WO2019062916A1 - 导体段及具有其的定子组件、电机 - Google Patents

导体段及具有其的定子组件、电机 Download PDF

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Publication number
WO2019062916A1
WO2019062916A1 PCT/CN2018/108642 CN2018108642W WO2019062916A1 WO 2019062916 A1 WO2019062916 A1 WO 2019062916A1 CN 2018108642 W CN2018108642 W CN 2018108642W WO 2019062916 A1 WO2019062916 A1 WO 2019062916A1
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WO
WIPO (PCT)
Prior art keywords
slot
conductor segment
stator
conductor
layer
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Application number
PCT/CN2018/108642
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English (en)
French (fr)
Inventor
林焕炜
游斌
齐文明
Original Assignee
比亚迪股份有限公司
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Publication of WO2019062916A1 publication Critical patent/WO2019062916A1/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
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/12—Stationary parts of the magnetic circuit
    • H02K1/16—Stator cores with slots for windings
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/12—Stationary parts of the magnetic circuit
    • H02K1/16—Stator cores with slots for windings
    • H02K1/165—Shape, form or location of the slots
    • 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
    • H02K3/32—Windings characterised by the shape, form or construction of the insulation
    • H02K3/40—Windings characterised by the shape, form or construction of the insulation for high voltage, e.g. affording protection against corona discharges
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K2213/00—Specific aspects, not otherwise provided for and not covered by codes H02K2201/00 - H02K2211/00
    • H02K2213/03—Machines characterised by numerical values, ranges, mathematical expressions or similar information

Definitions

  • the present disclosure relates to the field of electrical machines, and more particularly to a conductor segment of a stator assembly, a stator assembly including the same, and a motor including the stator assembly.
  • the bending step is formed by bending inwardly between the legs of the U-shaped shape toward one of the legs to form a bending step
  • the end portion of the U-shaped portion of the hairpin coil ie, the card-issuing end
  • the bent corner of the bent step is too small, the flat copper wire surface paint is easily damaged, resulting in poor insulation.
  • 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 conductor segment of a stator assembly that is reliable and easy to solder.
  • the present disclosure also discloses a stator assembly including the conductor segments.
  • the present disclosure also discloses an electric machine including the stator assembly.
  • a conductor segment of a stator assembly is adapted to be inserted into different stator slots of a stator core, the conductor segments having a rectangular cross section and including: the bends and the respectively a first in-slot portion and a second in-slot portion connected to the bent portion; a first welded portion is connected to an end of the first in-slot portion; and an end portion of the second in-slot portion is connected to the first portion a second welded portion; wherein the free ends of the first welded portion and the second welded portion each have a chamfered portion.
  • the lower wire is conveniently inserted when the stator core is inserted, and the risk of scratching the adjacent copper wire patent leather when the wire is broken can be reduced, and the reliability of the motor is improved.
  • chamfering on the welded end is also convenient for welding.
  • the outer surface of the chamfered portion has a slope and has an angle ⁇ with a horizontal plane, the angle ⁇ ⁇ 45 degrees.
  • the included angle ⁇ ranges from 45 to 60 degrees.
  • the slope of the outer surface of the chamfered portion is parallel to the short side of the rectangular shape.
  • the chamfered portion is formed in an inverted tapered shape at an end of the second welded portion and the first welded portion.
  • the method further includes: a first connecting portion connected between the first in-slot portion and the first welded portion, the first connecting portion being opposite to the The first groove is partially bent, the first welded portion is bent with respect to the first connecting portion and is parallel to the first groove inner portion; the second connecting portion is connected to the second connecting portion Between the second in-slot portion and the second welded portion, the second connecting portion is bent with respect to the second in-slot portion, and the second welded portion is bent with respect to the second connecting portion and Parallel to the inner portion of the second groove.
  • an angle ⁇ 1 between the first connecting portion and the first in-slot portion, and an angle ⁇ 2 between the second connecting portion and the second in-slot portion are both Obtuse angle.
  • the ⁇ 1 and ⁇ 2 satisfy: 100 degrees ⁇ ⁇ 1 ⁇ 160 degrees; 100 degrees ⁇ ⁇ 2 ⁇ 160 degrees.
  • the first connecting portion and the first in-slot portion are connected by a rounded corner, and the first connecting portion and the first welded portion are connected by a rounded corner.
  • the conductor segments are formed in a generally U-shape.
  • the conductor segment has a rectangular cross section, and the short side of the rectangle is perpendicular to the stator groove bottom wall.
  • the conductor segments have a uniform cross section in the extending direction of the conductor segments.
  • a stator assembly comprising: a cylindrical stator core having a plurality of stator slots spaced along a circumferential direction of the stator core;
  • the conductor segment of the first aspect embodiment is disclosed, wherein the first in-slot portion and the second in-slot portion of the conductor segment are respectively located in the same slot layer of the two stator slots that are apart from the predetermined number of slots.
  • the conductor segments are each located within the outermost layer of the two stator slots, or within the innermost layer, a predetermined number of slots.
  • An electric machine includes the stator assembly according to the embodiment of the second aspect of the present disclosure.
  • Figure 1a is a schematic illustration of a conductor segment in accordance with one embodiment of the present disclosure
  • Figure 1b is an enlarged view of the portion A of Figure 1a;
  • Figure 2 is a plan view of the conductor segment shown in Figure 1a;
  • 3a is a schematic view of a bent portion of a conductor segment in accordance with a first embodiment of the present disclosure
  • Figure 3b is a torsion diagram of the bent portion shown in Figure 3a;
  • FIG. 4a is a schematic view of a bent portion of a conductor segment in accordance with a second embodiment of the present disclosure
  • Figure 4b is a torsion diagram of the bent portion shown in Figure 4a;
  • FIG. 5 is a schematic illustration of a stator assembly showing a stator core and a conductor segment as an example, in accordance with an embodiment of the present disclosure.
  • 6a-7b are schematic views of conductor segments in different stages of fabrication in accordance with a first embodiment of the present disclosure.
  • FIG. 8 is a schematic diagram of a motor in accordance with an embodiment of the present disclosure.
  • first in-slot portion 120 a first in-slot portion 120, a second in-slot portion 130,
  • first connecting portion 141 a first connecting portion 141, a second connecting portion 142,
  • Stator core 200 Stator core 200, stator slot 210,
  • 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.
  • FIGS. 5 and 1a which includes a conductor segment according to an embodiment of the first aspect of the present disclosure.
  • a stator assembly includes a stator core 200 and stator windings.
  • the stator core 200 has a cylindrical shape, and the stator core 200 has a plurality of stator slots 210 thereon.
  • the stator slot 210 is formed on the inner peripheral wall of the stator core 200 and penetrates the stator core 200 in the axial direction (for example, the up and down direction shown in FIG. 5), and the plurality of stator slots 210 are along the stator core 200.
  • the circumferential spacing is arranged.
  • the depth direction of the stator slots 210 coincides with the radial direction of the stator core 200.
  • Each stator slot 210 has a plurality of slot layers therein.
  • the stator slot has a plurality of layers formed by stator windings.
  • the slot layer includes a, b, c, d, e, which are sequentially arranged.
  • the innermost layer is the a layer
  • the outermost layer is the f layer.
  • the stator winding includes a plurality of conductor segments each including a bent portion 110 and a first in-slot portion 120 and a second in-slot portion 130 respectively connected to the bent portion, the first in-slot portion 120 passing through one of the stator slots One of the slot layers 210, the second in-slot portion 130 passes through one of the other slot slots 210, and the first in-slot portion 120 and the second in-slot portion 130 pass through the stator slot 210 and terminate at the end thereof Exceeding the stator core 200.
  • One end of the bent portion 110 in the conductor segment 100 is the hairpin end I of the stator winding, and the end of the end portion of the first in-slot portion 120 and the second in-slot portion 130 is referred to as the welding end II of the stator winding, as shown in FIG.
  • the weld end II is formed by sequentially welding the first in-slot portion 120 of the plurality of conductor segments 100 and the second in-slot portion 130 of the conductor segment 100 adjacent thereto.
  • the conductor segments include at least the same layer conductor segment 100 and a cross-layer conductor segment (not shown). Wherein the first in-slot portion 120 and the second in-slot portion 130 of the cross-layer conductor segment are respectively located in different slot layers of the two stator slots 210 separated by a predetermined number of slots, generally, the first in-slot portion 120 and the first The number of groove layers in the two-slot inner portion 130 differs by one, and may be positive 1 or negative 1.
  • the cross-layer conductor segments can be used for forward crossing, that is, the groove layer in which the second in-slot portion 130 is located is radially inward than the groove layer in which the first in-slot portion 120 is located, and can also be used for reverse crossing. That is, the groove layer in the second groove portion is located radially outward of the groove layer in which the inner portion of the first groove is located.
  • the first in-slot portion 120 and the second in-slot portion 130 of the same-layer conductor segment 100 are respectively located in the same groove layer of the two stator slots 210 which are apart from the predetermined number of slots, and more specifically, the same-layer conductor segments 100 are located at a distance from each other.
  • a conductor segment 100 of a stator assembly may be described below with reference to FIGS. 1a-5, which may be a peer conductor segment or a cross-layer conductor segment.
  • the conductor segment 100 is formed in a generally U-shape and includes a bend 110, a first in-slot portion 120, and a second in-slot portion 130.
  • the conductor segment 100 has a rectangular shape in cross section, the rectangular shape having a long side and a short side.
  • the conductor segments can be made of flat copper wire.
  • the first welded portion 151 is connected to the end of the first in-slot portion 120
  • the second welded portion 152 is connected to the end of the second in-slot portion 130, wherein the first welded portion 151 and the second welded portion
  • the free ends of the portions 152 each have a chamfered portion 160.
  • the conductor segment of the embodiment of the present disclosure by providing the chamfered portion 160 at the welding end, it is convenient to take off the wire when inserting the stator core 200, and at the same time, the risk of scratching the adjacent copper wire patent leather when the wire is broken can be reduced, and the reliability of the motor can be improved. .
  • chamfering on the welded end is also convenient for welding.
  • the outer surface of the chamfered portion 160 has a slope and has an angle ⁇ with the horizontal plane, and the angle ⁇ is ⁇ 45 degrees. It is considered that if the angle of the angle ⁇ is too large, the height of the chamfered portion 160 is too high, so that the height of the welded end is too high, affecting the axial dimension, and on the other hand, the thickness of the chamfered portion 160 is too small. It is not conducive to the lower line and is easy to bend; and the angle of the angle ⁇ is too small to be guided and easy to go offline. Thus, in some embodiments of the present disclosure, the included angle ⁇ ranges from 45-60 degrees.
  • the bevel of the outer surface of the chamfered portion 160 is parallel to the short side of the rectangular shape of the cross section of the conductor segment, which facilitates the formation of the chamfered portion.
  • the chamfered portion 160 is formed in an inverted tapered shape at both ends of the second welded portion 152 and the first welded portion 151, whereby the lower thread is more convenient and less susceptible to damage to the adjacent copper patent leather.
  • the height of the chamfered portion 160 can be within the normal range, that is, it does not affect the axial dimension, and is easy to guide and not affect. Offline effect.
  • the height h of the chamfered portion 160 is ⁇ 4 mm.
  • the height h of the chamfered portion 160 is ⁇ 2 mm, thereby facilitating welding.
  • the conductor segment further includes: a first connecting portion 141 and a second connecting portion 142, the first connecting portion 141 being connected to the first in-slot portion 120 and the first solder portion Between 151, the first connecting portion 141 is bent with respect to the first in-slot portion 120, and the first welded portion 151 is bent with respect to the first connecting portion 141 and is parallel to the first in-slot portion 120.
  • the second connecting portion 142 is connected between the second in-slot portion 130 and the second welded portion 152 , the second connecting portion 142 is bent relative to the second in-slot portion 130 , and the second welded portion 152 is opposite to the second connecting portion 142 .
  • the bend is parallel to the second in-slot portion 130.
  • the first connecting portion 141 and the first in-slot portion 120 and the first soldering portion 151 are respectively connected by rounded corners, and correspondingly, the second connecting portion 142 and the second in-slot portion are respectively The 130 and the second welded portion 152 are respectively connected by rounded corners.
  • the angle ⁇ 1 between the first connecting portion 141 and the first in-slot portion 120, and the angle ⁇ 2 between the second connecting portion 142 and the second in-slot portion 130 are both obtuse angles.
  • ⁇ 1, ⁇ 2 satisfy: 100 degrees ⁇ ⁇ 1 ⁇ 160 degrees; 100 degrees ⁇ ⁇ 2 ⁇ 160 degrees.
  • the portions of the first in-slot portion 120 and the second in-slot portion 130 that exceed the stator core are first bent to form the first connecting portion 141 and the second connecting portion 142, and at the first The ends of the connecting portion 141 and the second connecting portion 142 form the first welded portion 151 and the second welded portion 152, so that the lower thread is more reliable and the welding is more convenient.
  • the bend 110 further includes a connecting section 113 connected between the first layer section 111 and the second layer section 112, at least one of the first layer section 111 and the second layer section 112.
  • the twist is made such that the first layer segment 111 and the second layer segment 112 are not on the same concentric circle of the stator core 200.
  • the first layer segment 111 and the second layer segment 112 are respectively twisted in opposite directions with respect to the connecting portion 113 in the radial direction to cause the first layer segment 111 and
  • the second interval 112 is not located on the same straight line or concentric circle.
  • the first layer segment 111 and the second layer segment 112 are both arc segments, while the first layer segment 111 and the second layer segment 112 are not located on the same circle or concentric circles.
  • the arc segments in which the first layer segment 111 and the second layer segment 112 are located are not concentric.
  • the arc lengths of the first layer segment 111 and the second layer segment 112 are not equal.
  • the connecting section 113 is inclined with respect to the radial direction of the stator, the first layer section 111 is twisted in a radially outward direction with respect to the connecting section 113, and the second layer section 112 is oriented radially inward with respect to the connecting section 113.
  • the direction is reversed.
  • the arc o1 is a part of the base circle of the bent portion 110, and the so-called base circle refers to the circle before the bend portion 110 is not bent;
  • the arc o2 is the second layer segment 112. A portion of the circle in which the torsion is located; and the arc o3 is a portion of the circle in which the first layer segment 111 is twisted.
  • the radial distance d between the free ends of the first interval 111 and the second interval 112 is greater than the radial extent of the first in-slot portion 120 or the second in-slot portion 130.
  • first interval 111 and the second interval 112 may also be straight segments (not shown).
  • the connecting section 113 is inclined with respect to the radial direction of the stator, and the angle ⁇ 1 between the first layer section 111 and the connecting section 113, and the angle ⁇ 2 between the second layer section 112 and the connecting section 113 are both It is an obtuse angle. 11 is not equal to ⁇ 2, so that a better anti-interference effect can be ensured.
  • one of the first layer segment 111 and the second layer segment 112 is twisted radially relative to the connecting segment 113, while the other is not processed, thereby making the first
  • the one layer segment 111 and the second layer segment 112 are not located on the same straight line or concentric circle.
  • the first layer segment 111 and the second layer segment 112 are both arc segments, and the arc segments where the first layer segment 111 and the second layer segment 112 are located are different, that is, the first layer segment 111 and the second layer layer. Segments 112 are not located on the same concentric circle.
  • the arc segment in which one of the first layer segment 111 and the second layer segment 112 is located is concentric with the stator core 200 and the other is not concentric with the stator core 200.
  • the arc lengths of the first layer segment 111 and the second layer segment 112 are not equal.
  • the connecting section 113 is inclined with respect to the radial direction of the stator, and the first layer section 111 is twisted in a radially outward direction with respect to the connecting section 113, as shown in FIGS. 4a and 4b, the arc o1
  • the so-called base circle refers to a circle before the bend portion 110 is not bent
  • the arc shape o2 is a part of a circle in which the first layer segment 111 is twisted.
  • the connecting section 113 is inclined with respect to the radial direction of the stator, and the second layer section 112 can be twisted with respect to the connecting section 113 in a radially inward direction.
  • the radial distance d between the free ends of the first interval 111 and the second interval 112 is greater than the radial extent of the first in-slot portion 120 or the second in-slot portion 130.
  • the present disclosure is not limited to this.
  • the first layer segment 111 and the second layer segment 112 may also be straight line segments (not shown).
  • the connecting section 113 is inclined with respect to the radial direction of the stator, and the angle ⁇ 1 between the first layer section 111 and the connecting section 113, and the angle ⁇ 2 between the second layer section 112 and the connecting section 113 are both It is an obtuse angle. 11 is not equal to ⁇ 2, so that a better anti-interference effect can be ensured.
  • the first in-slot portion 120 and the first layer segment 111 are located in the first surface Y1, and the second in-slot portion 130 and the second layer segment 112 are located in the second surface Y2.
  • the first surface Y1 is a curved surface or a plane
  • the second surface Y2 is a curved surface or a plane. That is, when the first layer segment 111 and the second layer segment 112 are both arc segments, as shown in FIG. 2, the first surface Y1 and the second surface Y2 are both curved surfaces.
  • the first surface Y1 and the second surface Y2 are both planar (not shown). Thereby, the structural compactness of the stator winding can be more ensured.
  • the cross-section of the conductor segments 100 perpendicular to their direction of extension is a rectangular shape.
  • the conductor segments have a rectangular cross section, and the short sides of the rectangle are perpendicular to the bottom wall of the stator slot 210.
  • the conductor segments have the same cross section in the direction in which the conductor segments extend.
  • the conductor segments 100 are made of flat copper wire.
  • the conductor segments 100 having a rectangular cross-section when inserted into the stator slots, on the one hand, the structure between the first or second in-slot portions of the adjacent trough layers can be made compact, and on the other hand, the surface insulation can be ensured.
  • the integrity of the patent leather ensures excellent insulation properties.
  • the conductor segment 100 includes a bent portion 110, a first in-slot portion 120, and a second in-slot portion 130.
  • the conductor segments 100 are made of flat copper wire.
  • the bent portion 110 includes a first layer section 111, a second layer section 112, and a connecting section 113 connected between the first layer section 111 and the second layer section 112, the first layer section Both 111 and second interval 112 are arcuate in shape.
  • the first in-slot portion 120 is connected to one end of the first layer segment 111 away from the connecting portion 113
  • the second in-slot portion 130 is connected to one end of the second layer segment 112 away from the connecting portion 113.
  • the conductor segment 100 further includes: a first connecting portion 141 and a second connecting portion 142, a first soldering portion 151 and a second soldering portion 152, the first connecting portion 141 being connected to the first in-slot portion 120 and the first soldering portion 151
  • the first connecting portion 141 is bent with respect to the first in-slot portion 120
  • the first welded portion 151 is bent with respect to the first connecting portion 141 and is parallel to the first in-slot portion 120.
  • the second connecting portion 142 is connected between the second in-slot portion 130 and the second welded portion 152
  • the second connecting portion 142 is bent relative to the second in-slot portion 130
  • the second welded portion 152 is opposite to the second connecting portion 142 .
  • the bend is parallel to the second in-slot portion 130.
  • the free ends of the first welded portion 151 and the second welded portion 152 each have a chamfered portion 160.
  • the outer surface of the chamfered portion 160 has a sloped surface and has an angle ⁇ with the horizontal plane, the angle ⁇ is ⁇ 45 degrees, and the chamfered portion 160 is at the second welded portion 152 and the first welded portion 151.
  • the ends are each formed into an inverted tapered shape.
  • the chamfered portion 160 has a height h ⁇ 2 mm to facilitate soldering.
  • the connecting section 113 is inclined with respect to the radial direction of the stator, and the first layer section 111 is twisted in a radially outward direction with respect to the connecting section 113, as indicated by the arc o3, the second layer The segment 112 is twisted in a radially inward direction relative to the connecting segment 113, such as an arc o2.
  • the radial distance d between the free ends of the first layer segment 111 and the second layer segment 112 is greater than the radial width of the first in-slot portion 120 or the second in-slot portion 130.
  • first in-slot portion 120 and the first layer segment 111 are located in the first surface Y1
  • second in-slot portion 130 and the second layer segment 112 are located in the second surface Y2, wherein the first surface Y1 and the second surface Y2 All are curved surfaces, as shown in Figure 2.
  • the manufacturing method of the conductor segment according to the above first embodiment is as follows:
  • the two sides of the U-shaped flat copper wire are pressed by the arc-face tooling or equipment, and the arc surfaces of the two straight sides are controlled differently, and the inner layer edge is rotated in the direction of the notch.
  • the outer edge of the straight line is rotated in the opposite direction.
  • the schematic diagram is shown in Figure 4a.
  • the straight edge is at the base circle o1, the inner edge arc is o3, and the outer edge arc is o2.
  • the ends of the U-shaped flat copper wire with the curved surface feature are cut into sharp corners, and after the lower wire is inserted into the iron core, the welded end is twisted and formed, and the coil is finally formed as shown in Figs. 1a-5.
  • the entire stator winding formed after the insertion of the stator core is compact in structure while also ensuring good insulation performance.
  • the conductor segment 100 includes a bent portion 110, a first in-slot portion 120, and a second in-slot portion 130.
  • the conductor segments 100 are made of flat copper wire.
  • the bent portion 110 includes a first layer section 111, a second layer section 112, and a connecting section 113 connected between the first layer section 111 and the second layer section 112, the first layer section Both 111 and second interval 112 are arcuate in shape.
  • the first in-slot portion 120 is connected to one end of the first layer segment 111 away from the connecting portion 113
  • the second in-slot portion 130 is connected to one end of the second layer segment 112 away from the connecting portion 113.
  • the conductor segment 100 further includes: a first connecting portion 141 and a second connecting portion 142, a first soldering portion 151 and a second soldering portion 152, the first connecting portion 141 being connected to the first in-slot portion 120 and the first soldering portion 151
  • the first connecting portion 141 is bent with respect to the first in-slot portion 120
  • the first welded portion 151 is bent with respect to the first connecting portion 141 and is parallel to the first in-slot portion 120.
  • the second connecting portion 142 is connected between the second in-slot portion 130 and the second welded portion 152
  • the second connecting portion 142 is bent relative to the second in-slot portion 130
  • the second welded portion 152 is opposite to the second connecting portion 142 .
  • the bend is parallel to the second in-slot portion 130.
  • the free ends of the first welded portion 151 and the second welded portion 152 each have a chamfered portion 160.
  • the outer surface of the chamfered portion 160 has a sloped surface and has an angle ⁇ with the horizontal plane, the angle ⁇ is ⁇ 45 degrees, and the chamfered portion 160 is at the second welded portion 152 and the first welded portion 151.
  • the ends are each formed into an inverted tapered shape.
  • the height h of the chamfered portion 160 is ⁇ 2 mm to facilitate welding.
  • the connecting section 113 is inclined with respect to the radial direction of the stator, and on the basis of the arc o1, the first layer section 111 is twisted in a radially outward direction with respect to the connecting section 113, such as Curved o2.
  • the radial distance d between the free ends of the first layer segment 111 and the second layer segment 112 is greater than the radial width of the first in-slot portion 120 or the second in-slot portion 130.
  • first in-slot portion 120 and the first layer segment 111 are located in the first surface Y1
  • second in-slot portion 130 and the second layer segment 112 are located in the second surface Y2, wherein the first surface Y1 and the second surface Y2 All are curved surfaces, as shown in Figure 2.
  • the manufacturing method of the conductor segment according to the above embodiment is as follows:
  • the two sides of the U-shaped flat copper wire are pressed by the arc-face tooling or equipment, and the arc surfaces of the two straight sides are controlled differently, and the inner layer edge is rotated in the direction of the notch.
  • the outer side is concentric with the inner core of the stator core, and no rotation offset is required.
  • the schematic diagram is shown in Fig. 4a, and the straight side and outer side connecting members are in the base circle o1 (concentric with the inner circle of the stator core 200) At the inner side, the arc of the inner layer is o2.
  • the ends of the U-shaped flat copper wire with the curved surface feature are cut into sharp corners, and after the lower wire is inserted into the iron core, the welded end is twisted and formed, and the coil is finally formed as shown in Figs. 1a-5.
  • the entire stator winding formed after the insertion of the stator core is compact in structure while also ensuring good insulation performance.
  • FIG. 6a to FIG. 7b a molding method of the conductor segment according to the above-described first embodiment will be described by taking FIG. 6a to FIG. 7b as an example.
  • the molding method includes the following steps:
  • the straight flat copper wire 100' is bent into a "Z" shape to form a top and bottom misalignment feature.
  • the two sides 1 and 2 of the flat copper wire are located on different planes, as shown in FIG. 6a and FIG. 6b;
  • the flat copper wire with the "Z”-shaped bending feature is folded into a "V" shape by tooling or equipment, and then the flat copper wire with the "V” shape feature is fixed in the middle of the tooling or equipment.
  • the two sides are bent to form a "U" shape, as shown in Fig. 7a, thereby initially forming the conductor segment 100 including the bent portion 110, the first in-slot portion 120 and the second in-slot portion 130, the top view of which is Shown in 7b.
  • the first layer section 111 and the second layer section 112 of the bent portion 110 of the "U"-shaped conductor segment 100 in FIG. 7b are pressed by a arc-face tooling or equipment to obtain a radial direction with respect to the stator.
  • the lower end of the first in-slot portion 120 is bent to form the first connecting portion 141, and is further bent at the end of the first connecting portion 141 to form the first welded portion 151, and is formed at the end of the first welded portion 151.
  • the chamfered portion 160 similarly, the lower end of the second in-slot portion 130 is bent to form the second connecting portion 142, and is further bent at the end of the second connecting portion 142 to form the second welded portion 152, in the second welding
  • the end portion of the portion 152 forms a chamfered portion 160, thereby forming the conductor segment 100 of the first embodiment.
  • the conductor segment 100 On the basis of forming the conductor segment 100, it is laid down into the stator core 1, and the straight portion is torsionally formed by the fixture, and the stator winding is finally formed as shown in FIG.
  • the conductor segments according to embodiments of the present disclosure are twisted in the radial direction by the first layer segment 111 and/or the second layer segment 112 of the bent portion 100, while the first in-slot portion 120 and the second in-slot portion 130 are not Any processing is performed, so that the conductor segments of the related art in which the bending step features are to be provided do not affect the height of the conductor segments in the axial direction, thereby not affecting the height of the entire stator winding, thereby forming the stator windings after molding.
  • Compact structure
  • the stator winding formed by using the conductor segments described above has a small amount of copper, a smaller copper consumption, and a higher motor efficiency, and by providing a chamfered portion 160 at the welding end, it is convenient to take off the line when the stator core 200 is inserted, and at the same time It can reduce the risk of scratching the adjacent copper wire patent leather when the line is off, and improve the reliability of the motor.
  • chamfering on the welded end is also convenient for welding.
  • an electric machine 1000 includes a stator assembly 100 according to the above-described embodiments of the present disclosure.
  • the motor 1000 shown in FIG. 8 may include a stator assembly 100, and the conductor segments of the stator assembly and the stator assembly may be the stator assembly and its conductor segments described in the embodiments of FIGS. 1 through 7 described above, to avoid repetition, I will not go into details.

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Abstract

一种导体段和具有其的定子组件、电机。导体段(100)包括：折弯部(110)和分别连接至折弯部(110)的第一槽内部分(120)和第二槽内部分(130)；第一槽内部分(120)的端部连接有第一焊接部(151)；第二槽内部分(130)的端部连接有第二焊接部(152)；其中第一焊接部(151)和第二焊接部(152)的自由端均具有倒角部(160)。

Description

导体段及具有其的定子组件、电机
相关申请的交叉引用
本公开基于申请号为201710910195.7，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
本公开涉及电机领域，尤其是涉及一种定子组件的导体段、包括该导体段的定子组件、以及包括该定子组件的电机。
背景技术
相关技术中，用于插装型定子组件的同层发卡线圈中，通过在其U形形状的头部朝向其中一条支腿之间向内折弯以形成折弯台阶，该折弯台阶会使得发卡线圈的U型部分端部(即发卡端)变高；另外，由于该折弯台阶的折弯圆角太小，容易损伤扁铜线表面漆皮，导致绝缘不良。
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的导体段，所述导体段下线可靠且焊接方便。
本公开还公开了一种包括该导体段的定子组件。
本公开还公开了包括该定子组件的电机。
根据本公开第一方面实施例的一种定子组件的导体段，适于插入定子铁芯的不同定子槽内，所述导体段的横截面为矩形形状，且包括：所述折弯部和分别连接至所述折弯部的第一槽内部分和第二槽内部分；所述第一槽内部分的端部连接有第一焊接部；所述第二槽内部分的端部连接有第二焊接部；其中所述第一焊接部和所述第二焊接部的自由端均具有倒角部。
根据本公开实施例的导体段，通过在焊接端设置倒角部，在插入定子铁芯时方便下线，同时可以减少下线时划伤相邻铜线漆皮的风险，提高电机可靠性。另外，在焊接端上带有倒角，还方便焊接。
根据本公开的一个示例，所述倒角部的外表面呈斜面且与水平面之间具有夹角β， 所述夹角β≥45度。
根据本公开的一个示例，所述夹角β的范围为45-60度。
根据本公开的一个示例，所述倒角部的外表面所在的斜面与所述矩形形状的短边平行。
根据本公开的一个示例，所述倒角部在所述第二焊接部和第一焊接部的端部形成为倒锥面形状。
根据本公开的一个示例，所述倒角部的高度h满足：tanβ＝h/0.5b，其中b为所述矩形形状的长边的长度。
根据本公开的一个示例，还包括：第一连接部，所述第一连接部连接在所述第一槽内部分和所述第一焊接部之间，所述第一连接部相对于所述第一槽内部分折弯，所述第一焊接部相对于所述第一连接部折弯且与所述第一槽内部分平行；第二连接部，所述第二连接部连接在所述第二槽内部分和所述第二焊接部之间，所述第二连接部相对于所述第二槽内部分折弯，所述第二焊接部相对于所述第二连接部折弯且与所述第二槽内部分平行。
根据本公开的一个示例，所述第一连接部与所述第一槽内部分之间的夹角γ1、所述第二连接部与所述第二槽内部分之间的夹角γ2均为钝角。可选地，所述γ1、γ2满足：100度≤γ1≤160度；100度≤γ2≤160度。
根据本公开的一个示例，所述第一连接部与所述第一槽内部分之间通过圆角连接，所述第一连接部与所述第一焊接部之间通过圆角连接。
根据本公开的一个示例，所述导体段形成为大体U形形状。
根据本公开的一个示例，所述导体段的横截面为长方形形状，所述长方形的短边垂直于所述定子槽底壁。
根据本公开的一个示例，在所述导体段的延伸方向上，所述导体段的横截面均匀。
根据本公开第二方面实施例的一种定子组件，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；根据本公开第一方面实施例所述的导体段，所述导体段的第一槽内部分和第二槽内部分分别位于相距预定槽数的两个定子槽的相同槽层内。
根据本公开的一个示例，所述导体段均位于相距预定槽数的两个定子槽的最外层内、或最内层内。
根据本公开第三方面实施例的一种电机，包括根据本公开第二方面实施例所述的定子组件。
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1a是根据本公开一个实施例的导体段的示意图；
图1b是图1a中圈示A部的放大图；
图2是图1a中所示的导体段的俯视图；
图3a是根据本公开第一实施例的导体段的折弯部的示意图；
图3b是图3a中所示的折弯部的扭转示意图；
图4a是根据本公开第二实施例的导体段的折弯部的示意图；
图4b是图4a中所示的折弯部的扭转示意图；
图5是根据本公开一个实施例的定子组件的示意图，其中示出了定子铁芯和作为示例的导体段。
图6a-图7b是根据本公开第一实施例的导体段在制作不同时期的示意图。
图8为根据本公开一个实施例的电机的示意图。
附图标记：
导体段100，折弯部110，第一层段111，第二层段112，连接段113，
第一槽内部分120，第二槽内部分130，
第一连接部141，第二连接部142，
第一焊接部151，第二焊接部152，倒角部160，
定子铁芯200，定子槽210，
发卡端I，焊接端II
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”、“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。
首先，将以图5和图1a对根据本公开第二方面实施例的定子组件进行简单描述，该定子组件包括根据本公开第一方面实施例所述的导体段。
根据本公开实施例的定子组件包括：定子铁芯200和定子绕组。如图5所示，定子铁芯200为圆筒形，定子铁芯200上具有多个定子槽210。具体而言，定子槽210形成于定子铁芯200的内周壁上，并沿轴向(例如图5中所示的上下方向)贯穿定子铁芯200，且多个定子槽210沿定子铁芯200的周向间隔布置，作为一个实施例，定子槽210的深度方向与定子铁芯200的径向方向一致。每个定子槽210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。
定子绕组包括多个导体段，导体段均包括折弯部110和分别连接至折弯部的第一槽内部分120和第二槽内部分130，第一槽内部分120穿过其中一个定子槽210中的其中一个槽层，第二槽内部分130穿过另一个定子槽210中的其中一个槽层，第一槽内部分120和第二槽内部分130穿过定子槽210后其端部超出定子铁芯200。
导体段100中的折弯部110所在一端为定子绕组的发卡端I、且第一槽内部分120和第二槽内部分130的端部所在一端称为定子绕组的焊接端II，如图5所示，焊接端II是由多个导体段100的第一槽内部分120和与其相邻的导体段100的第二槽内部分130依次焊接形成。
导体段至少包括同层导体段100和跨层导体段(图未示出)两种形式。其中，跨层导体段的第一槽内部分120和第二槽内部分130分别位于相距预定槽数的两个定子槽 210的不同槽层内，一般来讲，第一槽内部分120和第二槽内部分130所在槽层数相差1，可以是正1或负1。换句话说，跨层导体段可以用于正向跨越，即第二槽内部分130所在槽层比第一槽内部分120所在槽层沿径向向内一层，也可以用于反向跨越，即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。
而同层导体段100的第一槽内部分120和第二槽内部分130分别位于相距预定槽数的两个定子槽210的相同槽层内，更具体地，同层导体段100均位于相距预定槽数的两个定子槽210的最外层内、或最内层内。
值得注意的是，上述提到的两个定子槽210之间相距“预定槽数”，一般是y个定子槽，其中y为整数且y＝z/2p。对于8极48槽的定子组件来说，y＝6。也就是说，每个导体段的第一槽内部分120和第二槽内部分130之间相差6个定子槽。
下面将参考图1a-图5描述根据本公开实施例的定子组件的导体段100，该导体段100可以作为同层导体段或者跨层导体段。如图1a所示，导体段100形成为大体U形形状且包括折弯部110、第一槽内部分120和第二槽内部分130。导体段100的横截面为矩形形状，该矩形形状具有长边和短边。可选地，导体段可采用扁铜线制成。
如图1a所示，第一槽内部分120的端部连接有第一焊接部151，第二槽内部分130的端部连接有第二焊接部152，其中第一焊接部151和第二焊接部152的自由端均具有倒角部160。
根据本公开实施例的导体段，通过在焊接端设置倒角部160，在插入定子铁芯200时方便下线，同时可以减少下线时划伤相邻铜线漆皮的风险，提高电机可靠性。另外，在焊接端上带有倒角，还方便焊接。
根据本公开的一些实施例，如图1b所示，倒角部160的外表面呈斜面且与水平面之间具有夹角β，夹角β≥45度。考虑到如果夹角β的角度过大时，会导致倒角部160的高度太高，从而导致焊接端的高度太高，影响轴向尺寸，另一方面会导致倒角部160的厚度太小，不利于下线，容易折弯；而夹角β的角度过小时，起不到导向、容易下线的作用。因此，在本公开一些实施例中，夹角β的范围为45-60度。
如图1b所示，倒角部160的外表面所在的斜面与导体段横截面的矩形形状的短边平行，这样便于形成倒角部。在一些实施例中，倒角部160在第二焊接部152和第一焊接部151的端部均形成为倒锥面形状，由此下线更方便，也更不易损伤相邻铜线漆皮。
在一些可选的实施例中，如图1b所示，倒角部160的高度h可满足：tanβ＝h/0.5b，其中b为所述矩形形状的长边的长度。通过将高度h与导体段横截面的长边尺寸、以及 角度β之间满足上述公式，使得倒角部160的高度可在正常范围内，即既不影响轴向尺寸，又易于导向、不影响下线效果。在一些具体的示例中，倒角部160的高度h≤4mm。作为一个实施例，倒角部160的高度h≤2mm，由此便于焊接。
如图1a所示，在本公开的一些实施例中，导体段还包括：第一连接部141和第二连接部142，第一连接部141连接在第一槽内部分120和第一焊接部151之间，第一连接部141相对于第一槽内部分120折弯，第一焊接部151相对于第一连接部141折弯且与第一槽内部分120平行。第二连接部142连接在第二槽内部分130和第二焊接部152之间，第二连接部142相对于第二槽内部分130折弯，第二焊接部152相对于第二连接部142折弯且与第二槽内部分130平行。可选地，如图1a所示，第一连接部141与第一槽内部分120和第一焊接部151之间分别通过圆角连接，相应地，第二连接部142与第二槽内部分130和第二焊接部152之间分别通过圆角连接。
在可选的实施例中，第一连接部141与第一槽内部分120之间的夹角γ1、第二连接部142与第二槽内部分130之间的夹角γ2均为钝角。作为一个实施例，γ1、γ2满足：100度≤γ1≤160度；100度≤γ2≤160度。
根据本公开实施例的导体段，将第一槽内部分120和第二槽内部分130的超过定子铁芯的部分先折弯形成第一连接部141和第二连接部142，并在第一连接部141和第二连接部142的端部形成第一焊接部151和第二焊接部152，从而下线更加可靠，焊接更加方便。
下面将参考图1a-图7b对导体段用于同层跨越时(即同层导体段)进行详细描述。
根据本公开的一些实施例，折弯部110还包括连接在第一层段111和第二层段112之间的连接段113，第一层段111和第二层段112的至少一个向径向扭转以使第一层段111和第二层段112不在定子铁芯200的同一同心圆上。
在其中的一些实施例中，如图3a和图3b所示，第一层段111和第二层段112分别相对于连接段113沿径向的相反方向扭转，以使第一层段111和第二层段112并不位于同一条直线或同心圆上。可选地，第一层段111和第二层段112均为弧线段，同时第一层段111和第二层段112并不位于同一圆或同心圆上。第一层段111和第二层段112所在的弧线段不同心。或者可选地，第一层段111和第二层段112的弧长不等。
具体而言，连接段113相对于定子的径向方向倾斜，第一层段111相对于连接段113朝向径向向外的方向扭转，第二层段112相对于连接段113朝向径向向内的方向扭转。如图3a和图3b所示，弧线o1为折弯部110的基础圆的一部分，所谓基础圆指的是折弯部110未折弯之前所在的圆；弧形o2为第二层段112扭转后所在的圆的一部分；而 弧形o3为第一层段111扭转后所在圆的一部分。
如图3a所示，第一层段111和第二层段112的自由端在径向上的距离d大于第一槽内部分120或第二槽内部分130的径向宽度。由此，当多个导体段100同时插入到定子铁芯200的定子槽210内之后，相邻的导体段之间的防干涉效果更好。
当然，本公开并不限于此。在本公开的另一些示例中，第一层段111和第二层段112还可以均为直线段(图未示出)。在这种情况下，连接段113相对于定子的径向方向倾斜，第一层段111和连接段113之间的夹角α1、第二层段112和连接段113之间的夹角α2均为钝角。α1不等于α2，从而可以保证较好的防干涉效果。
在另一些实施例中，如图4a和图4b所示，第一层段111和第二层段112的其中一个相对于连接段113向径向扭转，而另一个不做处理，从而使得第一层段111和第二层段112并不位于同一条直线或同心圆上。可选地，第一层段111和第二层段112均为弧线段，第一层段111和第二层段112所在的弧线段不同心，即第一层段111和第二层段112并不位于同一同心圆上。作为一个实施例，第一层段111和第二层段112中的其中一个所在的弧线段与定子铁芯200同心，而另一个与定子铁芯200不同心。或者可选地，第一层段111和第二层段112的弧长不等。
在其中一个具体示例中，连接段113相对于定子的径向方向倾斜，第一层段111相对于连接段113朝向径向向外的方向扭转，如图4a和图4b所示，弧线o1为折弯部110的基础圆的一部分，所谓基础圆指的是折弯部110未折弯之前所在的圆；弧形o2为第一层段111扭转后所在的圆的一部分。而在另一个具体的实施例中，连接段113相对于定子的径向方向倾斜，第二层段112可以相对于连接段113朝向径向向内的方向扭转。
如图4a所示，第一层段111和第二层段112的自由端在径向上的距离d大于第一槽内部分120或第二槽内部分130的径向宽度。由此，当多个导体段100同时插入到定子铁芯200的定子槽210内之后，相邻的导体段之间的防干涉效果更好。
当然，本公开并不限于此。在本公开的另一些实施例中，第一层段111和第二层段112还可以均为直线段(图未示出)。在这种情况下，连接段113相对于定子的径向方向倾斜，第一层段111和连接段113之间的夹角α1、第二层段112和连接段113之间的夹角α2均为钝角。α1不等于α2，从而可以保证较好的防干涉效果。
根据本公开的一些实施例，如图2所示，第一槽内部分120和第一层段111位于第一面Y1内，第二槽内部分130和第二层段112位于第二面Y2内。可选地，第一面Y1为弧形面或平面，第二面Y2为弧形面或平面。也就是说，当第一层段111和第二层段112均为弧线段时，如图2所示，第一面Y1和第二面Y2均为弧面。而当第一层段111 和第二层段112均为直线段时，第一面Y1和第二面Y2均为平面(图未示出)。由此，可以更加保证定子绕组的结构紧凑程度。
在本公开的一些实施例中，导体段100的垂直于其延伸方向的横截面均为矩形形状。可选地，导体段的横截面为长方形形状，长方形的短边垂直于定子槽210底壁。可选地，在导体段的延伸方向上，导体段的横截面相同。在一个具体的实施例中，导体段100由扁铜线制成。
通过采用矩形形状横截面的导体段100，使得在插入定子槽内时，一方面可以使得位于相邻槽层的第一或第二槽内部分之间的结构紧凑，另一方面可以保证表面绝缘漆皮的完整，从而保证优良的绝缘性能。
下面参考图1a-图5描述根据本公开两个具体实施例的导体段。
实施例一，
如图1a所示，根据该实施例的导体段100包括折弯部110、第一槽内部分120和第二槽内部分130。在本实施例中，如图1a和2所示，导体段100由扁铜线制成。
如图2和图4a所示，折弯部110包括第一层段111、第二层段112和连接在第一层段111和第二层段112之间的连接段113，第一层段111和第二层段112均为弧形形状。第一槽内部分120连接在第一层段111的远离连接段113的一端，第二槽内部分130连接在第二层段112的远离连接段113的一端。
导体段100还包括：第一连接部141和第二连接部142、第一焊接部151和第二焊接部152，第一连接部141连接在第一槽内部分120和第一焊接部151之间，第一连接部141相对于第一槽内部分120折弯，第一焊接部151相对于第一连接部141折弯且与第一槽内部分120平行。第二连接部142连接在第二槽内部分130和第二焊接部152之间，第二连接部142相对于第二槽内部分130折弯，第二焊接部152相对于第二连接部142折弯且与第二槽内部分130平行。其中第一焊接部151和第二焊接部152的自由端均具有倒角部160。
如图1b所示，倒角部160的外表面呈斜面且与水平面之间具有夹角β，夹角β≥45度，且倒角部160在第二焊接部152和第一焊接部151的端部均形成为倒锥面形状。在一个实施例中，倒角部160的高度h≤2mm，以便于焊接。
如图4a和图4b所示，连接段113相对于定子的径向方向倾斜，第一层段111相对于连接段113朝向径向向外的方向扭转，如弧形o3所示，第二层段112相对于连接段113朝向径向向内的方向扭转，如弧形o2。
其中，第一层段111和第二层段112的自由端在径向上的距离d大于第一槽内部分120或第二槽内部分130的径向宽度。
同时，第一槽内部分120和第一层段111位于第一面Y1内，第二槽内部分130和第二层段112位于第二面Y2内，其中第一面Y1和第二面Y2均为弧面，如图2所示。
此外，根据上述实施例一中的导体段的制作方法如下：
制作成U型线圈时，将“U”字型扁铜线两边通过弧面工装或设备压紧，对两直线边的圆弧面控制不一，内层边沿直线部分往槽口方向旋转偏移，外层边沿直线部分往反向旋转偏移，原理图如图4a所示，直线边在基础圆o1处，内层边圆弧如o3，外层边圆弧如o2。将带弧面特征的“U”字型扁铜线两端切成尖角，下线入铁芯后，焊接端扭转成型，此时线圈最终成型如图1a-图5所示。
根据本公开上述实施例的导体段，插入定子铁芯后形成的整个定子绕组的结构紧凑，同时还可以保证良好的绝缘性能。
实施例二，
如图1a所示，根据该实施例的导体段100包括折弯部110、第一槽内部分120和第二槽内部分130。在本实施例中，如图1a和2所示，导体段100由扁铜线制成。
如图2和图4a所示，折弯部110包括第一层段111、第二层段112和连接在第一层段111和第二层段112之间的连接段113，第一层段111和第二层段112均为弧形形状。第一槽内部分120连接在第一层段111的远离连接段113的一端，第二槽内部分130连接在第二层段112的远离连接段113的一端。
导体段100还包括：第一连接部141和第二连接部142、第一焊接部151和第二焊接部152，第一连接部141连接在第一槽内部分120和第一焊接部151之间，第一连接部141相对于第一槽内部分120折弯，第一焊接部151相对于第一连接部141折弯且与第一槽内部分120平行。第二连接部142连接在第二槽内部分130和第二焊接部152之间，第二连接部142相对于第二槽内部分130折弯，第二焊接部152相对于第二连接部142折弯且与第二槽内部分130平行。其中第一焊接部151和第二焊接部152的自由端均具有倒角部160。
如图1b所示，倒角部160的外表面呈斜面且与水平面之间具有夹角β，夹角β≥45度，且倒角部160在第二焊接部152和第一焊接部151的端部均形成为倒锥面形状。作为一个实施例，倒角部160的高度h≤2mm，以便于焊接。
如图4a和图4b所示，连接段113相对于定子的径向方向倾斜，在弧形o1的基础 上，将第一层段111相对于连接段113朝向径向向外的方向扭转，如弧形o2。
其中，第一层段111和第二层段112的自由端在径向上的距离d大于第一槽内部分120或第二槽内部分130的径向宽度。
同时，第一槽内部分120和第一层段111位于第一面Y1内，第二槽内部分130和第二层段112位于第二面Y2内，其中第一面Y1和第二面Y2均为弧面，如图2所示。
外，根据上述实施例中的导体段的制作方法如下：
制作成U型线圈时，将“U”字型扁铜线两边通过弧面工装或设备压紧，对两直线边的圆弧面控制不一，内层边沿直线部分往槽口方向旋转偏移，外层边与定子铁芯内圆铁芯同心，无需旋转偏移，原理图如图4a所示，直线边和外层边连接件在基础圆o1(与定子铁芯200的内圆同心)处，内层边圆弧如o2。将带弧面特征的“U”字型扁铜线两端切成尖角，下线入铁芯后，焊接端扭转成型，此时线圈最终成型如图1a-图5所示。
根据本公开上述实施例的导体段，插入定子铁芯后形成的整个定子绕组的结构紧凑，同时还可以保证良好的绝缘性能。
下面以图6a-图7b为例描述根据上述实施例一的导体段的成型方法。
该成型方法包括以下步骤：
S1，将直扁铜线100’通过折弯成“Z”字型，形成上下边错位特征，此时，扁铜线两边1和2位于不同平面上，如图6a和图6b所示；
S2，将具有“Z”字型折弯特征的扁铜线，通过工装或设备，折成“V”字型，然后将具有“V”字型特征的扁铜线，通过工装或设备固定中间部分，两边折弯，形成“U”字型，如图7a所示，从而初步形成了包括折弯部110、第一槽内部分120和第二槽内部分130的导体段100，其俯视图如7b所示。
S3，将图7b中的“U”字型导体段100的折弯部110的第一层段111和第二层段112通过弧面工装或设备压紧，先得到相对于定子的径向方向倾斜的连接段113，同时第一层段111相对于连接段113朝向径向向外的方向扭转，如图3a和图3b中的弧形o3所示，第二层段112相对于连接段113朝向径向向内的方向扭转，如图3a和图3b中的弧形o2所示。
S4，将第一槽内部分120的下端折弯形成第一连接部141，并在第一连接部141的端部再折弯形成第一焊接部151，在第一焊接部151的端部形成倒角部160；同样地，将第二槽内部分130的下端折弯形成第二连接部142，并在第二连接部142的端部再折弯形成第二焊接部152，在第二焊接部152的端部形成倒角部160，由此形成了实施例一的导体段100。
在形成该导体段100的基础上，将其下线到定子铁芯1内，并将直线部分通过工装夹具扭转成型，最终成型后定子绕组如图5所示。
根据本公开实施例的导体段，通过将折弯部100的第一层段111和/或第二层段112在径向上进行扭转，而第一槽内部分120和第二槽内部分130不进行任何处理，由此相对于相关技术中要设置折弯台阶特征的导体段，在轴向方向上不会影响导体段的高度，从而不会影响整个定子绕组的高度，从而成型后的定子绕组结构紧凑。另外，由于径向扭转，相对于相关技术中的折弯台阶特征，能够有效减小折弯带来的绝缘层破坏风险，可以保护扁铜线表面漆皮，保证良好的绝缘性能。此外，采用上述导体段后成型的定子绕组采用的铜量少，铜耗更小，电机效率更高，而且通过在焊接端设置倒角部160，在插入定子铁芯200时方便下线，同时可以减少下线时划伤相邻铜线漆皮的风险，提高电机可靠性。另外，在焊接端上带有倒角，还方便焊接。
参照图8，根据本公开第三方面实施例的一种电机1000，包括根据本公开上述实施例所述的定子组件100。图8所示的电机1000可以包括定子组件100，定子组件和定子组件的导体段可以为上述图1至图7的实施例中所描述的定子组件和它的导体段，为避免重复，在此不再详细赘述。
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 (17)

  1. 一种定子组件的导体段，其特征在于，适于插入定子铁芯的不同定子槽中，其特征在于，包括：
    折弯部和分别连接至所述折弯部的第一槽内部分和第二槽内部分；
    第一焊接部，所述第一槽内部分的端部连接有第一焊接部；
    第二焊接部，所述第二槽内部分的端部连接有第二焊接部；
    其中，所述第一焊接部和所述第二焊接部的自由端均具有倒角部。
  2. 根据权利要求1所述的导体段，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所述的导体段，其特征在于，所述倒角部的外表面呈斜面且与水平面之间具有夹角β，所述夹角β≥45度。
  4. 根据权利要求3所述的导体段，其特征在于，所述夹角β的范围为45-60度。
  5. 根据权利要求3或4所述的导体段，其特征在于，所述倒角部的外表面所在的斜面与所述矩形形状的短边平行。
  6. 根据权利要求3-5中任一项所述的导体段，其特征在于，所述倒角部在所述第二焊接部和第一焊接部的端部形成为倒锥面形状。
  7. 根据权利要求5或6所述的导体段，其特征在于，所述倒角部的高度h满足：tanβ＝h/0.5b，其中b为所述矩形形状的长边的长度。
  8. 根据权利要求1-7中任一项所述的导体段，其特征在于，还包括：
    第一连接部，所述第一连接部连接在所述第一槽内部分和所述第一焊接部之间，所述第一连接部相对于所述第一槽内部分折弯，所述第一焊接部相对于所述第一连接部折弯且与所述第一槽内部分平行；
    第二连接部，所述第二连接部连接在所述第二槽内部分和所述第二焊接部之间，所述第二连接部相对于所述第二槽内部分折弯，所述第二焊接部相对于所述第二连接部折弯且与所述第二槽内部分平行。
  9. 根据权利要求8所述的导体段，其特征在于，所述第一连接部与所述第一槽内部分之间的夹角γ1、所述第二连接部与所述第二槽内部分之间的夹角γ2均为钝角。
  10. 根据权利要求9所述的导体段，其特征在于，所述γ1、γ2满足：
    100度≤γ1≤160度；100度≤γ2≤160度。
  11. 根据权利要求8-10中任一项所述的导体段，其特征在于，所述第一连接部与所述第一槽内部分之间通过圆角连接，所述第一连接部与所述第一焊接部之间通过圆角 连接。
  12. 根据权利要求1-11中任一项所述的导体段，其特征在于，所述导体段形成为U形形状。
  13. 根据权利要求1-12中任一项所述的导体段，其特征在于，所述导体段的横截面为长方形形状，所述长方形的短边垂直于所述定子槽底壁。
  14. 根据权利要求13所述的导体段，其特征在于，在所述导体段的延伸方向上，所述导体段的横截面均匀。
  15. 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；
    根据权利要求1-14中任一项所述的导体段，所述导体段的第一槽内部分和第二槽内部分分别位于相距预定槽数的两个定子槽的相同槽层内。
  16. 根据权利要求15所述的定子组件，其特征在于，所述导体段均位于相距预定槽数的两个定子槽的最外层内、或最内层内。
  17. 一种电机，其特征在于，包括根据权利要求15或16所述的定子组件。
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