WO2020029731A1 - 电机绕组生产方法和绕组结构 - Google Patents

电机绕组生产方法和绕组结构 Download PDF

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Publication number
WO2020029731A1
WO2020029731A1 PCT/CN2019/094958 CN2019094958W WO2020029731A1 WO 2020029731 A1 WO2020029731 A1 WO 2020029731A1 CN 2019094958 W CN2019094958 W CN 2019094958W WO 2020029731 A1 WO2020029731 A1 WO 2020029731A1
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straight
wire
welded
bent
wires
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PCT/CN2019/094958
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English (en)
French (fr)
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林中尉
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苏州阿福机器人有限公司
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Publication of WO2020029731A1 publication Critical patent/WO2020029731A1/zh

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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/08—Forming windings by laying conductors into or around core parts
    • H02K15/085—Forming windings by laying conductors into or around core parts by laying conductors into slotted stators
    • 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

Definitions

  • the present invention relates to a motor winding, and in particular, to a method for producing a motor winding and a winding structure.
  • This technology first needs to make flat wires into hairpin U-shaped conductors 5 (as shown in Figure 1), and then insert the U-shaped conductors into the core wire grooves in order. Then, referring to Figures 2 and 3, the two wire ends of the U-shaped conductor are bent toward the U-shaped sides to form two wire ends opposite each other, and then the opposite ends are welded to form a motor winding.
  • the bent part of the U-shaped conductor in the prior art needs both an arc-shaped part, an offset part, and an inclined part, the forming process is complicated, and the production efficiency is low.
  • an insulating material needs to be provided between the wire and the wire after passing through the iron core to meet the insulation requirements. The use of the insulating material increases the flow resistance of the fluid around the wire, which is not conducive to heat dissipation and reduces the heat dissipation performance of the winding.
  • the purpose of the present invention is to provide a method for producing a motor winding, which does not require pre-forming of wires, is easy to realize automated production, has simple process, high production efficiency, and low production cost.
  • a straight wire is inserted into a core wire slot, and both ends of the straight wire protruding from both ends of the core wire slot are bent in different directions along the circumferential direction or near the circumferential direction or near the tangent direction, and then Weld the two straight wires after bending to form a winding; when the two ends of each straight wire are bent, for the two straight wires welded at the same end, the ends of each straight wire are bent in the direction of the other straight wire to which they are welded;
  • the two welded two straight wires are offset in the radial or near radial direction with respect to the non-welded parts, so that there is an interlayer insulation space between the non-welded parts of the two welded straight wires. .
  • the bent portions at both ends of the straight wire may be straight lines, arcs, or polylines, or a combination of straight lines and arcs, and so on.
  • Two straight wires are welded to form a combined layer. There must be a certain space between the parts of the two combined layers protruding from the core for the insulation between the combined layers (instead of the insulating material). For this reason, if the distance between the straight wires in the core is not When the insulation requirements cannot be met when using insulating materials, then, while the two ends of the straight wire are bent along the circumferential direction or near the circumferential direction or near the tangential direction, the ends of the straight wire must be offset in the radial direction. This offset keeps a certain distance between two adjacent combined layers.
  • the offset can be performed while the aforementioned straight wire is bent along the circumferential direction or near the tangential direction, or it can be before or after, it can be an independent process link, or it can be performed simultaneously with other processes, for example: during welding Through the pressure of the welding machine, the end of the straight wire is pressed in a direction capable of generating an inter-layer space, and the space required for inter-layer insulation (inter-layer insulation space) is formed while welding.
  • the above motor winding production method bends both ends of a straight wire at the same time, or sequentially bends both ends of a straight wire.
  • the ends of the multi-segment straight wire are bent at the same time, or the ends of the multi-segment straight wire are bent, or the ends of the multi-segment straight wire are bent alternately.
  • the welding method includes electric welding, resistance welding, ultrasonic welding, and brazing.
  • the straight wire is a wire that is not pre-bent and can pass through the core wire slot smoothly.
  • each section of straight wires is inserted into the core wire slot at the same time or one after the other.
  • the straight wire is a rectangular wire with a rectangular cross section.
  • the invention also provides a motor winding structure with a simple structure, which requires no insulation material between the wires after passing through the iron core and the wires, and has good heat dissipation.
  • two ends of a straight wire protruding from both ends of the core wire slot are bent in different directions along the circumferential direction or near the circumferential direction or near the tangent direction, and then the bent two straight wires are bent.
  • the welded part of at least one straight wire is offset in a radial direction or close to the radial direction relative to the non-welded part, so that there is an interlayer insulation space between the non-welded parts of the two straight wires that are welded.
  • a combination layer formed by welding two pieces of straight wires and a combination layer formed by welding two other pieces of straight wires located on different diameters of the iron core has an inter-layer insulation space.
  • a straight wire is used to insert into the core wire slot, and the wire does not need to be formed in advance.
  • the wire needs to be made into a U-shaped or S-shaped, or a half-U, half-S-shaped in advance. Then it goes down to the production method in the trough, it is easy to realize automated production, and then the straight wires inserted into the iron core trough are bent at both ends and then welded to form a motor winding.
  • the process is simple, high efficiency, low production cost, and fast and efficient.
  • the invention adopts a straight wire to facilitate the insertion into the core wire slot, which is beneficial to protecting the insulation layer of the motor from being damaged, and can obtain a high-quality motor winding.
  • the interlayer insulation space is formed between the non-welded parts of the two sections of straight wires that are welded together, and the combined layer formed by welding the two sections of straight wires is directly connected to the other two sections of the iron core with different diameters.
  • no insulation material is required between the inter-layer insulation space and the inter-layer insulation space, which not only reduces costs and processes, but also makes the heat dissipation fluid flow resistance between straight wires. Small, which is good for heat dissipation of straight wires.
  • Figure 1 is a schematic diagram of a U-shaped conductor
  • FIG. 2 is a schematic diagram after a U-shaped conductor is inserted into an iron core wire groove
  • FIG. 3 is a schematic diagram of a welding state after a wire end of a U-shaped conductor is bent
  • FIG. 4 is a schematic view of a straight wire inserted into an iron core wire groove
  • FIG. 5 is a schematic view of a straight wire inserted into an iron core wire groove, and an end portion is bent and welded;
  • FIG. 6 is a schematic diagram after welding the upper side of two straight wires
  • Figure 8 is a schematic diagram of two combined layers.
  • the straight wires 1, 2, 3, and 4 are inserted into the core wire slot at the same time or sequentially according to the same slot pitch. Then bend the two ends of the straight wire protruding from both ends of the core wire slot and weld them to form a winding.
  • both ends are bent in the circumferential direction or near the circumferential direction or near the tangent direction, but the directions are different.
  • the upper end 11 of the straight wire 1 is bent clockwise, and the lower end 12 is bent counterclockwise.
  • the upper end 21 of the straight wire 2 is bent counterclockwise, and the lower end 22 is clockwise. bending.
  • each straight wire is bent in the direction of the other straight wire welded to it.
  • the straight wire 1 and the straight wire 2 which are welded at the lower end, the lower end of the straight wire 1 is bent toward the straight wire 2 and the lower end of the straight wire 2 is bent toward the straight wire 1; the straight wire 2 and the straight wire 3 which are welded at the upper end,
  • the upper end 21 of the straight lead 2 is bent in the direction of the straight lead 3, and the upper end 31 of the straight lead 3 is bent in the direction of the straight lead 2.
  • the upper or lower end of the bent straight wire may be straight or curved.
  • each straight wire is an approximate “S” shape, and then the ends are welded, and each straight wire forms a through winding. , And finally set the lead-out line at the required position.
  • the upper ends 21 and 31 of the two straight wires 2 and 3 are welded on the side, and the welding portion 211 of the upper end 21 of the straight wire 2 is offset in the radial direction of the core with respect to the non-welded portion, so that the two welded sections Interlayer insulation spaces 6 are formed between the non-welded portions of the straight wires 2 and 3.
  • the offset welded portion 211 is substantially parallel to the non-welded portion.
  • the upper ends 21 and 31 of the two straight wires 2 and 3 are welded at the end faces, and the welding portion 211 of the upper end 21 of the straight wire 2 is offset in the radial direction of the core with respect to the non-welded portion, so that the welded portions An interlayer insulation space 6 is formed between the non-welded parts of the two straight wires 2 and 3.
  • the offset welded portion 211 is substantially parallel to the non-welded portion.
  • the lower ends 12 and 22 of the two straight wires 1 and 2 are welded on the side, and the welding portion 121 of the lower end 12 of the straight wire 1 is not welded.
  • the part is offset in the radial direction of the iron core, so that an interlayer insulation space 6 is formed between the non-welded parts of the two straight wires 1, 2 that are welded.
  • the offset welding portion 121 is substantially parallel to the non-welding portion.
  • the lower ends 32 and 42 of the two straight wires 3 and 4 are welded on the side, and the welding portion 321 of the lower end 32 of the straight wire 3 is offset in the radial direction of the core with respect to the non-welded portion, so that the two welded straight wires 3 and 3 are An interlayer insulation space 6 is formed between the non-welded parts of 4.
  • the offset welding portion 3211 is substantially parallel to the non-welding portion.
  • the black areas shown in Figures 6-8 represent the melting zone during welding.
  • inter-group insulation space 7 between the combined layer 8 formed by welding the two sections of straight wires 1 and 2 and the combined layer 9 formed by welding the two sections of straight wires 3 and 4.
  • the combined layer 8 formed by welding the two straight wires 1 and 2 and the combined layer 9 formed by welding the two straight wires 3 and 4 are adjacent in the radial direction of the core.
  • the bending may be performed simultaneously at both ends, or separately and or alternately, each straight wire may be sequentially bent, or multiple pieces may be bent simultaneously.
  • the offset of the soldering portion in order to form the inter-layer insulation space 6 and the offset of the ends of the straight wires in order to form the inter-layer insulation space 7 may be performed simultaneously or successively.
  • the offset of the welding part or the end of the straight wire can be performed while the aforementioned end of the straight wire is bent in the circumferential direction or near the tangential direction, or it can be an independent process before or after. It can also be performed simultaneously with other processes.
  • a straight wire is used to insert the core wire slot, and the wire does not need to be formed in advance (the prior art requires the wire to be made into a U-shaped or S-shaped, or a half-U, half-S-shaped and then lowered into the slot), It is easy to realize automatic production, welding the ends of the straight wires after bending to form motor windings, the process is simple, the efficiency is high, the production cost is low, and fast, efficient and high-quality winding production can be achieved.
  • the straight wire according to the present invention is easy to insert into a motor, is beneficial to protect the insulation layer of the motor from damage, and can obtain high-quality motor windings.
  • the welding includes all kinds of welding methods such as electric welding, resistance welding, ultrasonic welding and the like, which can reliably weld the wires together.
  • the processes adopted for welding such as: pre-welding shaping, surface treatment, and addition of flux materials, are all technological measures adopted to achieve welding, which all belong to the scope of welding processes and do not affect the scope of protection of the present invention.
  • the straight wire according to the present invention can meet the needs of plugging, can pass through the core wire slot smoothly, and the wire without the wire being bent in advance belongs to the straight wire described in this patent, such as a near-linear wire.
  • the straight wire insertion according to the present invention may be a piece of straight wire inserted into the core wire slot separately or at the same time, or a long wire is extended through the core wire slot and then extended, and then the other end is cut to form a section. Straight wires inserted in the motor slot, repeat this.
  • the method described in the present invention is mainly used to make the main body of the motor winding, which is not affected by the connecting leads of the winding.
  • the winding formed by this method can be provided with lead wires and or connecting wires at will according to the design needs of the motor winding.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Manufacture Of Motors, Generators (AREA)

Abstract

一种电机绕组及其生产方法，该方法包括以下步骤：将直导线（1、2、3、4）插入铁芯线槽，对伸出铁芯线槽两端的直导线两端（11、12、21、22、31、32、42）沿着圆周方向或接近圆周方向或接近切线方向，向不同方向弯曲，再把弯曲后两段直导线焊接，形成绕组；每段直导线两端弯曲时，对于同一端相焊接的两段直导线，每段直导线端部均向与其焊接的另一段直导线方向弯曲；相焊接的两段直导线，至少一根直导线的焊接部位相对于非焊接部位在径向或接近径向方向偏移，使得相焊接的两段直导线的非焊接部位之间具有层间绝缘空间。该方法不要预先成型，很容易实现自动化生产，工艺简单，生产效率高，生产成本低，散热好。

Description

电机绕组生产方法和绕组结构 技术领域
本发明涉及电机绕组，具体地说，是一种电机绕组生产方法和绕组结构。
背景技术
随着电机应用的普及，电机的性能需要改进和提升，以便提高功率密度和效率等，常规的电机采用多条细圆截面的圆导线组合，绕制成绕组，然后下到电机槽内，由于圆导线之间热传导困难，且在相互排列时，圆导线之间存在着较大的间隙，因此，目前的发展方向是，使用截面为矩形的导线(简称扁线)代替圆截面导线，但是，使用的扁线绕制困难，工艺性差。
以美国雷米公司的专利技术为例，该技术首先需要将扁线制成发夹式的U型导体5(如图1所示)，然后，将U型导体依次排列插入铁芯线槽内，之后，参见图2、3，再将U型导体的两个导线端部向U型两侧弯曲，形成两个导线端部两两相对，之后将相对端部的焊接起来，形成电机绕组。该结构和工艺中所使用的发夹式结构，U型导体的成型工艺复杂，且插入电机时，由于导线之间是相互叠压的(一个U型导体的导线的一端在另一个U型导体的导线的下面)，因此，任何一个U型导体都不能一次插入，工艺复杂，难以实现自动化生产，即便实现，装备的成本也很高，同时生产效率低。
另外，由于实际生产中，现有技术的U型导体的折弯部分，既需要有圆弧型部分，也要有偏移部分，还要有倾斜部分，成型工艺复杂，生产效率低。同时，穿过铁芯后的导线与导线之间需要设置绝缘材料，以满足绝缘要求，绝缘材料的使用，增大了导线周围流体的流动阻力，不利于散热，使绕组的散热性能下降。
发明内容
本发明的目的是提供一种导线不需要预先成型，很容易实现自动化生产，工艺简单，生产效率高，生产成本低的电机绕组的生产方法。
本发明所述电机绕组生产方法，将直导线插入铁芯线槽，对伸出铁芯线槽两端的直导线两端沿着圆周方向或接近圆周方向或接近切线方向，向不同方向弯曲，再把弯曲后两段直导线焊接，形成绕组；每段直导线两端弯曲时，对于同一端相焊接的两段直导线，每段直导线端部均向与其焊接的另一段直导线方向弯曲；相焊接的两段直导线，至少一段直导线的焊接部位相对于非焊接部位在径向或接近径向方向偏移，使得相焊接的两段直导线的非焊接部位之间具有层间绝缘空间。
上述的电机绕组生产方法，直导线两端的弯曲部位可以是直线，也可以是弧形，也可以是折线，还可以是直线和圆弧相结合的形状等等。
上述的电机绕组生产方法，两段直导线焊接而形成的组合层与相邻的位于铁芯不同直径上的另外两段直导线焊接而形成的组合层之间具有层组间绝缘空间。
焊接的两段直导线伸出铁芯的部分相对面的非焊接部位之间留有一定的空间(能够满足绝缘要求的空间)，用于绕组的相间绝缘，以取代绝缘材料，所以该结构使绕组的端部不使用绝缘材料，该绕组结构比使用绝缘材料的绕组的散热性能高。为此，在相对焊接的两段直导线的对接头附近，两段直导线端部同时或者其中的一段直导线的端部弯折，两段直导线连接后形成上述层间绝缘空间。
两段直导线焊接而形成组合层。在两个组合层伸出铁芯的部位之间需要留有一定的空间，用于组合层间的绝缘(取代绝缘材料)，为此，位于铁芯内的直 导线之间的间距如果在不使用绝缘材料的情况下不能满足绝缘要求时，那么，直导线两端沿着圆周方向或接近圆周方向或接近切线方向弯曲的同时，直导线的端部需沿着径向有一定的偏移，该偏移使得两个相邻的组合层之间保留一定的距离。该偏移可以在前述的直导线沿着圆周方向或接近切线方向弯曲的同时进行，也可以在之前或之后，可以是独立的工艺环节，也可以是与其它工艺同时进行，例如：在焊接时，通过焊机的压力，将直导线的端部向能够产生层间空间的方向压，在焊接的同时形成层组间绝缘所需的空间(层组间绝缘空间)。
上述的电机绕组生产方法，对一段直导线的两端同时弯曲，或者对一段直导线的两端先后弯曲。
上述的电机绕组生产方法，同时对多段直导线的端部进行弯曲，或者先后对多段直导线的端部进行弯曲，或者交替对多段直导线的端部进行弯曲。
上述的电机绕组生产方法，焊接方法包括电焊、电阻焊、超声波焊接、钎焊。
上述的电机绕组生产方法，所述直导线为未预先折弯、能够顺利穿过铁芯线槽的导线。
上述的电机绕组生产方法，各段直导线同时或先后插入铁芯线槽。
上述的电机绕组生产方法，直导线为截面为矩形的扁线。
本发明同时提供了一种结构简单、穿过铁芯后的导线与导线之间无需绝缘材料，散热好的电机绕组结构。
本发明所述的电机绕组结构，其是对伸出铁芯线槽两端的直导线两端沿着圆周方向或接近圆周方向或接近切线方向，向不同方向弯曲，再把弯曲后两段直导线焊接而成；每段直导线两端弯曲时，对于同一端相焊接的两段直导线，每段直导线端部均向与其焊接的另一段直导线方向弯曲；相焊接的两段直导线， 至少一段直导线的焊接部位相对于非焊接部位在径向方向或接近径向偏移，使得相焊接的两段直导线的非焊接部位之间具有层间绝缘空间。
上述的电机绕组结构，两段直导线相焊接而形成的组合层与位于铁芯不同直径上的另外两段直导线相焊接而形成的组合层之间具有层组间绝缘空间。
本发明的有益效果：该工艺方案，使用直导线插入铁芯线槽，导线不需要预先成型，相对于现有技术都需要预先将导线制作成U型或S型，或半U、半S型然后下到线槽内的生产方法，很容易实现自动化生产，然后插入铁芯线槽的直导线两端弯曲之后进行焊接，形成电机绕组，工艺简单，效率高，生产成本低，可实现快速高效、高质量的绕组生产。本发明采用直导线便于插入铁芯线槽，有利于保护电机的绝缘层不受损害，可以获得高质量的电机绕组。
该电机绕组结构，由于使得相焊接的两段直导线的非焊接部位之间形成层间绝缘空间，加上两段直导线焊接而形成的组合层与位于铁芯不同直径上的另外两段直导线焊接而形成的组合层之间具有层组间绝缘空间，层间绝缘空间和层组间绝缘空间一般均无需使用绝缘材料，不但降低成本，减少工序，还使得直导线之间散热流体流动阻力小，有利于直导线的散热。
附图说明
图1是U型导体示意图；
图2是U型导体插入铁芯线槽后示意图；
图3是U型导体的导线端部弯曲后焊接状态示意图；
图4是直导线插入铁芯线槽后示意图；
图5是直导线插入铁芯线槽、端部弯曲焊接后示意图；
图6是两段直导线上端侧面焊接后示意图；
图7是两段直导线上端端面焊接后示意图；
图8是两个组合层示意图。
具体实施方式
参见图4-5所示的电机绕组生产方法，将直导线1、2、3、4同时或先后按照相同的槽间距规律插入铁芯线槽内。然后对伸出铁芯线槽两端的直导线两端弯曲后焊接，形成绕组。
弯曲时，对于同一段直导线来说，两端均沿着圆周方向或接近圆周方向或接近切线方向的弯曲，但方向不同。
如，从任何一端观察，直导线1的上端11是向顺时针方向弯曲，下端12是向逆时针方向弯曲；直导线2的上端21是向逆时针方向弯曲，则下端22是向顺时针方向弯曲。
对于同一端相焊接的两段直导线中，每段直导线端部均向与其焊接的另一段直导线方向弯曲。如，下端相焊接的直导线1和直导线2，直导线1的下端向直导线2方向弯曲，直导线2的下端向直导线1方向弯曲；上端相焊接的直导线2和直导线3，直导线2的上端21向直导线3方向弯曲，直导线3上端31向直导线2方向弯曲。弯曲后的直导线上端或下端可以是直线，也可以是弧形。
参见图5，对于需要焊接的两段直导线弯曲至两段直导线的端部相对，每段直导线都是近似的“S”型，然后端部焊接，各段直导线形成一个贯通的绕组，最后在需要的位置设置引出线。
参见图6，两段直导线2、3的上端21、31在侧面相焊接，直导线2上端21的焊接部位211相对于非焊接部位在铁芯径向方向偏移，使得相焊接的两段直导线2、3的非焊接部位之间形成层间绝缘空间6。偏移后的焊接部位211基本与非焊接部位相平行。
或者，参见图7，两段直导线2、3的上端21、31在端面相焊接，直导线2 上端21的焊接部位211相对于非焊接部位在铁芯径向方向偏移，使得相焊接的两段直导线2、3的非焊接部位之间形成层间绝缘空间6。偏移后的焊接部位211基本与非焊接部位相平行。
参见图8，对于在铁芯径向方向有多个组合层的电机绕组，两段直导线1、2的下端12、22在侧面相焊接，直导线1下端12的焊接部位121相对于非焊接部位在铁芯径向方向偏移，使得相焊接的两段直导线1、2的非焊接部位之间形成层间绝缘空间6。偏移后的焊接部位121基本与非焊接部位相平行。两段直导线3、4的下端32、42在侧面相焊接，直导线3下端32的焊接部位321相对于非焊接部位在铁芯径向方向偏移，使得相焊接的两段直导线3、4的非焊接部位之间形成层间绝缘空间6。偏移后的焊接部位3211基本与非焊接部位相平行。
图6-8中所示的涂黑区域表示的是焊接时的熔融区。
两段直导线1、2焊接而形成的组合层8与两段直导线3、4焊接而形成的组合层9之间具有层组间绝缘空间7。两段直导线1、2焊接而形成的组合层8、两段直导线3、4焊接而形成的组合层9在铁芯的径向方向上相邻。为了形成层组间绝缘空间7，需要将两段直导线3、4的下端和/或两段直导线1、2的下端在铁芯径向方向偏移。
所述的弯曲，可以是两端同时进行，也可以是分别和或交替进行，可以是每段直导线先后弯曲，也可以是多段同时弯曲。为了形成层间绝缘空间6而对焊接部位的偏移，为了形成层组间绝缘空间7而对直导线端部的偏移，可以同时或先后进行。对焊接部位的偏移或者对直导线端部的偏移可以在前述的直导线端部沿着圆周方向或接近切线方向弯曲的同时进行，也可以在之前或之后，可以是独立的工艺环节，也可以是与其它工艺同时进行。
该工艺方案，使用直导线插入铁芯线槽，导线不需要预先成型(现有技术 都需要预先将导线制作成U型或S型，或半U、半S型然后下到线槽内)，很容易实现自动化生产，对弯曲之后的直导线端部进行焊接，形成电机绕组，工艺简单，效率高，生产成本低，可实现快速高效、高质量的绕组生产。
本发明所述的直导线便于插入电机，有利于保护电机的绝缘层不受损害，可以获得高质量的电机绕组。
所述的焊接，包括各种电焊、电阻焊、超声波焊接等所有可以将导线可靠地焊在一起的焊接方法。为焊接所采取的工艺，例如：焊前的整形、表面处理、增加助焊材料等为实现焊接所采取的工艺措施，都属于焊接工艺范围，不影响本发明的保护范围。
在电机绕组的生产过程中需要的其它步骤，不影响本发明的保护范围。如对于直导线插入、弯曲等工艺，该工艺过程中可以根据需要穿插其它的常规工艺，例如：在直导线插入铁芯之前或之后，在铁芯线槽内放置绝缘材料等，在直导线插入之前或之后进行导线端部的剥油漆处理等，这都在本发明的保护范围内。
本发明所述的直导线，只要能够满足插线需要，能够顺利穿过铁芯线槽，且导线未预先折弯的导线，都属于本专利所述的直导线，如接近直线的导线。
本发明所述的直导线插入，可以是一段一段的直导线分别或同时插入铁芯线槽，也可以是一根长导线穿过铁芯线槽后，伸出，再切断另一端，形成一段插在电机槽内的直导线，如此重复。
本发明所述的方法，主要用于制作电机绕组主体，不受绕组的连接引线影响，本方法形成的绕组，可以根据电机绕组的设计需要，任意设置引出线和或连接线，这都在本发明的保护范围内。

Claims (10)

  1. 电机绕组生产方法，其特征是：将直导线插入铁芯线槽，对伸出铁芯线槽两端的直导线两端沿着圆周方向或接近圆周方向或接近切线方向，向不同方向弯曲，再把弯曲后两段直导线焊接，形成绕组；每段直导线两端弯曲时，对于同一端相焊接的两段直导线，每段直导线端部均向与其焊接的另一段直导线方向弯曲；相焊接的两段直导线，至少一段直导线的焊接部位相对于非焊接部位在径向或接近径向方向偏移，使得相焊接的两段直导线的非焊接部位之间具有层间绝缘空间。
  2. 如权利要求1所述的电机绕组生产方法，其特征是：两段直导线焊接而形成的组合层与另外两段直导线焊接而形成的组合层之间具有层组间绝缘空间。
  3. 如权利要求1所述的电机绕组生产方法，其特征是：对一段直导线的两端同时弯曲，或者对一段直导线的两端先后弯曲。
  4. 如权利要求1所述的电机绕组生产方法，其特征是：同时对多段直导线的端部进行弯曲，或者先后对多段直导线的端部进行弯曲，或者交替对多段直导线的端部进行弯曲。
  5. 如权利要求1所述的电机绕组生产方法，其特征是：焊接方法包括电焊、电阻焊、超声波焊接、钎焊。
  6. 如权利要求1所述的电机绕组生产方法，其特征是：所述直导线为未预先折弯、能够顺利穿过铁芯线槽的导线。
  7. 如权利要求1所述的电机绕组生产方法，其特征是：各段直导线同时或先后插入铁芯线槽。
  8. 如权利要求1所述的电机绕组生产方法，其特征是：直导线为截面为 矩形的扁线。
  9. 电机绕组结构，其特征是：其是对伸出铁芯线槽两端的直导线两端沿着圆周方向或接近圆周方向或接近切线方向，向不同方向弯曲，再把弯曲后两段直导线焊接而成；每段直导线两端弯曲时，对于同一端相焊接的两段直导线，每段直导线端部均向与其焊接的另一段直导线方向弯曲；相焊接的两段直导线，至少一段直导线的焊接部位相对于非焊接部位在径向或接近径向方向偏移，使得相焊接的两段直导线的非焊接部位之间具有层间绝缘空间。
  10. 如权利要求9所述的电机绕组结构，其特征是：两段直导线相焊接而形成的组合层与相邻的位于铁芯不同直径上的另外两段直导线相焊接而形成的组合层之间具有层组间绝缘空间。
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