2，
导体段21，U形折弯部211，第一槽内部分212，第二槽内部分213，
发卡端22，焊接端23，
星点线24，引出线25，
中性线3，弧形连接件31，触角32，第一连接段321，第二连接段322，弯曲段323，避让空间5。
具体实施方式
下面详细描述本公开的实施例，所述实施例的示例在附图中示出，其中自始至终相同或类似的标号表示相同或类似的元件或具有相同或类似功能的元件。下面通过参考附图描述的实施例是示例性的，仅用于解释本公开，而不能理解为对本公开的限制。
在本公开的描述中，需要理解的是，术语“中心”、“长度”、“宽度”、“厚度”、“上”、“下”、“竖直”、“水平”、“顶”、“底”“内”、“外”、“轴向”、“径向”、“周向”等指示的方位或位置关系为基于附图所示的方位或位置关系，仅是为了便于描述本公开和简化描述，而不是指示或暗示所指的装置或元件必须具有特定的方位、以特定的方位构造和操作，因此不能理解为对本公开的限制。此外，术语“第一”、“第二”仅用于描述目的，而不能理解为指示或暗示相对重要性或者隐含指明所指示的技术特征的数量。由此，限定有“第一”、“第二”的特征可以明示或者隐含地包括一个或者更多个该特征。在本公开的描述中，除非另有说明，“多个”的含义是两个或两个以上。
在本公开的描述中，需要说明的是，除非另有明确的规定和限定，术语“安装”、“相连”、“连接”应做广义理解，例如，可以是固定连接，也可以是可拆卸连接，或一体地连接；可以是机械连接，也可以是电连接；可以是直接相连，也可以通过中间媒介间接相连，可以是两个元件内部的连通。对于本领域的普通技术人员而言，可以具体情况理解上述术语在本公开中的具体含义。
下面参考图1-图6描述根据本公开实施例的定子组件100。其中，本公开实施例的定子组件100可以用于m相电机中，且m＝1、2、3……。也就是说，定子组件100可以用于一相电机、两相电机、三相电机等。下面仅以m相电机为三相电机为例进行说明，当然，本领域技术人员在阅读了下面的技术方案后显然可以理解m相电机为其他相电机的技术方案，因此这里不再一一赘述。
如图1所示，本公开实施例的定子组件100包括定子铁芯1、定子绕组2和中性线3。
具体地，所述定子铁芯为圆筒形，定子铁芯1上具有多个定子槽；定子槽形成于定子铁芯1的内周壁上，并沿轴向(例如图1中所示的上下方向)贯穿定子铁芯1，且多个定子槽沿定子铁芯1的圆周方向间隔布置，所述定子槽的深度方向与定子铁芯的径向方向一致。
每个定子槽11中具有多个槽层，具体地说，定子绕组插入到定子槽11后，定子槽内具有定子绕组形成的多个层，在本发明的一些实施例中，槽层包括依次排列的a、b、c、d、e、f各层，在每个定子槽11中，在定子铁芯1的径向方向上位于最内层的为a层，位于最外层的为f层。
在一个实施例中，三相电机的转子包括八个磁极，相应地，设置在定子铁芯上定子槽的总数目为48。
定子绕组，所述定子绕组2包括多个导体段21，每个导体段21包括设置在定子铁芯的定子槽中的槽内部分、设置在定子铁芯外部的第一端和第二端，槽内部分连接在第一端和第二端之间，多个导体段21的第二端形成焊接端23，定子绕组2各相的星点线24均位于焊接端23上。
如图1所示，每个导体段21包括：槽内部分(例如下文中所述的第一槽内部分212和第二槽内部分213)和折弯部，其中，槽内部分设置在定子槽中，折弯部连接槽内部分，槽内部分穿过定子槽后，槽内部分的端部(例如图1中所示的槽内部分的上端)超出定子铁芯1，槽内部分超出定子铁芯1的端部(例如图1中所示的槽内部分的上端)形成定子绕组2的焊接端23。定子绕组2各相的星点线均位于焊接端23上，也就是说，定子绕组2的各相星点线24均从焊接端23引出并通过中性线3连接。
中性线3沿定子铁芯的周向环绕定子绕组2的焊接端23，由此，可以减小星点线24与中性线3之间的距离，方便中性线3与焊接端23的星点线24连接。
中性线3与各相的星点线24相连。也就是说，每相星点线24分别与中性线3相连。这样，可以使每个星点线24与中性线3的连接位置占用空间小，且连接方式更为简单。
定子绕组2各相的星点线24与中性线3直接连接。也就是说，星点线24均直接与中性线3连接，通过与中性线3连接实现将多个星点线24连接在一起，而不是通过中间的过渡连接物间接与中性线3连接，简言之，利用中性线3直接将定子绕组2内的所有星点线24连接在一起，减少了焊接部位，使中性线与星点线的连接更加稳定。由此，连接方便，简单快捷。例如，定子绕组2中每相绕组中的每路星点线24均分别直接与中性线3焊接连接。
下面描述本公开定子组件100的一个具体实施例。
如图1和图2所示，本实施例的定子组件100用于三相电机，三相电机的定子绕组2为三相绕组：U相绕组、V相绕组和W相绕组，每相绕组中的并联支路数为2，即2路并联。当然，每相绕组的并联支路数也可以为1、3、4或5以上等等。下面仅以每相绕组并联支路数为2为例进行说明，本领域技术人员在阅读了下面的技术方案后显然可以理解每相绕组的并联支路数为1、3、4或5的技术方案，因此这里不再一一赘述。
当三相绕组采用Y形连接(即星形连接)时，每一相绕组中的每一路的一端为引出线25且另一端为星点线24，即：定子绕组2共具有六条引出线25和六条星点线24，引出线25用于与外部电路电连接，星点线通过连接在一起引出。
具体地，如图2所示，三相绕组的六条引出线25分别为：U相一路引出线25a、U 相二路引出线25b、V相一路引出线25c、V相二路引出线25d、W相一路引出线25e、W相二路引出线25f。三相绕组的六条星点线24分别为：U相一路星点线a、U相二路星点线b、V相一路星点线c、V相二路星点线d、W相一路星点线e、W相二路星点线f。
六条星点线24分别与中性线3相连，也就是说，每一相中每一路的星点线24均分别与中性线3相连。
相关技术中，中性线具有将U相绕组的中性点连接部与V相绕组的中性点连接部连接的UV连接线和将V相绕组的中性点连接部与W相绕组的中性点连接部连接的VW连接线，上述技术中的中性线是由两根线U形线分别将三个连接部位两两相连，这样会导致中间焊接部位较厚，占用空间较大，且焊接性能难以保证。由此，在本公开的实施例中，可以减少由于中性线3与星点线24连接部位而占用的定子组件100的轴向及径向的空间，使结构更为紧凑。且连接方式简单，便于批量生产。
根据本公开实施例的定子组件100，通过设置中性线3，并将星点线24分别与中性线3相连，替代现有技术中，中性线是由两根线U形线分别将三个星点线的连接部位两两相连，由此，可以简化星点线24与中性线3的连接结构，减少了焊接部位，减少其占用的定子组件100的轴向和径向空间，结构紧凑，使电机的机壳和端盖占用的空间尽量减小，达到电机小型化的要求，使中性线与星点线的连接更加稳定。
在一些实施例中，导体段21的横截面为非圆形。导体段21的横截面的形状为矩形，该横截面为垂直于导体段长度方向上所截平面。导体段21垂直于其长度方向的横截面为矩形形状，由此，可以提高定子槽内线圈的槽满率，也就是说，通过将导体段21的横截面设置为矩形，在同样容积的定子槽内，可以布置更多的导体段21，从而使定子槽内的多个导体段21布置更为紧凑。当然，导体段21垂直于其长度方向的横截面还可以为其他形状例如梯形等等。
在一些实施例中，导体段21可以为U形导体段，U形导体段包括设置在定子槽中的第一槽内部分和第二槽内部分，所述第一端为连接第一槽内部分和第二槽内部分的U形折弯部；多个U形导体段中的U形折弯部形成定子绕组的发卡端，且第一槽内部分和第二槽内部分的第二端形成定子绕组的焊接端。
如图1所示，所述U形导体段21均包括：U形折弯部211、第一槽内部分212和第二槽内部分213，其中，第一槽内部分212和第二槽内部分213设置在定子槽内，且第一槽内部分212和第二槽内部分213分别与U形折弯部211连接，且第一槽内部分212和第二槽内部分213穿过定子槽后其端部超出定子铁芯1。例如图3所示，第一槽内部分212的下端和第二槽内部分213的下端均与U形折弯部211相连，且第一槽内部分212的上端和第二槽内部分213的上端均穿过定子槽，并伸出定子铁芯1的轴向的端部 (例如图1中所示的定子铁芯1的上端)，以方便多个导体段21相连。
其中，多个导体段21中的U形折弯部211所在一端为定子绕组2的发卡端22、且第一槽内部分212和第二槽内部分213的端部所在一端称为定子绕组2的焊接端23，在本公开中，为了描述清楚，假定图中的焊接端23所在一端为上端，发卡端22所在一端为下端。
在一些实施例中，当每相中包括多路星点线时，每相中的多路星点线可以单独与中性线连接。
另外，每相中的多路星点线也可以合并连接后与中性线连接。具体地，每相中的多路星点线之间可以直接焊接或通过连接条焊接。
例如，每相中多路星点线的线端均竖直向上延伸，且每相中多路星点线的线端焊接连接后，再与中性线焊接。
在一些示例中，定子绕组2的各相星点线24与中性线3面接触且焊接固定。由此，可以提高连接效率和连接可靠性。这里，星点线与中性线面接触是指，星点线的一侧表面与中性线的一侧表面贴合并接触，以增大星点线和中性线之间的接触面积，提高焊接的可靠性。例如，星点线的朝向中性线一侧的表面与中性线的朝向星点线的一侧的表面贴合接触然后焊接连接在一起。
在一些示例中，如图1所示，定子绕组2各相星点线24的线端沿定子铁芯轴向向外(例如沿图1中所示的向上的方向)延伸，并形成轴向突出部241，中性线3与轴向突出部241分别连接。
轴向突出部241超过焊接端23的端部预定距离，预定距离大于等于中性线3在定子铁芯1轴向(例如图中所述的上下方向)上的尺寸。预定距离大于中性线3在定子铁芯1轴向上的距离。这里，中性线3在定子铁芯1轴向上的尺寸是指，中性线3在沿定子铁芯1轴向方向上的高度或尺寸。
更中性线与轴向突出部241的径向外表面焊接固定。简化结构，方便焊接，且减少径向上的占用空间。
具体如图1所示，在沿图1中所示的上下方向上，星点线24的线端向上延伸且其上端面高于焊接端23的上端面，且星点线24的上端面与焊接端23的上端面之间的距离不小于中性线3沿上下方向的高度。这样，当星点线24的端部与中性线3沿定子铁芯1的径向内外相对连接时，可以使焊接端23上的最外层线与中性线3沿定子铁芯1的轴向间隔开，避免干涉。
这里，需要说明的是，中性线3可以焊接在星点线24的线端端部，还可以连接在线端的中间部分，对于电连接效果来说，并无太大差别。
如图1所示，定子绕组的各相引出线25位于定子绕组径向上最外层。
如图1所示，定子绕组的各相星点线24位于径向上次外层，也就是说，星点线24位于定子绕组2沿定子铁芯1的径向方向的次外层。
这里，需要说明的是，星点线的引出位置以及引出线的引出位置取决于定子绕组的绕线方式。本实施例的定子组件所采用的具体绕线方式将在下文中具体描述，当本公开实施例的定子组件采用下述的绕线方法，最终绕线完成后，各相星点线位于定子绕组的次外层，各相引出线位于定子绕组的最外层。当采用别的绕线方式时，各相星点线可以位于定子绕组的最外层。
在一些示例中，如图2和图3所示，定子绕组2的各相星点线24的线端可以沿定子铁芯1的径向向外延伸并折弯预设角度，以形成径向突出部242，中性线3与径向突出部242分别连接。由此，方便中性线3沿定子铁芯1的径向避开焊接端23上的最外层线，以避免干涉。
其中，当每相中包括多路星点线时，每相中多路星点线的线端可以均沿定子铁芯1的径向向外延伸并折弯预设角度并且焊接连接后，再与中性线焊接。由此，方便中性线3沿定子铁芯1的径向避开焊接端23上的最外层线，以避免干涉。
径向突出部242超过焊接端的绕组最外层预定距离，预定距离大于等于中性线在定子铁芯径向上的尺寸。预定距离大于中性线的在定子铁芯径向上的尺寸。这里，中性线在定子铁芯径向上的尺寸是指，中性线在定子铁芯径向方向的厚度尺寸。
中性线与径向突出部242的径向外表面焊接固定。简化结构，方便焊接，且减少轴向上的占用空间。
定子绕组各相星点线24向外延伸折弯的角度为60度-150度。更定子绕组各相星点线24向外折弯的角度为90度。
下面结合附图对中性线3进行进一步描述。
在一些实施例中，如图1和图3所示，中性线3可以形成为弧形线段形状。此时，弧形线段状的中性线3可以大体平行于定子铁芯1的周向，以方便中性线3与沿定子铁芯1周向间隔的多个星点线24连接。
如图3所示，中性线3垂直于其长度方向的横截面可以为圆形；中性线3垂直于其长度方向的横截面也可以为矩形，如图1所示。当然，本公开不限于此，中性线3垂直于其长度方向的横截面也可以为扁圆形、多边形等其他形状。
如图4和图5所示，在一些实施例，中性线3可以包括：弧形连接件31和多个触角32，多个触角32分别与定子绕组的各相星点线24相连。由此，可以避免弧形连接件31与焊接端23最外层绕组干涉。
弧形连接件31在径向上与焊接端23上径向最外层绕组之间具有间隙。由此，可以进一步避免弧形连接件31与焊接端23上径向最外层绕组干涉。
其中，中性线3可以包括与星点线24一一对应的多个触角32，以便于每个触角32对应连接一路星点线24。例如，当电机为3相且每相绕组均包括两个并联支路时，绕组线圈具有六路星点线24，此时用于该定子组件100的中性线3具有6个触角32，如图4所示。当电机为3相且每相绕组仅具有一个并联支路时，绕组线圈具有三个星点线24，此时，用于该定子组件100的中心线上可设有三个触角32，如图5所示。
如图5所示，每个触角32均可以包括第一连接段321、第二连接段322和弯曲段323，弯曲段323连接在第一连接段321和第二连接段322之间，第一连接段321连接至弧形连接件31，第二连接段322与星点线24的线端焊接。
第一连接段321和第二连接段322通过弯曲段323圆滑过渡。
可选地，如图5所示，触角32从弧形连接件31的上表面延伸出，且第一连接段321和第二连接段322均向上延伸。也就是说，第一连接段321连接在弧形连接件31的上表面上并向上延伸，弯曲段323连接在第一连接段321的上端，第二连接段322的下端与弯曲段323相连并向上延伸。
另外，触角32的第一连接段321也可以从弧形连接件31的径向内表面向内延伸出，第二连接段322向上延伸且与沿定子铁芯1的轴向向外(向上)延伸的星点线24焊接。例如，第一连接段321连接在弧形连接件31的内表面上并沿径向向内延伸，第二连接段322竖直向上延伸，弯曲段323连接在水平的第一连接段321和竖向的第二连接段322之间，此时，触角32呈L形状。
当然，本公开不限于此，如图6所示，触角32也可以形成为直线线段形状，且触角32从弧形连接件31的径向内表面向内延伸出，触角32与星点线24的线端焊接。触角32可以与星点线24向外折弯后的线端焊接。
这里，需要说明的是，中性线3具有触角32时，触角32的至少一部分沿径向向内延伸，这样，通过利用触角32向内伸入与星点线24的线端焊接，有利于将弧形连接件31与焊接端23的最外层绕组间隔开，以避免干涉。也就是说，当中性线3具有触角32时，相邻的两相对应的触角32之间构成了避让空间5，避让空间5适于容纳位于相邻两相的星点线24之间的最外层绕组。
在本公开的一些实施例中，中性线在定子铁芯周向上的跨度大于等于各相星点线在周向上的最大跨度。以保证中性线有足够的长度可以连接各相的星点线。例如图1所示，中性线沿定子铁芯周向上的长度不小于三相星点线中距离最远的两星点线之间沿定子铁芯周向上的距离，也就是说，中性线在周向上的跨度大于等于三相星点线线在周向上 的跨度，这样中性线才能连接到三相的星点线。
可选地，中性线垂直于其长度方向的横截面面积大于等于星点线的垂直于其长度方向的横截面积。
在本公开的一些实施例中，中性线3的垂直于定子铁芯径向方向的横截面面积大于等于每相中各路星点线24的截面积之和，星点线24的截面是指垂直于星点线24长度方向所截平面。具体地，定子绕组2的绕线并联支路数为1路时，中性线3的横截面面积大于等于星点线24的截面面积；定子绕组2的绕线并联之路数为2路时，中性线3的横截面面积大于等于两路的截面积之和。由此，可以满足中性线3与星点线24电连接需求，具体地，根据电阻的计算公式，导体的电阻的大小与导体的截面积大小呈反比，因此，中性线3的截面积大于等于每相中各路的星点线24的截面积之和，中性线3单位长度的电阻小于或等于每相中各路的星点线24单位长度的电阻，所以中性线3的单位长度的发热量小于或等于每相中各路的星点线24单位长度的发热量，避免了中性线3局部过热的问题。
在本公开的一些实施例中，中性线3可以被构成为横截面为长方形的扁线。在中性线3的延伸方向上，其横截面面积相同。
在本公开的一些实施例中，中性线3可以为压制成型的铜排。中性线3也可以为横截面为圆形的铜线。当然，在本公开的一些实施例中，中性线3也可以为散线。
中性线3的材料可以与导体段21的材料一致，以提高中性线3与星点线24之间连接的可靠性。
在本公开的一些实施例中，每相中的多路星点线24合并连接后、再与中性线3连接。可选地，每相中的多路星点线24之间可以直接焊接，也可以通过连接条焊接。
例如，每相绕组的并联支路数为2，在连接中性线3的过程中，同一相中的两路星点线24可以先焊接在一起，然后再将其中一路星点线24与连接块4焊接，连接块4再与中性线3焊接。
在本公开的一些实施例中，如图1-图6所示，定子绕组2的绕线并联支路数为至少一路，每相每路星点线24均单独与中性线3连接，例如，定子绕组2的绕线并联支路数为2路，所述定子绕组设置两个中性线3，每个中性线3与每相每路星点线24连接，所述两个中性线3在定子绕组的轴向上平行设置，可减小定子绕组径向上的空间。
参照图14，根据本公开第二方面实施例的电机1000，包括根据本公开第一方面实施例的定子组件100。
根据本公开实施例的电机的其他构成例如转子等的结构和操作均为本领域技术人员所熟知的，这里不再赘述。
根据本公开实施例的电机1000，通过设置根据本公开第一方面实施例的定子组件100，从而提高了电机的整体性能。
参照图15，根据本公开第三方面的车辆10000，包括根据发明第二方面实施例的电机1000。
根据本公开实施例的车辆，通过设置根据本公开第二方面实施例的电机，从而提高了车辆的整体性能。
参照图7-图13，下面以本公开实施例的定子组件用于8极48槽3相的电机为例对本公开实施例的定子组件中的定子绕组的绕线方法进行说明：即定子槽数z＝48，相数m＝3，其中，三相包括U相、V相和W相；极数2p＝8(即极对数为4)，且三相中的每相均包括两路。
如图10所示，定子组件100的定子绕组2中，U形导体段20的第一槽内部分202和第二槽内部分203之间的节距均为y个定子槽，其中y为整数且y＝z/2p。对于8极48槽的定子组件100来说，y＝6。也就是说，每个U形导体段20的第一槽内部分202和第二槽内部分203之间相差6个定子槽。
在下面的描述中，以每个定子槽11中以6层为例对本公开进行说明，6个槽层包括依次排列的a、b、c、d、e、f各层，在每个定子槽11中，在定子铁芯1的径向方向上位于最内层的为a层，位于最外层的为f层。
如图10所示的定子组件中，U相每一路的星点线和引出线之间相差6个定子槽，各相的两路之间在周向上相差1个定子槽；U相、V相、W相对应的星点线在周向上相差4个定子槽；U相、V相、W相对应的引出线在周向上相差4个定子槽。
更具体地，如图11和图12中所示，U相1路的引出线U1A和U相2路的引出线U2A之间相差1个定子槽，V相1路的引出线V1A和V相2路的引出线V2A之间相差1个定子槽；W相1路的引出线W1A和W相2路的引出线W2A之间相差1个定子槽。
如图11和图12中所示，U相1路的引出线U1A和U相1路的星点线U1B之间相差6个定子槽，U相2路的引出线U2A和U相2路的星点线U2B之间相差6个定子槽；同样地，V相中两路的引出线V1A和星点线V1B、引出线V2A和星点线V2B之间也相差6个定子槽；W相中两路的引出线W1A和星点线W1B、引出线W2A和星点线W2B之间也相差6个定子槽。
U相、V相、W相对应的星点线在周向上相差4个定子槽，具体而言，以第一路为例，U相1路的星点线U1B、V相1路的星点线V1B、和W相1路的星点线W1B在周向上依次相差4个槽，例如图10中所示，U1B从07槽e层引出，V1B从03槽e层引出，W1B从 47槽e层引出。类似地，第二路的U2B、V2B和W2B分别从08槽e层、04槽e层和48槽e层引出，它们之间依次相差4个定子槽。
相应地，U相、V相、W相对应的引出线在周向上相差4个定子槽。具体而言，以第一路为例，U相1路的引出线U1A、V相1路的引出线V1A、W相1路的引出线W1A在周向上依次相差4个槽，例如图10中所示，U1A自01槽f层引入，V1A从45槽f层引入，而W1A自41槽f层引入。类似地，第二路的U2A、V2A和W2A分别自02槽f层、46槽f层和42槽f层引入，它们之间依次相差4个定子槽。
而上述绕线线圈结构可以通过如下绕线方法进行绕制，如图11和图12所示，以U相第一路为例，其绕线路线如下：
1f→43f→1e→7d→13c→19b→25a→19a→13b→7c→1d→43e→37f→31f→37e→43d→1c→7b→13a→7a→1b→43c→37d→31e→25f→19f→25e→31d→37c→43b→1a→43a→37b→31c→25d→19e→13f→7f→13e→19d→25c→31b→37a→31a→25b→19c→13d→7e
其中U相第二路的绕线线路在周向上与所述U相第一路相差1个定子槽，
U相、V相、W相相邻相对应的星点线在周向上相差4个定子槽；
U相、V相、W相相邻相对应的引出线在周向上相差4个定子槽。
在通过上述绕组绕制方法进行绕制时，采用了多个第一U形导体段、多个第二U形导体段2002、多个第三U形导体段2003和多个第四U形导体段2004，仍以U相第一路为例，参考图16和上述绕线路线，绕制每相每路定子绕组的情况具体如下：
引出线U1A在焊接端上引入初始槽第1槽的径向最外槽层1f，与第一U形导体段2001的第一槽内部分连接，第一U形导体段2001沿第一方向同层跨越6个定子槽，到达第43槽的径向最外槽层43f；例如，第二方向为电机转子旋转的方向，第一方向为电机旋转转子的反方向。
通过多个第二U形导体段2002沿第二方向跨越且依次连接，每个第二U形导体段2002跨越6个定子槽，每个第二U形导体段2002的第二槽内部分所在槽层比第一槽内部分所在槽层沿径向向内一层，直至第二槽内部分位于径向次内槽层为止，即通过一个第二U形导体段2002从第43槽的径向最外槽层43f跨越至第1槽的径向次外槽层1e，通过下一个第二U形导体段2002从第1槽的径向次外槽层1e跨越至第7槽的槽层7d，以此类推，直至到达第19槽的径向次内层19b；
通过一个第三U形导体段2003沿第一方向同层跨越6个定子槽，从第25槽的径向最内槽层25a到达第19槽的径向最内槽层19a；
通过多个第四U形导体段2004沿第一方向跨越且依次连接，每个第四U形导体段2004跨越6个定子槽，每个第四U形导体段2004的第二槽内部分所在槽层比第一槽内部分所在槽层沿径向向外一层，直至第二槽内部分位于径向次外槽层为止，即，通过一个第四U形导体段2004从第19槽的径向最内槽层19a跨越至第13槽的径向次内槽层13b，通过下一个第四U形导体段2004从第13槽的径向次内槽层13b跨越至第7槽的槽层7c，以此类推，直至到达第43槽的径向次外层43e；
再采用第一U形导体段2001、第二U形导体段2002、第三U形导体段2003和第四U形导体段2004重复上述设置，直至某个第四U形导体段2004的第二槽内部分到达终止槽第7槽的径向最外槽层的相邻层(即次外槽层7e)且连接该相该路的星点线U1B，其中终止槽第7槽在在第二方向上与初始槽相差6个定子槽。
在一些实施例中，针对适用于8极48槽3相的电机的定子组件，在其初始定子组件100的基础上，可选择将其加工成两路方案或一路方案。
当用户选择为两路方案时，将U、V、W三相的第一路星点线U1B、V1B、W1B、以及第二路星点线U2B、V2B、W2B分别向外折弯，并通过中心线3焊接相连，如图12所示，最后将U、V、W三相的第一路引出线U1A、V1A、W1A、以及第二路引出线U2A、V2A、W2A通过焊接端子焊接固定后与外部控制器接口相连。
当用户选择为一路方案时，将U、V、W三相的第二路引出线U2A、V2A、W2A拉长折弯后，与U、V、W三相的第一路星点线U1B、V1B、W1B分别焊接固定，且第二路星点线U2B、V2B、W2B分别向外折弯，通过中性线3焊接相连。最后，将U、V、W三相的第一路引出线U1A、V1A、W1A通过焊接端子焊接固定后与定子组件以外的控制器接口相连。
当然，当定子槽数、极数和相数不同时，每相每路的定子绕组结构也是不同的。
例如，当定子槽数为72，极数为8，相数为3且包括U相、V相和W相，每相包括三路(图未示出)，其中，U相每一路的星点线和引出线之间相差9个定子槽11，U相的三路之间两两在周向上相差1个定子槽11；V相的三路之间两两在周向上相差1个定子槽11，W相的三路之间两两在周向上相差1个定子槽11，U相、V相、W相对应的星点线在周向上相差6个定子槽11，U相、V相、W相对应的引出线在周向上相差6个定子槽11。
值得注意的是，在一些优选的实施例中，在线圈绕组的焊接端II上，任一相每一路的星点线位于径向上最外层，且任一相每一路的引出线位于径向上的次外层，这样便于引出线的引入、星点线的引出，而且整个线圈绕组结构简单。
综上所述，采用上述绕线方法的根据本公开实施例的定子组件100，仅在焊接端上有焊接点，而在发卡端上无焊接端子，焊接工艺简单方便；绕线所需线圈种类少，所需设备少，容易实现批量生产。另外，采用此种绕线方法，使得同槽内相邻槽层之间的扁线电压差比现有方案小，能有效减少电机绝缘击穿风险，可靠性高；此外，绕组路数容易调整。
在本说明书的描述中，参考术语“一个实施例”、“一些实施例”、“示意性实施例”、“示例”、“具体示例”、或“一些示例”等的描述意指结合该实施例或示例描述的具体特征、结构、材料或者特点包含于本公开的至少一个实施例或示例中。在本说明书中，对上述术语的示意性表述不一定指的是相同的实施例或示例。而且，描述的具体特征、结构、材料或者特点可以在任何的一个或多个实施例或示例中以合适的方式结合。
尽管已经示出和描述了本公开的实施例，本领域的普通技术人员可以理解：在不脱离本公开的原理和宗旨的情况下可以对这些实施例进行多种变化、修改、替换和变型，本公开的范围由权利要求及其等同物限定。

Claims (12)

  1. 一种定子组件，其特征在于，包括：
    圆筒形的定子铁芯，所述定子铁芯上具有沿所述定子铁芯的圆周方向间隔排列的多个定子槽；
    定子绕组，所述定子绕组包括多个导体段，每个所述导体段包括设置在定子槽中的槽内部分、设置在所述定子铁芯外部第一端和第二端，所述槽内部分连接在所述第一端和所述第二端之间，多个导体段的所述第二端形成焊接端，所述定子绕组各相的星点线均位于所述焊接端上；
    中性线，所述中性线沿周向环绕所述定子绕组的所述焊接端，且与各相的所述星点线直接相连。
  2. 根据权利要求1所述的定子组件，其特征在于，所述导体段的横截面为矩形形状。
  3. 根据权利要求2所述的定子组件，其特征在于，所述导体段为U形导体段，所述U形导体段包括设置在定子槽中的第一槽内部分和第二槽内部分，所述第一端为连接所述第一槽内部分和第二槽内部分的U形折弯部，多个所述U形导体段中的U形折弯部形成所述定子绕组的发卡端、且所述第一槽内部分和所述第二槽内部分的第二端形成所述定子绕组的焊接端。
  4. 根据权利要求1-3中任一项所述的定子组件，其特征在于，所述定子绕组的各相星点线与所述中性线面接触且焊接固定。
  5. 根据权利要求1-4中任一项所述的定子组件，其特征在于，所述定子绕组各相星点线的线端沿定子铁芯轴向向外延伸并形成轴向突出部，所述中性线与所述轴向突出部分别连接。
  6. 根据权利要求5所述的定子组件，其特征在于，所述轴向突出部超过所述发卡端的端部预定距离，所述预定距离大于等于所述中性线在定子铁芯轴向上的尺寸。
  7. 根据权利要求1-6中任一项所述的定子组件，其特征在于，所述定子绕组各相星点线的线端沿定子铁芯径向向外延伸并折弯预设角度，形成径向突出部，所述中性线与所述径向突出部分别连接。
  8. 根据权利要求7所述的定子组件，其特征在于，所述径向突出部超过所述焊接端的绕组最外层预定距离，所述预定距离大于等于所述中性线的在定子铁芯径向上的尺寸。
  9. 根据权利要求1-8中任一项所述的定子组件，其特征在于，所述中性线包括弧形连接件和多个触角，所述多个触角分别与所述定子绕组的各相星点线相连。
  10. 根据权利要求9所述的定子组件，其特征在于，所述弧形连接件在径向上与所述焊接端上径向最外层绕组之间具有间隙。
  11. 一种电机，其特征在于，包括根据权利要求1-10中任一项所述的定子组件。
  12. 一种车辆，其特征在于，包括根据权利要求11中所述的电机。
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