WO2019062915A1

WO2019062915A1 - Stator assembly and preparation method therefor

Info

Publication number: WO2019062915A1
Application number: PCT/CN2018/108641
Authority: WO
Inventors: 林焕炜; 游斌; 齐文明
Original assignee: 比亚迪股份有限公司
Priority date: 2017-09-29
Filing date: 2018-09-29
Publication date: 2019-04-04
Also published as: CN109586459A; CN109586459B

Abstract

Disclosed are a stator assembly and a preparation method therefor. A stator winding (2) of a stator assembly (100) comprises a plurality of U-shaped conductor sections (20), wherein a first in-slot portion (202) of each U-shaped conductor section (20) penetrates through one slot layer of one stator slot (11) therein, and a second in-slot portion (203) penetrates through one slot layer of the other stator slot (11) therein. The preparation method comprises: connecting one outgoing line of any phase to a star-point line in a different path of the phase.

Description

Stator assembly and preparation method thereof

Cross-reference to related applications

The present disclosure is based on a Chinese patent application filed on Sep. 29, 2017, the entire disclosure of which is hereby incorporated by reference.

Technical field

The present disclosure relates to the field of electric machines, and in particular to a stator assembly suitable for a drive motor of a vehicle, a method of manufacturing the stator assembly, and a stator assembly obtained by the post-processing using the preparation method.

Background technique

In the related art, in the winding parallel branch of the driving motor used by the vehicle, the one-way access and the two-way access respectively adopt different winding methods, and the number of roads is not adjustable, and it is difficult to match the requirements of different vehicle high-efficiency zones.

Summary of the invention

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 method of fabricating a stator assembly that is simple in construction, on the basis of which machining can be performed to obtain stator assemblies of different numbers of paths.

The present disclosure also proposes a stator assembly prepared using the above preparation method.

A method for preparing a stator assembly according to a first aspect of the present disclosure is applicable to a motor of a z-slot 2p-level m-phase, wherein the number of slots per phase per phase is q=z/m/(2p), and the number of parallel branches is a, a ≤ q, the stator assembly includes: a cylindrical stator core having a plurality of stator slots arranged in a circumferential direction of the stator core; a stator winding, the stator The winding includes a plurality of U-shaped conductor segments, each of the U-shaped conductor segments including a bent portion and a first in-slot portion and a second in-slot portion respectively connected to the bent portion, the U-shaped conductor segment The first in-slot portion passes through one of the one of the stator slots, the second in-slot portion passes through one of the other slot slots, the first in-slot portion and the second portion The inner portion of the slot passes through the stator slot and has its end beyond the stator core to form a soldering end, and the plurality of U-shaped conductor segments are located in the first slot of the adjacent layer on the soldering end a portion and a portion of the second groove are weldedly connected, and on the welded end, a star point line of each phase of each phase is located in a radial direction Secondary layer, and an outermost layer of each channel to any of a phase lead wire positioned in the radial direction;

The preparation method comprises: connecting one of the outgoing lines of any phase to the different road star points of the phase.

According to an embodiment of the present disclosure, on the welding end, the star point line and the lead line of each phase of each phase are different in the circumferential direction by 3q stator slots, and the multiplexed star point lines of any phase are in the circumferential direction. The two phases are different from one stator slot, and the multiplexed leads of either phase are different from each other by one stator slot in the circumferential direction.

According to an embodiment of the present disclosure, one of the outgoing lines of any phase differs from the different star-shaped dotted lines of the phase by 3q-1 stator slots in the circumferential direction.

According to an embodiment of the present disclosure, when q is an even number, the number of parallel branches of the stator assembly is a=2n or a=1, where n is a natural number of 1 to q/2;

Connect the lead line of the kth channel in each phase to the star point line of the k-1th road in the phase, where k is a natural number of 2 to q, and connect the lead wire of the 1st channel in each phase to the terminal. The star point line of the qth road in each phase is connected with the neutral line to form a stator assembly with the number of parallel branches a=1;

Dividing the parallel branches in each phase into n groups, and the lead lines of one of the at least one group of the n groups are connected with the star point lines of the other of the groups, and the star point and the neutral line of one of the groups Connected, the other lead wire in the group is connected to the terminal block to form a stator assembly with a parallel branch number a=2n.

According to an embodiment of the present disclosure, when q is an odd number, the number of parallel branches of the stator assembly is a=1 or a=q,

Connect the lead line of the kth channel in each phase to the star point line of the k-1th road in the phase, where k is a natural number of 2 to q; connect the lead wire of the 1st channel in each phase to the terminal The star point line of the qth road in each phase is connected with the neutral line to form a stator assembly with the number of parallel branches a=1;

When a=q, the star point line of each phase is connected with the neutral line; the lead line of each phase is connected with the terminal to form the stator assembly with the number of parallel branches a=q.

According to an embodiment of the present disclosure, the stator assembly has a stator slot number of 48, the number of poles is 8, the phase number is 3, and includes U phase, V phase, and W phase, and the number of slots per phase per phase is q=2, the number of parallel branches is 2,

Wherein, the star point line and the lead line of each U phase are different from each other by 6 stator slots;

The two channels of each phase differ by one stator slot in the circumferential direction;

The star-point lines corresponding to the adjacent phases in the U phase, the V phase, and the W are different in the circumferential direction by 4 stator slots;

The lead lines corresponding to the adjacent phases in the U phase, the V phase, and the W phase are different in the circumferential direction by 4 stator slots;

The preparation method comprises: connecting a second way lead line of any phase to a first road star point line of the phase to form a stator assembly having a parallel branch number of 1.

According to an embodiment of the present disclosure, the stator assembly has a stator slot number of 72, the number of poles is 8, the phase number is 3, and includes U phase, V phase, and W phase, and the number of slots per phase per phase is q=3, the number of parallel branches is 3,

Wherein, the star point line and the lead line of each U phase are different from each other by 9 stator slots;

The two phases of the U phase are different from each other in the circumferential direction by one stator slot;

The two phases of the V phase are separated by one stator slot in the circumferential direction;

The two phases of the W phase are separated by one stator slot in the circumferential direction;

The adjacent star-point lines in the U phase, the V phase, and the W phase are different in the circumferential direction by 6 stator slots;

The adjacent corresponding lead lines in the U phase, the V phase, and the W phase are different in the circumferential direction by 6 stator slots;

The preparation method includes: connecting a second way lead line of any phase to a first road star point line of the phase, and connecting a third way lead line of any phase to a second road star point line of the phase, A stator assembly having a number of parallel branches of one is formed.

According to an embodiment of the present disclosure, the first in-slot portion and the second in-slot portion of the plurality of U-shaped conductor segments located in different layers are soldered on the soldering end to enable the The winding direction of the windings is configured to be in each phase of each phase:

S31, the lead wire is led out to the radially outermost groove layer of the initial groove;

S32. Cross the y stator slots in the same layer along the first direction;

S33. Starting from a radial sub-outer groove layer spanning the y stator slots, spanning in a second direction, the number of layers of the groove layer varies by one layer across y stator slots, wherein the number of layers is radially External to internal variation up to the radial sub-groove layer;

S34. Starting from a radially innermost groove layer spanning the y stator slots, the same layer spans the y stator slots in the first direction;

S35. Starting from a radial sub-inner groove layer spanning y stator slots, spanning in a first direction, the number of layers of the groove layer varies by one layer across each of the y stator slots, wherein the number of layers is radially from the inside to the bottom External change up to the radial sub-outer trough layer;

S36. Starting from a radially outermost groove layer spanning the y stator slots, the same layer spans the y stator slots in the first direction;

S37, repeating S33-S36 until the winding reaches the adjacent layer of the radially outermost groove layer of the termination groove, and then the star point line of the phase is extracted, wherein the termination groove is in the forward direction from the initial groove y stator slots;

Wherein the first direction and the second direction are opposite directions on the circumference of the stator core.

According to an embodiment of the present disclosure, the cross section of the U-shaped conductor segment perpendicular to the extending direction thereof is a rectangular shape.

According to an embodiment of the present disclosure, the U-shaped conductor segments have equal cross-sectional areas in the extending direction of the U-shaped conductor segments.

The stator assembly according to the second aspect of the present disclosure is prepared using the method of preparing the stator assembly according to the above-described first aspect of the present disclosure.

The additional aspects and advantages of the present disclosure will be set forth in part in the description which follows.

DRAWINGS

The above and/or additional aspects and advantages of the present disclosure will become apparent and readily understood from

1 is a schematic view of a stator core in a stator assembly in accordance with an embodiment of the present disclosure;

2 is a schematic illustration of a U-shaped conductor segment in a stator assembly in accordance with an embodiment of the present disclosure;

Figure 3 is a schematic view showing the welded connection between the U-shaped conductor segments shown in Figure 2;

4 is a schematic view of a stator assembly as an initial arrangement according to an embodiment of the first aspect of the present disclosure, wherein an 8-pole 48-slot 3 phase is illustrated;

5 is a schematic view showing the winding manner of the stator assembly of FIG. 4, wherein the U-phase 1 road is taken as an example;

Figure 6 is a final stator assembly of the stator assembly of Figure 4 after being processed to form a 2-way connection;

Figure 7 is a final stator assembly of the stator assembly of Figure 4 after being machined to form a 1-way connection.

Reference mark:

Stator assembly 100, stator core 1, stator slot 11,

Stator winding 2, U-shaped conductor segment 20, bent portion 201, first in-slot portion 202, second in-slot portion 203,

Neutral line 3, hairpin end I, soldering end II;

Three phases: U phase, V phase, W phase

U phase 1 way lead line U1A; U phase 2 way lead line U2A;

U phase 1 road star point line U1A; U phase 2 road star point line U2B;

V phase 1 way lead line V1A; V phase 2 way lead line V2A;

V phase 1 road star point line V1A; V phase 2 road star point line V2B;

W phase 1 way lead line W1A; W phase 2 way lead line W2A;

W phase 1 road star point line W1A; W phase 2 road star point line W2B

Detailed ways

The embodiments of the present disclosure are described in detail below, and the examples of the embodiments are illustrated in the drawings, wherein the same or similar reference numerals are used to refer to the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are intended to be illustrative only, and are not to be construed as limiting.

In the description of the present disclosure, it is to be understood that the orientation or positional relationship indicated by the terms "center", "axial", "radial", "circumferential", etc. is based on the orientation or positional relationship shown in the drawings. The present disclosure and the simplifications of the disclosure are merely intended to be illustrative, and not to be construed as limiting the scope of the disclosure. Moreover, the terms "first" and "second" are used for descriptive purposes only and are not to be understood as indicating or implying a relative importance or implicitly indicating the number of technical features indicated. Thus, features defining "first" and "second" may include one or more of the features either explicitly or implicitly. In the description of the present disclosure, "a plurality of" means two or more unless otherwise stated.

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. The specific meanings of the above terms in the present disclosure can be understood in the specific circumstances by those skilled in the art.

A method of manufacturing a stator assembly according to an embodiment of the first aspect of the present disclosure will be described below with reference to FIGS.

The method for preparing the stator assembly of the embodiment of the present disclosure is applicable to a motor of a z-slot 2p-level m-phase, wherein the number of slots per phase per phase is q=z/m/(2p), and the number of parallel branches is a, a≤ q.

As shown in FIGS. 1 to 4, the stator assembly includes: a cylindrical stator core and a stator winding, wherein the stator core has a plurality of stator slots arranged in a circumferential direction along the stator core; The 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. In some embodiments of the invention, the slot layers include sequential arrangements. Each of the layers a, b, c, d, e, and f is a layer located in the innermost layer in the radial direction of the stator core 1 and a layer f in the outermost layer. The stator winding includes a plurality of U-shaped conductor segments, each U-shaped conductor segment including a bent portion, a first in-slot portion and a second in-slot portion, the first in-slot portion and the second in-slot portion being respectively connected to the bent portion .

The first slot portion of the U-shaped conductor segment passes through one of the slot slots in one of the stator slots, and the second slot portion passes through one of the slot slots in the other stator slot, the first slot inner portion and the second slot portion After the inner portion passes through the stator slot, its end portion extends beyond the stator core to form a welded end, and the first slot inner portion of the plurality of U-shaped conductor segments located in the adjacent layer and the second slot inner portion are weldedly connected at the soldering end.

According to the preparation method of the stator assembly of the present disclosure, the number of windings of the stator assembly can be adjusted, and the adjustment mode is simple and quick; and the vehicle requirements of different motor voltage levels can be matched, and the vehicle requirements of different high-efficiency zones can also be matched.

According to some embodiments of the present disclosure, on the welded end, the star point line of each phase of each phase is located in the radially outer outer layer, and the lead line of each phase of each phase is located at the outermost radial direction; On the welding end, the star point line and the lead line of each phase of each phase are different from each other by 3q stator slots in the circumferential direction, and the multi-way star point line of any phase differs by one stator slot in the circumferential direction, either phase The multi-channel lead wires are separated by one stator slot in the circumferential direction.

According to some embodiments of the present disclosure, one of the outgoing lines of any phase differs from the different star-shaped dotted lines of the phase by 3q-1 stator slots in the circumferential direction.

According to some embodiments of the present disclosure, when q is an even number, the number of parallel branches of the stator assembly is a=2n or a=1, where n is a natural number of 1 to q/2;

According to some embodiments of the present disclosure, when q is an odd number, the number of parallel branches of the stator assembly is a=1 or a=q,

In some embodiments of the present disclosure, the stator assembly has a stator slot number of 48, a pole number of 8, a phase number of 3, and includes U phase, V phase, and W phase, and the number of slots per phase per phase is q=2, The number of parallel branches is 2.

Among them, the star point line and the lead line of each U phase are different from each other by 6 stator slots; the two channels of each phase are different in the circumferential direction by one stator slot; the U phase, the V phase, and the adjacent phase in W correspond to each other. The star-point line differs by four stator slots in the circumferential direction; the adjacent corresponding lead lines in the U-phase, V-phase, and W-phase are different in the circumferential direction by four stator slots.

In some embodiments of the present disclosure, the stator assembly has a stator slot number of 72, a pole number of 8, a phase number of 3, and includes U phase, V phase, and W phase, and the number of slots per phase per phase is q= 3. The number of parallel branches is 3.

Among them, there are 9 stator slots between the star point line and the lead line of each U phase; the two phases of the U phase are different from each other in the circumferential direction by 1 stator slot; One stator slot is different in the upward direction; two stators in the W phase are different in the circumferential direction by one stator slot; the adjacent star-point lines in the U phase, V phase, and W phase are different in the circumferential direction by 6 stator slots. The adjacent corresponding lead lines in the U phase, the V phase, and the W phase are different in the circumferential direction by 6 stator slots.

According to some embodiments of the present disclosure, the first in-slot portion and the second in-slot portion of the plurality of U-shaped conductor segments located in different layers are soldered on the soldering end to enable the The winding direction of the windings is configured to be in each phase of each phase:

S32. Cross the y stator slots in the same layer along the first direction;

In some embodiments of the present disclosure, the cross section of the U-shaped conductor segment perpendicular to its direction of extension is a rectangular shape. Thereby, the tank full rate can be improved. The U-shaped conductor segments have equal cross-sectional areas in the direction of extension of the U-shaped conductor segments.

According to the stator assembly of the embodiment of the present disclosure, by adopting the preparation method of the above-described stator assembly, the number of windings can be adjusted, so that the vehicle requirements of different motor voltage levels can be matched, and the vehicles of different high-efficiency zones can also be matched. demand. In addition, since the number of roads can be adjusted to be different, so that the voltage difference between adjacent layers in each stator slot is different, the requirements for the layer insulation system are different, and thus different roads can be selected according to actual risks and cost control. Number plan.

Specific embodiments of a stator assembly and a method of fabricating the same according to embodiments of the present disclosure are described below.

A stator assembly in accordance with an embodiment of the present disclosure may be described in accordance with FIGS. 1-4, which may be used as an initial stator assembly and machined to customer requirements to obtain a final stator assembly in a final form of different numbers of paths.

A stator assembly 100 according to an embodiment of the present disclosure includes a stator core 1 and a stator winding 2.

As shown in FIG. 1, the stator core 1 has a plurality of stator slots 11, each of which has a plurality of slot layers, and the stator winding 2 includes a plurality of U-shaped conductor segments 20. As shown in FIGS. 2 and 3, each U-shaped conductor segment 20 includes a bent portion 201 and a first in-slot portion 202 and a second in-slot portion 203 that are respectively connected to the bent portion 201, and the first in-slot portion 202 Passing through one of the slot slots in one of the stator slots 11, the second in-slot portion 203 passes through one of the slot slots in the other stator slot 11, the first in-slot portion 202 and the second in-slot portion 203 passing through the stator After the groove 11, its end portion is beyond the stator core 1.

The cross section of the U-shaped conductor segment 20 perpendicular to its extending direction is a rectangular shape. Optionally, the U-shaped conductor segment 20 has a rectangular cross section, and the short side of the rectangle is perpendicular to the bottom wall of the stator slot 11. In the direction in which the U-shaped conductor segments 20 extend, the cross-sectional areas of the U-shaped conductor segments 20 are equal.

As shown in FIG. 4, one end of the bent portion 201 in the plurality of U-shaped conductor segments 20 is the card-issuing end I of the stator winding 2, and the end of the end portion of the first in-slot portion 202 and the second in-slot portion 203 is called As the welding end II of the stator winding 2, as shown in Fig. 3, the welding end 2 is a first in-slot portion 202 of a plurality of U-shaped conductor segments 20 and a second in-slot portion of the U-shaped conductor segment 20 adjacent thereto. 203 is formed by welding in sequence.

Wherein the welding end II, the star point line and the lead line of each phase of each phase are different in the circumferential direction by 3q stator slots 11, and the multiplex lines of any phase are different in the circumferential direction by one stator slot 11;

The corresponding star point lines between the multiple phases are different in the circumferential direction by 2q stator slots 11;

The corresponding lead lines between the multiple phases are different in the circumferential direction by 2q stator slots 11,

Wherein, the number of slots per phase per phase is q=z/m/(2p), and the number of parallel branches is g, g≤q;

Where z is the number of stator slots, m is the number of phases, and 2p is the number of poles.

The stator assembly 100 herein is suitable for a z-slot 2p-stage m-phase motor, where the number of slots z can be 24, 48, 72, etc., the number of phases m can be three-phase, two-phase or single-phase, and the pole-number p can It is 8-pole, 4-pole, etc. It can be set according to the specific motor.

It should be noted here that "phase difference" refers to the difference between the two slots. For example, if the initial slot is 1, then the difference is 6 slots and then the 7th slot.

According to the stator assembly of the embodiment of the present disclosure, the distance between the lead wire and the star point line is the smallest, and can be used as the structure of the initial stator component, for example, the factory structure setting, and the number of winding parallel branches can be separately adjusted according to customer requirements. . Thus, on the basis of the stator assembly, if the user needs to access 1 way, the stator assembly of the embodiment of the present disclosure can be processed to adjust it into a stator assembly having a parallel branch number of 1 channel, and then with the rotor, etc. The components are assembled to obtain a motor that is connected all the way; accordingly, when two-way access is required, the stator assembly of the embodiment of the present disclosure is processed to adjust it to a stator assembly having two parallel branches.

The stator assembly according to an embodiment of the present disclosure is adjustable in the number of lines, so that the vehicle requirements of different motor voltage levels can be matched, and the vehicle requirements of different high efficiency areas can also be matched. In addition, since the number of roads can be adjusted to be different, so that the voltage difference between adjacent layers in each stator slot is different, the requirements for the layer insulation system are different, and thus different roads can be selected according to actual risks and cost control. Number plan.

According to an embodiment of the present disclosure, the above-described winding coil structure may be wound by the following winding method:

S1, a plurality of U-shaped conductor segments 20 are provided, each U-shaped conductor segment 20 including a bent portion and a first in-slot portion 202 and a second in-slot portion 203 respectively connected to the bent portion, the first in-slot portion 202 And the pitch between the second in-slot portion 203 is y stator slots 11, wherein y is an integer and y = z / 2p;

S2, passing the first in-slot portion 202 of the U-shaped conductor segment 20 through one of the slot layers in one of the stator slots 11, and the second in-slot portion 203 passing through one of the slot slots in the other stator slot 11, An in-slot portion 202 and a second in-slot portion 203 pass through the stator slot 11 and have their ends beyond the stator core to form a welded end;

S3, soldering the first in-slot portion 202 and the second in-slot portion 203 of the plurality of U-shaped conductor segments 20 on the soldering end so that the winding direction of the coil is configured in each phase :

S31, the lead wire is led out to the radially outermost groove layer of the initial groove, the initial groove is the stator groove 11 which is inserted for the first time when the lead wire is ready to be wound;

S32, the same layer spans the y stator slots 11 along the first direction;

S33. Starting from a radial sub-outer groove layer spanning the y stator slots 11, spanning in a second direction, the number of layers of the groove layer is changed by one layer every y-seat stator slots, wherein the number of layers is radially outward Change to the inside until the radial inner groove layer;

S34, from the radially innermost groove layer after spanning the y stator slots, the same layer spans the y stator slots 11 in the first direction;

S37, repeating S33-S36 until the winding reaches the adjacent layer of the radially outermost groove layer of the termination groove, and then the star point line of the phase is extracted, wherein the termination groove is in the forward direction from the initial groove y stator slots; wherein the term "terminating slot" herein refers to the last stator slot that passes after the coil is wound.

For the sake of clarity, in the following description, a stator assembly according to an embodiment of the present disclosure is used for an 8-pole 48-slot 3-phase motor as an example, that is, the number of stator slots is z=48, and the number of phases is m=3, wherein The three phases include the U phase, the V phase, and the W phase; the pole number is 2p=8 (ie, the pole pair is 4), and each of the three phases includes two paths.

As shown in FIG. 4, in the stator winding 2 of the stator assembly 100, the pitch between the first in-slot portion 202 and the second in-slot portion 203 of the U-shaped conductor segment 20 is y stator slots, where y is an integer And y=z/2p. For an 8-pole 48-slot stator assembly 100, y=6. That is, the first in-slot portion 202 and the second in-slot portion 203 of each U-shaped conductor segment 20 differ by six stator slots.

In the following description, the present disclosure will be described by taking six layers in each of the stator slots 11 as an example. The six-layer lines include layers a, b, c, d, e, and f which are sequentially arranged, in each of the stator slots 11 In the radial direction of the stator core 1, the inner layer is the a layer, and the outermost layer is the f layer.

In the stator assembly shown in FIG. 4, the star point line and the lead line of each U phase are different from each other by 6 stator slots 11, and the two channels of each phase are different in the circumferential direction by one stator slot 11; U phase, The star-point lines corresponding to the adjacent phases in the V phase and the W are different in the circumferential direction by four stator slots 11; the adjacent adjacent lead wires in the U phase, the V phase, and the W phase are different in the circumferential direction by four stator slots 11.

More specifically, as shown in FIG. 5 and FIG. 6, 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.

As shown in FIG. 5 and FIG. 6, the U-phase 1 way lead line U1A and the U-phase 1 way star point line U1B are different from each other by 6 stator slots, and the U-phase 2 way lead lines 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 adjacent star-point lines in the U-phase, V-phase, and W-phase are different from each other in the circumferential direction by four stator slots. Specifically, taking the first path as an example, the U-phase 1-way star-point line U1B and V-phase 1 The star point line V1B of the road and the star point line W1B of the W phase 1 road are sequentially different by 4 slots in the circumferential direction. For example, as shown in FIG. 2, U1B is taken out from the 07 slot e layer, and V1B is taken out from the 03 slot e layer, W1B. It is taken out from the 47-slot e layer. Similarly, 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.

Accordingly, adjacent ones of the U phase, the V phase, and the W phase are adjacent to each other by four stator slots 11 in the circumferential direction. Specifically, taking the first path as an example, 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. 2 As shown, U1A is introduced from the 01-slot f layer, V1A is introduced from the 45-slot f-layer, and W1A is introduced from the 41-slot f-layer. Similarly, 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. 5 and FIG. 6, taking the A-phase first road as an example, the winding line is as follows:

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

The winding circuit of the second phase of the A phase is different from the first phase of the A phase by one stator slot in the circumferential direction.

The adjacent star-point lines in the A phase, the B phase, and the C phase are different in the circumferential direction by 4 stator slots;

The adjacent corresponding lead lines in the A phase, the B phase, and the C phase are different in the circumferential direction by four stator slots.

Of course, when the number of stator slots, the number of poles, and the number of phases are different, the winding structure of each phase is different.

For example, when the number of stator slots is 72, the number of poles is 8, the number of phases is 3, and the U phase, the V phase, and the W phase are included, 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.

It should be noted that in some embodiments, on the welding end II of the stator winding, 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 is convenient for the introduction of the lead wire, the extraction of the star point line, and the structure of the entire stator winding is simple.

A method of fabricating the stator assembly 100 according to an embodiment of the present disclosure for processing the stator assembly 100 of the above-described embodiment according to user requirements to obtain different number of stator assemblies will be described below. The stator assembly 100 is suitable for use in a z-slot 2p-stage m-phase motor. The number of slots per phase per phase is q=z/m/(2p), and the number of parallel branches is g, g≤q.

The preparation method according to an embodiment of the present disclosure includes:

S1, select the number of ways g, g is a natural number greater than or equal to 1.

When q is an odd number, g has 2 choices: q road and 1 road;

When q is an even number, g has q/2+1 choices, q, q/2, q/4, ..., 1;

S2, when the number of selected paths g=q, the star point lines of each of the m phases are outwardly bent and connected by the neutral line 3; the lead wires of each of the m phases are fixed by welding and interface with the external controller. Connected. Alternatively, the material in the neutral line 3 herein may conform to the material of the U-shaped conductor segment 20.

S3. When the number of selected channels g=1, the lead line of the kth path in each phase is stretched and bent outward, and then fixed and fixed to the star point line of the k-1th road in the corresponding phase, wherein k is 2~ The natural number of q; the lead wire of the first way in each phase is welded and fixed and connected to the external controller interface; the star point lines of the other roads except the first road in each phase are bent outward and pass the neutral line 3 connection.

At this time, for the sake of clarity, take the 4-way U-phase winding as an example. If you want to turn it into one way, you can do it in the following way: U-phase 4th lead wire is stretched and then U-phase 3 way The star-point line connection, the U-phase 3-way lead-out line is stretched and connected to the U-phase 2-way star-point line, and the U-phase 2-way lead-out line is stretched and then the U-phase 1 way star-point line Connection, the U-phase 1 way lead wire is fixed and connected to the external controller after welding; in addition, the U-phase 4 way star point line is connected by the first neutral line 3; the U-phase 3 way star point line passes the second neutral Line 3 is connected; the U-phase 2 way star point line is connected by the third neutral line 3.

When S4 and q are even numbers, the q channels in each phase are divided into q/2 groups, and the lead wires of one of the at least one group of the q/2 group are stretched and bent and fixed with the star line of the other road, one of which is fixed. The star point lines are bent outward and connected by a neutral line 3, and the other line of leads is soldered and connected to an external controller interface.

For the sake of clarity, the U phase in the 4 way is taken as an example. If you want to change it to the second way, you can do it by: 4 ways in the U phase are divided into 2 groups, and the 1st and 2nd roads are the first. One group, the third road and the fourth road are the second group, wherein the lead line of the second road is welded and fixed to the star point line of the first road, and the star point line of the second road is connected with the neutral line 3, the first one The road is connected to the external controller. The lead wire of the 4th road is welded and fixed to the star point line of the 3rd road, the star point line of the 4th road is connected with the neutral line 3, and the 3rd road is connected with the external controller. Thus, two roads were finally formed.

According to the preparation method of the stator assembly according to the embodiment of the present disclosure, the number of windings of the stator assembly is adjustable, and the adjustment mode is simple and quick; and the vehicle requirements of different motor voltage levels can be matched, and the vehicle requirements of different high-efficiency zones can also be matched. . In addition, since the number of roads can be adjusted to be different, so that the voltage difference between adjacent layers in each stator slot is different, the requirements for the layer insulation system are different, and thus different roads can be selected according to actual risks and cost control. Number plan.

In one of the embodiments of the present disclosure, in the step S2 and the step S3, the connection by the neutral wire 3 is a welding.

In other embodiments, in the above steps S2 and S3, the angle at which the star point line and the lead line are bent outward is 60-150 degrees. Alternatively, the angle of the outward bend may be substantially 90 degrees. It is easy to weld and simple and convenient.

In describing the preparation method of the stator assembly of the embodiment of the present disclosure, for the convenience of description, the stator assembly according to the embodiment of the present disclosure is used for an 8-pole 48-slot 3-phase motor as an example, that is, the number of stator slots z=48, The phase number m=3, wherein the three phases include the U phase, the V phase, and the W phase; the number of poles is 2p=8 (ie, the pole number is 4), and each phase of the three phases includes two paths, as shown in FIG. Figure 5 shows.

For a stator assembly suitable for an 8-pole 48-slot 3-phase motor, a two-way solution or a one-way solution can be selected based on its initial stator assembly 100.

When the user selects a two-way scheme, 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. 7, finally, the first lead wires U1A, V1A, W1A of the three phases of U, V, W, and the second lead wires U2A, V2A, W2A are welded and fixed by soldering terminals. Connected to an external controller interface.

When the user selects a one-way scheme, 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 welding through the center line 3. Finally, the first lead wires U1A, V1A, and W1A of the U, V, and W phases are soldered and fixed by soldering terminals, and then connected to an external controller interface.

The stator assembly 200 according to Embodiment 3 of the present disclosure will be described below, which is obtained by the processing means of the step S2 in the above-described manufacturing method, wherein the same components as those in the stator assembly 100 of the embodiment are given the same reference numerals.

The stator assembly 200 according to an embodiment of the present disclosure is suitable for a z-slot 2p-stage m-phase motor, wherein the number of slots per phase per phase is q=z/m/(2p), and the number of parallel branches is g, g≤ q. The stator assembly includes a stator core 1 and a stator winding 2. As shown in FIG. 2, the stator core 1 has a plurality of stator slots 11 each having a plurality of slot layers therein.

The stator winding 2 includes a plurality of U-shaped conductor segments 20, each U-shaped conductor segment 20 including a bent portion 201 and a first in-slot portion 202 and a second in-slot portion 203 that are respectively connected to the bent portion 201, the first groove The inner portion 202 passes through one of the slot slots in one of the stator slots 11, and the second in-slot portion 203 passes through one of the slot layers in the other stator slot 11, the first in-slot portion 202 and the second in-slot portion 203 After passing through the stator slot 11, the end thereof extends beyond the stator core 1.

The corresponding lead lines between the multiple phases are spatially different from each other by 2q stator slots 11;

The star point lines of each of the m phases are outwardly bent and connected by a neutral line 3; the lead wires of each of the m phases are soldered and fixed and connected to an external controller interface. Alternatively, the material of the neutral wire 3 is identical to the material of the U-shaped conductor segment 20. Alternatively, the neutral wire 3 is formed in an arc shape and is concentric with the stator core 1, thereby facilitating welding and a good joining effect. Of course, the cross section of the neutral wire 3 may also be formed in a rectangular shape, and a cross section equal to the cross-sectional area of the U-shaped conductor segment 20 may also be employed.

As shown in FIG. 6, when the stator assembly is applied to an 8-pole 48-slot 3-phase motor, that is, the number of stator slots is 48, the number of poles is 8, the number of phases is 3, and the U phase, the V phase, and the W phase are included. After step S2, an 8-pole 48-slot 3-phase 2-way stator assembly 200 is formed. On the basis of the stator assembly 100 of the first aspect, the stator assembly 200 bends the two-point star line of the U phase, the V phase, and the W phase outward, and is connected by the neutral wire 3; the U phase, the V phase After the two leads of the phase and W are soldered and fixed, they are connected to the external controller interface. Optionally, the two outgoing lines corresponding to the U phase, the V phase, and the W are fixed by welding end II.

The stator assembly 300 according to Embodiment 4 of the present disclosure will be described below, which is obtained by the processing means of the step S3 in the above-described manufacturing method, wherein the same components as those in the stator assembly 100 of the first aspect embodiment are given the same reference numerals.

The stator assembly 300 according to an embodiment of the present disclosure is suitable for a z-slot 2p-stage m-phase motor, wherein the number of slots per phase per phase is q=z/m/(2p), and the number of parallel branches is g, g≤ q. The stator assembly includes a stator core 1 and a stator winding 2. As shown in FIG. 2, the stator core 1 has a plurality of stator slots 11 each having a plurality of slot layers therein.

On the welding end II, the star point line and the lead line of each phase of each phase are different from each other by 3q stator slots 11 in the circumferential direction, and the multiplex lines of any one phase are different from each other by one stator slot 11 in the circumferential direction;

Wherein, the lead line of the kth channel in each phase is sequentially welded and fixed to the star point line of the k-1th road in the corresponding phase, wherein k is a natural number of 2 to q; and the lead wire of the first channel in each phase is fixed after welding The external controller interface is connected; the star point lines of the other roads except the first one in each phase are connected by the neutral line 3.

In some embodiments, the lead line of the kth path in each phase is first bent outward, and then sequentially fixed to the star point line of the k-1th road in the corresponding phase.

In some alternative examples, the star-point lines of the other roads except the first one in each phase are first bent outward and then connected through the neutral line 3.

Alternatively, the material of the neutral wire 3 is identical to the material of the U-shaped conductor segment 20. Alternatively, the neutral wire 3 is formed in an arc shape and is concentric with the stator core 1, thereby facilitating welding and a good joining effect. Of course, the cross section of the neutral wire 3 may also be formed in a rectangular shape, and a cross section equal to the cross-sectional area of the U-shaped conductor segment 20 may also be employed.

As shown in Fig. 7, when the stator assembly is applied to an 8-pole 48-slot 3-phase motor, that is, the number of stator slots is 48, the number of poles is 8, the number of phases is 3, and the U-phase, V-phase, and W-phase are included. 2, at this time, after step S3, an 8-pole 48-slot 3-phase 1-way stator assembly 300 is formed. The stator assembly 200 is elongated and bent by the second phase lead wires of the U phase, the V phase, and the W phase on the basis of the stator assembly 100 of the first embodiment, respectively, and is respectively U phase, V phase, and W phase. The first road star line is welded and fixed, and the second road star line of the U phase, the V phase and the W phase is bent outward, and is connected by the neutral wire 3 welding; the first phase corresponding to the U phase, the V phase and the W phase After the lead wire is soldered and fixed, it is connected to the external controller interface. Optionally, the two outgoing lines corresponding to the U phase, the V phase, and the W are fixed by welding end II.

Of course, in another example of the present disclosure, assuming that the number of parallel branches of the stator assembly 100 is four, if it is to be turned into one way, it can be performed by: the U-phase 4th lead wire is elongated and bent Connected with the U-phase 3 way star point line, the U-phase 3 way lead line is stretched and bent and connected with the U-phase 2 way star point line. The U-phase 2 way lead line is stretched and bent and U-phase 1 The star point line of the road is connected, and the lead line of the U phase 1 road is fixed by welding to the external controller; in addition, the star line of the U phase 4 is connected by the first neutral line 3; the star line of the U phase 3 way Connected by the second neutral line 3; the star line of the U phase 2 is connected by the third neutral line 3.

The stator assembly 400 according to the fifth embodiment of the present disclosure is described below, which is obtained by the processing means of the step S4 in the above-described manufacturing method, wherein the same components as those in the stator assembly 100 of the first aspect embodiment are given the same reference numerals.

The stator assembly 400 according to an embodiment of the present disclosure is suitable for a z-slot 2p-level m-phase motor, wherein the number of slots per phase per phase is q=z/m/(2p), and the number of parallel branches is g, g≤ q. The stator assembly includes a stator core 1 and a stator winding 2. As shown in FIG. 2, the stator core 1 has a plurality of stator slots 11 each having a plurality of slot layers therein.

On the welding end II: the star point line and the lead line of each phase are different in the circumferential direction by 3q stator slots 11, and the multiplex lines of any phase are different in the circumferential direction by one stator slot 11;

Where q is an even number, q channels in each phase are divided into q/2 groups, and at least one of the at least one group of the q/2 group is welded to the star line of the other road, and one of the star points passes through The sex line 3 is connected, and the other lead wire is soldered and fixed to be connected to an external controller interface.

In some embodiments, the lead wires of one of the paths are first stretched and then soldered to the star line of the other road. In other examples, one of the star-point lines is bent outward and then connected through the neutral line 3.

When the stator assembly is applied to a 6-pole, 72-slot, 3-phase motor, that is, the number of stator slots is 72, the number of poles is 6, the number of phases is 3, and the U-phase, V-phase, and W-phase are included, and the number of paths is 4. At this time, using the step S4 in the preparation method in the above second embodiment, the four channels in each phase are divided into two groups, the first group includes the first road and the second road, and the second group includes the third road and the second Four roads, in which the lead wire in the second road is bent and fixed with the star point line of the first road, and the star line of the second road is bent outward and connected through the neutral line 3, the first road After the lead wire is welded and fixed, it is connected to the external controller interface; the lead wire in the fourth road is stretched and bent and fixed with the star point line of the third road, and the star line of the fourth road is bent outward and passes the neutral Line 3 is connected, and the lead wire of the third way is soldered and fixed to be connected to an external controller interface (not shown).

In summary, according to the stator assembly 100 of the embodiment of the present disclosure, the

stator assembly

200, 300 of the third, fourth, and fifth embodiments of the present disclosure can be obtained through different steps in the method of manufacturing the stator assembly according to the embodiment of the present disclosure. 400. That is to say, through the stator assembly and the preparation method thereof in the embodiments of the present disclosure, the number of steps of the stator assembly is adjustable, the adjustment mode is simple and quick, and the vehicle requirements of different motor voltage levels can be matched, and the efficiency can also be matched. The overall vehicle demand in the district. In addition, since the number of roads can be adjusted to be different, so that the voltage difference between adjacent layers in each stator slot is different, the requirements for the layer insulation system are different, and thus different roads can be selected according to actual risks and cost control. Number plan.

In the description of the present specification, the description with reference to the terms "one embodiment", "some embodiments", "illustrative embodiment", "example", "specific example", or "some examples", etc. Particular features, structures, materials or features described in the examples or examples are included in at least one embodiment or example of the present disclosure. In the present specification, the schematic representation of the above terms does not necessarily mean the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in a suitable manner in any one or more embodiments or examples.

While the embodiments of the present invention have been shown and described, it will be understood by those skilled in the art The scope of the disclosure is defined by the claims and their equivalents.

Claims

The invention relates to a method for preparing a stator assembly, which is suitable for a z-slot 2p-level m-phase motor, wherein the number of slots per phase per phase is q=z/m/(2p), and the number of parallel branches is a, a≤q, Characterized by

The stator assembly includes:

a cylindrical stator core having a plurality of stator slots spaced along a circumferential direction of the stator core;

a stator winding, the stator winding including a plurality of U-shaped conductor segments, each of the U-shaped conductor segments including a bent portion and a first in-slot portion and a second in-slot portion respectively connected to the bent portion The first in-slot portion of the U-shaped conductor segment passes through one of the one of the stator slots, and the second in-slot portion passes through one of the other slot slots, the first slot a portion and the second in-slot portion pass through the stator slot and have their ends beyond the stator core to form a soldering end on which the plurality of U-shaped conductor segments are located in adjacent layers The first in-slot portion and the second in-slot portion are weldedly connected, and on the welded end, the star-point line of each phase of each phase is located in the radially outermost outer layer, and the lead-out line of each phase of each phase The outermost layer located in the radial direction;

The preparation method comprises:

Connect one of the outgoing lines of any phase to the different star-shaped dotted lines of the phase.
A method of manufacturing a stator assembly according to claim 1, wherein

On the welding end, the star point line and the lead line of each phase are different from each other by 3q stator slots in the circumferential direction, and the multi-way star point line of any phase differs by one stator slot in the circumferential direction. The multi-channel lead wires of one phase are different from each other by one stator slot in the circumferential direction.
The method of manufacturing a stator assembly according to claim 1 or 2, wherein one of the outgoing lines of any phase and the different road star points of the phase are different from each other by 3q-1 stator slots in the circumferential direction.
A method of manufacturing a stator assembly according to any one of claims 1 to 3, characterized in that

When q is an even number, the number of parallel branches of the stator assembly is a=2n or a=1, where n is a natural number of 1 to q/2;

Connect the lead line of the kth channel in each phase to the star point line of the k-1th road in the phase, where k is a natural number of 2 to q, and connect the lead wire of the 1st channel in each phase to the terminal. The star point line of the qth road in each phase is connected with the neutral line to form a stator assembly with the number of parallel branches a=1;

Dividing the parallel branches in each phase into n groups, and the lead lines of one of the at least one group of the n groups are connected with the star point lines of the other of the groups, and the star point and the neutral line of one of the groups Connected, the other lead wire in the group is connected to the terminal block to form a stator assembly with a parallel branch number a=2n.
A method of manufacturing a stator assembly according to any one of claims 1 to 4, characterized in that

When q is an odd number, the number of parallel branches of the stator assembly is a=1 or a=q,

Connect the lead line of the kth channel in each phase to the star point line of the k-1th road in the phase, where k is a natural number of 2 to q; connect the lead wire of the 1st channel in each phase to the terminal The star point line of the qth road in each phase is connected with the neutral line to form a stator assembly with the number of parallel branches a=1;

When a=q, the star point line of each phase is connected with the neutral line; the lead line of each phase is connected with the terminal to form the stator assembly with the number of parallel branches a=q.
The method for manufacturing a stator assembly according to any one of claims 1 to 5, wherein the stator assembly has a stator slot number of 48, a pole number of 8, a phase number of 3, and includes a U phase and a V phase. With W phase, the number of slots per phase per phase is q=2, and the number of parallel branches is 2.

Wherein, the star point line and the lead line of each U phase are different from each other by 6 stator slots;

The two channels of each phase differ by one stator slot in the circumferential direction;

The adjacent star-point lines in the U phase, the V phase, and the W phase are different in the circumferential direction by 4 stator slots;

The adjacent corresponding lead lines in the U phase, the V phase, and the W phase are different in the circumferential direction by 4 stator slots;

The preparation method comprises: connecting a second way lead line of any phase to a first road star point line of the phase to form a stator assembly having a parallel branch number of 1.
The method for manufacturing a stator assembly according to any one of claims 1 to 5, wherein the stator assembly has a stator slot number of 72, a pole number of 8, a phase number of 3, and includes a U phase and a V phase. With W phase, the number of slots per phase per phase is q=3, and the number of parallel branches is 3.

Wherein, the star point line and the lead line of each U phase are different from each other by 9 stator slots;

The two phases of the U phase are different from each other in the circumferential direction by one stator slot;

The two phases of the V phase are separated by one stator slot in the circumferential direction;

The two phases of the W phase are separated by one stator slot in the circumferential direction;

The adjacent star-point lines in the U phase, the V phase, and the W phase are different in the circumferential direction by 6 stator slots;

The adjacent corresponding lead lines in the U phase, the V phase, and the W phase are different in the circumferential direction by 6 stator slots;

The preparation method includes: connecting a second way lead line of any phase to a first road star point line of the phase, and connecting a third way lead line of any phase to a second road star point line of the phase, A stator assembly having a number of parallel branches of one is formed.
The method of manufacturing the stator assembly according to any one of claims 1 to 7, wherein the first slot inner portion of the plurality of U-shaped conductor segments located at different layers on the soldering end And the second in-slot portion is weldedly connected such that the winding direction of the winding is configured to be in each phase of each phase:

S31, the lead wire is led out to the radially outermost groove layer of the initial groove;

S32. Cross the y stator slots in the same layer along the first direction;

S33. Starting from a radial sub-outer groove layer spanning the y stator slots, spanning in a second direction, the number of layers of the groove layer varies by one layer across y stator slots, wherein the number of layers is radially External to internal variation up to the radial sub-groove layer;

S34. Starting from a radially innermost groove layer spanning the y stator slots, the same layer spans the y stator slots in the first direction;

S35. Starting from a radial sub-inner groove layer spanning y stator slots, spanning in a first direction, the number of layers of the groove layer varies by one layer across each of the y stator slots, wherein the number of layers is radially from the inside to the bottom External change up to the radial sub-outer trough layer;

S36. Starting from a radially outermost groove layer spanning the y stator slots, the same layer spans the y stator slots in the first direction;

S37, repeating S33-S36 until the winding reaches the adjacent layer of the radially outermost groove layer of the termination groove, and then the star point line of the phase is extracted, wherein the termination groove is in the forward direction from the initial groove y stator slots;

Wherein the first direction and the second direction are opposite directions on the circumference of the stator core.
The method of manufacturing a stator assembly according to any one of claims 1 to 8, characterized in that the cross section of the U-shaped conductor segments perpendicular to the direction in which they extend is a rectangular shape.
The method of manufacturing a stator assembly according to claim 9, wherein said U-shaped conductor segments have equal cross-sectional areas in an extending direction of said U-shaped conductor segments.
A stator assembly characterized by being produced using the production method according to any one of claims 1 to 10.