WO2019062922A1

WO2019062922A1 - Conductor segment and stator assembly thereof, and motor

Info

Publication number: WO2019062922A1
Application number: PCT/CN2018/108659
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: CN109586449A

Abstract

A stator assembly and a conductor segment thereof, and a motor. The conductor segment comprises: a bent portion (110), the bent portion (110) including a first layer segment (111), a second layer segment (112) and a connecting segment (113), the first layer segment (111) and the second layer segment (112) being twisted in radially opposite directions with respect to the connecting segment (113); a first in-slot portion (120), the first in-slot portion being connected to the first layer segment (111); and a second in-slot portion (130), the second in-slot portion being connected to the second layer segment (112).

Description

Conductor segment and its stator assembly, motor

Cross-reference to related applications

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

Technical field

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.

Background technique

In the related art, in the same layer hairpin coil for the cartridge type 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) becomes high; in addition, since the bent corner of the bent step is too small, the flat copper wire surface paint is easily damaged, resulting in poor insulation.

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 conductor segment of a stator assembly that makes the stator windings compact and has a good insulating effect.

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 according to an embodiment of the first aspect of the present disclosure, adapted to be inserted into a same slot layer of a different stator slot of a stator core, the conductor segment comprising: a bend, the bend comprising a layer segment, a second layer segment, and a connecting segment connected between the first layer segment and the second layer segment, the first layer segment and the second layer segment being respectively opposite to the connecting segment Torsing in a radial opposite direction; a first in-slot portion, the first in-slot portion being connected to an end of the first interval away from the connecting section; a second in-slot portion, the second in-slot A portion is connected to an end of the second interval away from the connecting segment.

According to the conductor segment of the embodiment of the present disclosure, the first in-slot portion and the second in-slot portion are not subjected to any treatment by twisting the first layer portion and the second layer portion of the bent portion in the radial direction, thereby being relatively In the related art, the conductor segments of the bent step feature are not affected in the axial direction, so that the height of the entire stator winding is not affected, so that the formed stator winding is compact. In addition, due to the radial torsion, compared with the bending step feature in the related art, the risk of insulation damage caused by bending can be effectively reduced, and the surface of the flat copper wire can be protected to ensure good insulation performance.

According to an example of the present disclosure, the conductor segments are formed in a generally U-shape.

According to an example of the present disclosure, the first interval and the second interval are both arc segments.

According to an example of the present disclosure, the arc segments in which the first layer segment and the second layer segment are located are not concentric.

According to an example of the present disclosure, the first layer segment and the second layer segment have unequal arc lengths.

According to an example of the present disclosure, the connecting section is inclined with respect to a radial direction of the stator, the first layer section is twisted in a radially outward direction with respect to the connecting section, the second layer section being opposite to the The connecting section is twisted in a radially inward direction.

According to an example of the present disclosure, the conductor segment has a rectangular shape in cross section, wherein a radial distance d1 of both ends of the connecting segment is greater than a width d2 of the connecting segment cross section. Thus, when a plurality of conductor segments are simultaneously inserted into the stator slots of the stator core, the interference prevention effect between adjacent conductor segments is better.

According to an example of the present disclosure, the first interval and the second interval are both straight segments.

According to an example of the present disclosure, the connecting section is inclined with respect to a radial direction of the stator, an angle α1 between the first layer section and the connecting section, the second layer section, and the connecting section The angle α2 between the two is an obtuse angle.

According to an example of the present disclosure, the α1 is not equal to the α2.

According to an example of the present disclosure, the first in-slot portion and the first layer segment are located in a first plane, and the second in-slot portion and the second layer segment are located in a second plane.

According to an example of the present disclosure, the first face is a curved face or a plane, and the second face is a curved face or a plane. Thereby, the structural compactness of the stator winding can be more ensured.

According to an example of the present disclosure, the cross section of the conductor segment perpendicular to the direction in which it extends is a rectangular shape.

According to an example of the present disclosure, the conductor segment has a rectangular cross section, and the short side of the rectangle is perpendicular to the stator groove bottom wall.

According to an example of the present disclosure, the conductor segments have the same cross section in the extending direction of the conductor segments.

By adopting the conductor segments of the 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 insulating patent leather can be ensured. Complete, thus ensuring excellent insulation properties.

A stator assembly according to an embodiment of the second aspect of the present disclosure, 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.

According to an example of the present disclosure, 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 according to an embodiment of the third aspect of the present disclosure includes a stator assembly according to an embodiment of the second 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 conductor segment in accordance with an embodiment of the present disclosure;

Figure 2 is a plan view of the conductor segment shown in Figure 1;

Figure 3 is a schematic view of the bent portion of the conductor segment shown in Figure 1;

Figure 4 is a torsion diagram of the bent portion shown in Figure 3;

5 is a schematic illustration of a stator assembly in accordance with an embodiment of the present disclosure showing a stator core and a conductor segment as an example.

6 is a schematic diagram of a motor in accordance with an embodiment of the present disclosure.

Reference mark:

Conductor segment 100, bent portion 110, first layer segment 111, second layer segment 112, connecting segment 113,

a first in-slot portion 120, a second in-slot portion 130,

a first connecting portion 141, a second connecting portion 142,

First weld portion 151, second weld portion 152,

Stator core 200, stator slot 210,

Card issuing end I, welding end II

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 terms "center", "top", "bottom", "inner", "outer", "axial", "radial", "circumferential", etc. are indicated. The orientation or positional relationship is based on the orientation or positional relationship shown in the drawings, and is merely for the convenience of describing the present disclosure and the simplified description, and does not indicate or imply that the device or component referred to has a specific orientation, is constructed in a specific orientation, and The operation is therefore not to be construed as limiting the disclosure. Moreover, the terms "first" and "second" are used for descriptive purposes only and are not to be construed 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.

First, a stator assembly according to an embodiment of the second aspect of the present disclosure will be briefly described with reference to FIGS. 5 and 1, which includes a conductor segment according to an embodiment of the first aspect of the present disclosure.

A stator assembly according to an embodiment of the present disclosure includes a stator core 200 and stator windings. As shown in FIG. 5, the stator core 200 has a cylindrical shape, and the stator core 200 has a plurality of stator slots 210 thereon. Specifically, 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. As an embodiment, 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. Specifically, after the stator winding is inserted into the stator slot 11, the stator slot has a plurality of layers formed by stator windings. In some embodiments of the invention, the slot layer includes a, b, c, d, e, which are sequentially arranged. In each of the stator slots 11, in the radial direction of the stator core 1, the innermost layer is the a layer, and 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. As shown, the welded end II is formed by sequentially welding the first welded portion 151 of the plurality of conductor segments 100 and the second welded portion 152 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. In other words, 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. The innermost of the two stator slots 210 of the predetermined number of slots, or the innermost layer.

It should be noted that the two stator slots 210 mentioned above are separated by a "predetermined number of slots", generally y stator slots, where y is an integer and y=z/2p, z is the number of slots, and 2p is the number of poles. . For an 8-pole 48-slot stator assembly, y=6. That is, there is a difference of 6 stator slots between the first in-slot portion 120 and the second in-slot portion 130 of each conductor segment.

A peer conductor segment 100 of a stator assembly in accordance with an embodiment of the present disclosure will now be described with reference to FIGS. As shown in FIG. 1, the same layer conductor segment 100 is formed in a generally U-shape and includes a bent portion 110, a first in-slot portion 120, and a second in-slot portion 130.

Specifically, as shown in FIGS. 2 and 3, the bent portion 110 includes a first layer segment 111, a second layer segment 112, and a connecting portion 113 connected between the first layer segment 111 and the second layer segment 112. The first in-slot portion 120 is connected to one end of the first layer segment 111 away from the connecting portion 113, and the second in-slot portion 130 is connected to one end of the second layer segment 112 away from the connecting portion 113.

As shown in FIGS. 3 and 4, 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 such that the first layer segment 111 and the second layer segment 112 are not located. On the same line or concentric circle.

It will be understood by those skilled in the art that after the conductor segments are inserted into the stator slots of the stator core, if the conductor segments are not twisted, the connecting segments of adjacent conductor segments will interfere, resulting in adjacent The conductor segments cannot be routed, ie the two conductor segments cannot be inserted into the stator slots.

The conductor segment according to an embodiment of the present disclosure does not perform any of the first in-slot portion 120 and the second in-slot portion 130 by twisting the first layer segment 111 and the second layer segment 112 of the bent portion 100 in the radial direction. The treatment is such that a relief space is formed below the connecting section to allow adjacent conductor segments to pass through, avoiding interference between two adjacent conductor segments, and does not affect the height of the conductor segments in the axial direction, thereby The height of the entire stator winding is affected, so that the formed stator winding is compact. In addition, due to the radial torsion, compared with the bending step feature in the related art, the risk of damage of the insulating layer caused by the bending can be effectively reduced, and the surface of the flat copper wire can be protected to ensure good insulation performance.

According to some embodiments of the present disclosure, the first interval 111 and the second interval 112 are both arc segments, while the first interval 111 and the second interval 112 are not located on the same circle or concentric circle. As an embodiment, the arc segments in which the first layer segment 111 and the second layer segment 112 are located are not concentric, so as to facilitate the first in-slot portion 120 connected to the first layer segment 111 and the first layer segment 112 connected to the second layer segment 112. The two-slot inner portion 130 can be inserted into different groove layers. For example, the first in-slot portion 120 and the second in-slot portion 130 can span one layer in the radial direction, and at this time, the bent portions 100 of the adjacent conductor segments are also Will not cause mutual interference. Or alternatively, the arc lengths of the first layer segment 111 and the second layer segment 112 are unequal, whereby the bent portions 100 between adjacent conductor segments can be staggered along the circumferential direction of the stator core to avoid mutual put one's oar in.

Specifically, 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. As shown in FIGS. 3 and 4, 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.

As shown in FIG. 3, the conductor segment 100 has a rectangular shape in cross section, wherein the radial distance d1 of both ends of the connecting portion 113 is larger than the width d2 of the cross section of the connecting portion 113. Thus, when the plurality of conductor segments 100 are simultaneously inserted into the stator slots 210 of the stator core 200, the interference prevention effect between adjacent conductor segments is better.

Of course, the present disclosure is not limited to this. In other embodiments of the present disclosure, the first layer segment 111 and the second layer segment 112 may also be straight line segments (not shown). In this case, the connecting section 113 is inclined with respect to the radial direction of the stator, and the angle α1 between the first layer section 111 and the connecting section 113, and the angle α2 between the second layer section 112 and the connecting section 113 are both It is an obtuse angle. As an embodiment, α1 is not equal to α2, so that a better anti-interference effect can be ensured.

According to some embodiments of the present disclosure, as shown in FIG. 2, 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. Inside. Optionally, the first surface Y1 is a curved surface or a plane, and 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. When the first layer segment 111 and the second layer segment 112 are both straight segments, 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.

In some embodiments of the present disclosure, the cross section of the conductor segment 100 perpendicular to its direction of extension is a rectangular shape. Optionally, 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. Alternatively, the conductor segments have the same cross section in the direction in which the conductor segments extend. In a specific embodiment, the conductor segments 100 are made of flat copper wire.

By adopting 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.

A conductor segment in accordance with an embodiment of the present disclosure is described below with reference to FIGS.

As shown in FIG. 1, the conductor segment 100 according to this embodiment includes a bent portion 110, a first in-slot portion 120, and a second in-slot portion 130. In the present embodiment, as shown in Figures 1 and 2, the conductor segments 100 are made of flat copper wire.

As shown in FIGS. 2 and 3, the bent portion 110 includes a first layer segment 111, a second layer segment 112, and a connecting portion 113 connected between the first layer segment 111 and the second layer segment 112, the first layer segment 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, and the second in-slot portion 130 is connected to one end of the second layer segment 112 away from the connecting portion 113. As shown in FIGS. 3 and 4, 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 by the curved shape 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.

Wherein, the conductor segment 100 has a rectangular shape in cross section, wherein the radial distance d1 of the connecting member 113 is greater than the width d2 of the cross section of the connecting segment 113.

Meanwhile, 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, wherein the first surface Y1 and the second surface Y2 All are curved surfaces, as shown in Figure 2.

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, and the first welded portion 151 is bent with respect to the first connecting portion 141 and is parallel to the first connecting portion 141. 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 connecting portion 142. The free ends of the first welded portion 151 and the second welded portion 152 each have a chamfered portion 160.

As shown in FIG. 1b, the outer surface of the chamfered portion 160 has a sloped surface and has an angle β with the horizontal plane, the angle β 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. As an embodiment, the height h of the chamfered portion 160 is ≤ 2 mm to facilitate welding.

Further, the method of fabricating the conductor segments according to the above embodiments is as follows:

When making a U-shaped coil, 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 4. 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.

According to the conductor segment of the above-described embodiment of the present disclosure, the entire stator winding formed after the insertion of the stator core is compact in structure while also ensuring good insulation performance.

An electric machine 1000 according to an embodiment of the third aspect of the present disclosure includes the stator assembly 100 according to the above-described embodiments of the present disclosure. 6 is a schematic diagram of a motor in accordance with an embodiment of the present disclosure. The motor 1000 shown in FIG. 6 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 above embodiments of FIGS. 1 to 5, in order to avoid redundancy, More details will be described.

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

A conductor segment of a stator assembly adapted to be inserted into the same slot layer of a different stator slot of a stator core, wherein the conductor segment comprises:

a bent portion, the bent portion including a first layer section, a second layer section, and a connecting section connected between the first layer section and the second layer section, the first layer section and the The second layer segments are respectively twisted in opposite directions with respect to the radial direction of the stator assembly relative to the connecting portion;

a first in-slot portion, the first in-slot portion being connected to an end of the first layer segment away from the connecting portion;

a second in-slot portion, the second in-slot portion being connected to an end of the second layer segment remote from the connecting portion.
The conductor segment of claim 1 wherein said conductor segments are formed in a generally U-shaped shape.
The conductor segment according to claim 1 or 2, wherein the first interval and the second interval are both arc segments.
The conductor segment of claim 3 wherein the arc segments in which the first interval and the second interval are located are not concentric.
The conductor segment according to claim 3 or 4, wherein the first layer segment and the second layer segment have unequal arc lengths.
A conductor segment according to any one of claims 3-5, wherein the connecting section is inclined with respect to a radial direction of the stator assembly, the first layer section being oriented toward the stator assembly relative to the connecting section Torsion in an outward direction, the second interval being twisted in a radially inward direction relative to the connecting segment towards the stator assembly.
The conductor segment according to claim 6, wherein the conductor segment has a rectangular cross section, wherein a radial distance d1 of both ends of the connecting segment is greater than a width d2 of the connecting segment cross section.
The conductor segment according to any one of claims 1 to 7, wherein the first interval and the second interval are straight segments.
The conductor segment according to claim 8, wherein said connecting section is inclined with respect to a radial direction of the stator assembly, and an angle α1, said second between said first layer section and said connecting section The angle α2 between the interval and the connecting section is an obtuse angle.
The conductor segment of claim 9 wherein said α1 is not equal to said α2.
The conductor segment according to any one of claims 1 to 10, wherein the first in-slot portion and the first layer segment are located in a first plane, the second in-slot portion and the The second interval is located in the second face.
The conductor segment of claim 11 wherein said first face is a curved face or plane and said second face is a curved face or plane.
The conductor segment according to any one of claims 1 to 12, wherein the conductor segment has a rectangular shape in cross section perpendicular to the direction in which it extends.
The conductor segment according to claim 12 or 13, wherein 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 segment according to claim 13 or 14, wherein the conductor segments have the same cross section in the direction in which the conductor segments extend.
A stator assembly, comprising:

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

The stator assembly according to any one of claims 1 to 15, wherein the first in-slot portion and the second in-slot portion of the conductor segment are respectively located in the same groove layer of the two stator slots which are apart from the predetermined number of slots.
The stator assembly of claim 16 wherein said conductor segments are each located within an outermost layer of the two stator slots, or within the innermost layer, a predetermined number of slots.
An electric machine comprising the stator assembly according to claim 16 or 17.