WO2023124701A1 - 绕组端部加工方法、绕组端部结构及定子组件 - Google Patents

绕组端部加工方法、绕组端部结构及定子组件 Download PDF

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Publication number
WO2023124701A1
WO2023124701A1 PCT/CN2022/134931 CN2022134931W WO2023124701A1 WO 2023124701 A1 WO2023124701 A1 WO 2023124701A1 CN 2022134931 W CN2022134931 W CN 2022134931W WO 2023124701 A1 WO2023124701 A1 WO 2023124701A1
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WIPO (PCT)
Prior art keywords
conductor
conductors
winding end
welding
root
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PCT/CN2022/134931
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English (en)
French (fr)
Inventor
虞兴翔
蒋大千
邵康
许长春
占智军
郝秀峰
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联合汽车电子有限公司
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Application filed by 联合汽车电子有限公司 filed Critical 联合汽车电子有限公司
Publication of WO2023124701A1 publication Critical patent/WO2023124701A1/zh

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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/46—Fastening of windings on the stator or rotor structure
    • H02K3/50—Fastening of winding heads, equalising connectors, or connections thereto
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • 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
    • H02K15/0025—Shaping or compacting conductors or winding heads after the installation of the winding in the core or machine ; Applying fastening means on winding heads
    • H02K15/0037—Shaping or compacting winding heads

Definitions

  • the invention relates to the technical field of motors, in particular to a winding end processing method, a winding end structure and a stator assembly.
  • the drive motor on an electric vehicle is one of the cores of the vehicle, and its service life and reliability are directly related to the life and safety of the vehicle. Therefore, the reliability and compactness of motor winding design are particularly important for the development of vehicle drive motors.
  • the new flat wire winding greatly improves the slot full rate of the motor, and has a good heat dissipation effect, so that the peak and continuous performance of the motor have been greatly improved.
  • the IPIN winding has high production convenience, high reliability and fault tolerance, so it is the first to be widely used in China.
  • the winding end 01 of the existing IPIN winding is mainly processed by the twisting process.
  • the pulling end 02 located at the head is clamped by tooling to apply the pulling force F, and each conductor forms two A bending point 03, 04.
  • the height of the end of the entire IPIN winding is high, the material waste is large, and the outer envelope size is large; on the other hand, when the pulling force F is applied, the bending The insulation layer at point 03 is prone to peeling off, which is prone to defects.
  • IPIN winding is strongly challenged by other types of flat wire motors, and gradually limits its application range.
  • the purpose of the present invention is to provide a winding end processing method, a winding end structure and a stator assembly, so as to solve the existing problem that the winding end has a large envelope size and damages the insulating layer.
  • the present invention provides a winding end processing method, which includes: cutting the head of the conductor to form a welding surface; the welding surface is at an angle to the axial direction of the conductor;
  • the two conductors to be connected are connected by laser welding at the welding surface.
  • the welding surfaces of the two conductors to be connected are located on the same plane; and/or; the welding line is perpendicular to the axial direction of the iron core.
  • the head of the conductor is subjected to a pretreatment step; the pretreatment step includes: thinning the head of the conductor toward the conductor to be connected , to form a connecting surface.
  • the extending direction of the connecting surface is arranged at an angle to the axial direction of the iron core.
  • the energy distribution of the laser welding is greater in the middle than at both ends.
  • the step of applying a pushing force to the conductor that protrudes after penetrating the iron core, so that the conductor is bent at the root includes:
  • Push force is applied to the head of the conductor to make the conductor bend at the root until it is formed.
  • the step of applying a pushing force to the conductor that protrudes after penetrating the iron core, so that the conductor is bent at the root includes:
  • the step of applying a pushing force to the conductor that protrudes after penetrating the iron core, so that the conductor is bent at the root includes:
  • the winding end processing method before applying a pushing force to the root of the conductor, the winding end processing method further includes: setting an auxiliary limiter at the root of the conductor, so that the auxiliary limiter can move along the radial direction of the conductor. against the conductor.
  • the winding end processing method further includes:
  • Coating or low-pressure overmolding is performed on the head of the conductor to form a head coating.
  • a pushing force is applied to the conductor that protrudes after penetrating the iron core, so that when the conductor is bent at the root, only a pushing force is applied to the conductor to keep the conductor in the iron core In the portion protruding from one end of the axial direction, there is no reverse bend relative to the bending direction of the root.
  • the winding end processing method is applied to the IPIN winding, and both axial ends of the conductors of the IPIN winding are processed using the winding end processing method.
  • the present invention also provides a winding end structure, which includes: two conductors to be connected;
  • the conductor is bent at the root protruding from the iron core, and the head of the conductor has a welding surface formed by chamfering before penetrating into the iron core, and the welding surface is at an angle to the axial direction of the conductor
  • the welding surfaces of the two conductors to be connected are adjacent to form a welding line; the two conductors to be connected are connected by laser welding at the welding surfaces.
  • the head of the conductor has a connection surface, and the connection surface faces another conductor to be connected; the connection surfaces of the two conductors to be connected are attached and connected to each other.
  • connection surface and the body of the conductor form a level difference in the direction in which the conductor is to be connected, and the connection surface is lower than the body of the conductor.
  • the conductor is a flat wire, the longer direction of the flat wire in the radial direction is the width direction, and the shorter direction in the radial direction is the thickness direction; the conductor is bent along the width direction at the root; the The connection surface is located in the thickness direction of the flat wire.
  • the conductor does not have a reverse bend relative to the bending direction of the root in a portion protruding from one axial end of the iron core.
  • the winding end structure is applied to the IPIN winding, and the axial ends of the conductors of the IPIN winding are bent at the root of the iron core, and the bending of the axial ends of the same conductor is in the opposite direction.
  • the winding end structure further includes a head coating, and the head coating covers the head of the conductor; the head coating is an electrical insulator.
  • the extending direction of the connecting surface is arranged at an angle to the axial direction of the iron core.
  • the connecting surface includes a slope section and/or a curved section.
  • the present invention also provides a stator assembly, which includes: an iron core and a winding arranged on the iron core; the conductor of the winding adopts the above-mentioned winding end structure.
  • a plurality of conductors are circumferentially distributed around the iron core on the same radius to form a conductor group;
  • the stator assembly includes at least two conductor groups arranged inside and outside in the radial direction of the iron core ; All the conductors in the same conductor group have the same bending direction, and the conductors in the inner and outer adjacent conductor groups have opposite bending directions; the two conductors to be connected are respectively located in the inner and outer adjacent of the conductor set.
  • the circumferential distribution positions of the conductors are the same; the circumferential distribution positions of the conductors to be connected are separated by 5 other conductors.
  • the winding end processing method includes: chamfering the head of the conductor to form a welding surface; the welding surface It is at an angle to the axial direction of the conductor; a pushing force is applied to the conductor protruding after penetrating the iron core, so that the conductor is bent at the root; after bending, the two conductors to be connected
  • the welding surfaces are adjacent to form a welding line; the two conductors to be connected are connected by laser welding at the welding surfaces.
  • the winding end structure adopts a thrust method to process the conductor, and the conductor head does not need to be pulled to apply force, so the head does not retain the pulling head, which reduces the height of the winding end and the outer envelope size .
  • the welding surface is connected by laser welding, which will not damage the insulating layer other than the welding surface, effectively improving the winding performance. reliability.
  • Fig. 1 is an overall schematic diagram of a stator assembly processed by a twisting process
  • Fig. 2 is a schematic diagram of a winding end structure processed by a twisting process
  • FIG. 3 is an overall schematic diagram of a stator assembly according to an embodiment of the present invention.
  • Fig. 4 is a schematic diagram of a winding end structure according to an embodiment of the present invention.
  • Fig. 5a is a schematic diagram of a typical unit of the winding end structure of the embodiment of the present invention, wherein the welding surfaces are located on the same plane to form welding lines;
  • Fig. 5b is a schematic diagram showing that the welding line cannot be formed on the welding surface of the embodiment of the present invention.
  • Fig. 5c is a schematic diagram of a typical unit of the winding end structure of the embodiment of the present invention, wherein the welding face is concave and angled to form a welding line;
  • Fig. 5d is a schematic diagram of a typical unit of the winding end structure of the embodiment of the present invention, wherein the welding face is convex and angled to form a welding line;
  • Fig. 5e is a schematic view before the conductor connection of the winding end structure of the embodiment of the present invention.
  • Fig. 5f is a schematic diagram of a typical unit of the end-winding structure of an embodiment of the present invention, where the connection faces are arranged at an angle to the axial direction of the core.
  • the singular forms “a”, “an” and “the” include plural objects, the term “or” is usually used in the sense of including “and/or”, and the term “several” Usually, the term “at least one” is used in the meaning of “at least one”, and the term “at least two” is usually used in the meaning of "two or more”.
  • the terms “first”, “second “Two” and “third” are used for descriptive purposes only, and should not be understood as indicating or implying relative importance or implicitly indicating the quantity of the indicated technical features.
  • a feature defined as “first”, “second”, and “third” may explicitly or implicitly include one or at least two of these features, and the term “head” generally refers to a conductor protruding from the stator core. and away from the end of the stator core, the term “root” generally refers to the end of the conductor protruding from the stator core and close to the stator core; the terms “one end” and “other end” and “near end” and “distal end” Usually refers to two corresponding parts, which not only include the endpoints, the terms “installation”, “connection”, and “connection” should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral body; it can be It can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediary, it can be the internal communication of two components or the interaction relationship between two components.
  • an element is arranged on another element, usually only means that there is a connection, coupling, cooperation or transmission relationship between the two elements, and the relationship between the two elements can be direct or indirect through an intermediate element.
  • connection, coupling, fit or transmission but should not be understood as indicating or implying the spatial posture relationship between two elements, that is, one element can be in any orientation such as inside, outside, above, below or on one side of another element, unless The content is clearly stated otherwise.
  • the purpose of the present invention is to provide a winding end processing method, a winding end structure and a stator assembly, so as to solve the existing problem that the winding end has a large envelope size and damages the insulating layer.
  • the insulating layer such as paint leather
  • Patent leather below 03 has an effect. Therefore, although the existing head-twisting process is easy to cause the paint skin at the bending point 03 to fall off during processing, it will not have a great impact on the paint skin during welding.
  • This embodiment proposes to process the conductor 10 by adopting a pushing force on the winding end structure, and the head of the conductor 10 does not need to be pulled and applied. Therefore, the head does not retain the pulling head, thereby reducing the height of the winding head and reducing the outer envelope size. Since there is no pulling head, the insulating layer of the conductor 10 generally extends to the head, so as to avoid problems such as short circuit when forming the winding.
  • the conductor head is welded according to the existing common welding method (such as brazing or resistance welding, etc.), it is easy to affect the insulating layer near the conductor head, resulting in defects such as detachment of the paint skin near the welded part.
  • the welding surface 12 can be formed by cutting the head of the conductor 10, and then after the conductor 10 is bent, the welding surface 12 of the conductor 10 to be connected is adjacent to form a welding line 13, The welding surface 12 is connected by laser welding, so that the insulating layer of the parts other than the welding surface 12 will not be damaged, and the reliability of the winding is effectively improved.
  • the embodiment of the present invention provides a winding end structure, which includes: two conductors 10 to be connected; 11.
  • the head of the conductor 10 has a welding surface 12 formed by chamfering before penetrating into the iron core 20, the welding surface 12 is at an angle to the axial direction of the conductor 10, and the two wires to be connected
  • the welding surfaces 12 of the conductors 10 are adjacent to form a welding line 13; the two conductors 10 to be connected are connected by laser welding at the welding surfaces 12.
  • the two conductors 10 to be connected here refer to the two conductors 10 that need to be connected according to the arrangement of the windings.
  • the two conductors 10 to be connected are often conductors 10 of the same phase.
  • Fig. 5a shows an example of a typical unit of the winding end structure, in which two conductors 10 are the conductors 10 to be connected after being bent. It can be understood that the bending directions of the two conductors 10 to be connected are opposite, so that the two conductors 10 can intersect and be connected.
  • the welding line 13 refers to the adjacent and overlapping edges of the two welding surfaces 12 . Specifically, the angles of the two welding surfaces 12 relative to the axial directions of the respective conductors 10 should be reasonably arranged so that after the two conductors 10 are bent, the adjacent edges of the two welding surfaces 12 can overlap to form a welding line 13 . If the adjacent edges of the two welding surfaces 12 are at an angle to each other, as shown in FIG. 5 b , the welding line 13 cannot be formed, and it is difficult to perform laser welding on it.
  • an embodiment of the present invention provides a winding end processing method, which includes:
  • Step S1 chamfering the head of the conductor 10 to form a welding surface 12; the welding surface 12 is at an angle to the axial direction of the conductor 10;
  • Step S2 Apply a pushing force to the protruding conductor 10 after penetrating the iron core, so that the conductor 10 produces a bend 11 at the root; after the bend, the welding surfaces 12 of the two conductors 10 to be connected are aligned adjoining to form a welding line 13;
  • Step S3 Connect the two conductors 10 to be connected by laser welding at the welding surface 12 .
  • the step of chamfering the head of the conductor 10 to form the welding face 12 is preferably performed before the conductor 10 is penetrated into the iron core 20 .
  • the welding surfaces 12 of the two conductors 10 to be connected are located on the same plane; and/or; the welding line 13 is perpendicular to the axial direction of the iron core 20 .
  • the welding surfaces 12 of the two conductors 10 to be connected are located on the same plane, and the two welding surfaces 12 are adjacent to form a welding line 13, which can be conveniently Laser welding is performed on the welding surface 12 so that the two conductors 10 to be connected form a reliable electrical connection.
  • the energy of laser welding is mainly distributed near the welding line 13, the influence on the paint skin of the conductor 10 can be effectively reduced, and the reliability of the winding can be effectively improved.
  • the two welding surfaces 12 located on the same plane can be perpendicular to the axial direction of the iron core 20 (that is, the vertical direction in the figure), so that the welding line 13 is also perpendicular to the iron core 20
  • the axial direction is convenient for laser welding.
  • the welding line 13 can also form a certain angle with the axial direction of the iron core 20 , and is not limited to be perpendicular, as long as the welding line 13 can be completely exposed to the laser welding machine.
  • the welding surfaces 12 of the two conductors 10 to be connected are not located on the same plane, and the two welding surfaces 12 are inclined relative to the respective conductors 10 shape, but the adjacent edges of the two welding surfaces 12 still keep overlapping to form a welding line 13.
  • laser welding of the welding face 12 is also possible.
  • the welding surfaces 12 are all planes. It can be understood that in some other embodiments, the welding surfaces 12 can also be curved surfaces, and the welding lines 13 are not limited to being straight, and can also be It can be arc-shaped, and those skilled in the art can change it according to the actual situation, and the present invention is not limited thereto.
  • the energy distribution of the laser welding is greater in the middle than at both ends.
  • the inventors found that if the energy distribution of laser welding is evenly distributed along the extending direction of the welding line 13 , it is easy to affect the insulating layer near the two ends of the welding line 13 .
  • the two conductors 10 to be connected do not need to be welded along the entire welding line 13, as long as reliable welding is ensured in the middle part of the welding line 13, the two conductors 10 to be connected can be effectively guaranteed to be welded. reliability of the electrical connection.
  • this embodiment proposes that the energy distribution of laser welding is greater in the middle than at both ends, so that the two conductors 10 to be connected can ensure a reliable electrical connection in the middle of the welding line 13, while the two ends of the welding line 13 are due to the middle position.
  • the transferred heat only needs a small amount of laser welding energy to complete the welding, and such a configuration will not affect the insulating layers near the two ends of the welding line 13 .
  • the head of the conductor 10 has a connection surface 14, and the connection surface 14 faces another conductor 10 to be connected; the two conductors 10 to be connected
  • the connection surfaces 14 are attached and connected to each other.
  • FIG. 5 e shows the state of the two conductors 10 to be connected before connection, and the opposite sides of the heads of the two conductors 10 have connection surfaces 14 .
  • the connecting surfaces 14 of the two are connected to each other, so that after welding, reliable electrical connection of the two conductors 10 can be ensured.
  • the extending direction of the connecting surface 14 is arranged at an angle to the axial direction of the iron core 20 .
  • laser welding laser is generally irradiated along the axial direction of the iron core 20 , which is approximately perpendicular to the welding surface 12 . The inventors found that if the extending direction of the connecting surface 14 is parallel to the irradiation direction of the laser, it is easy to weld through in some cases.
  • connection surface 14 can be configured to be arranged at an angle to the axial direction of the iron core 20 , so that the connection surface 14 of the two conductors 10 forms an angle with the irradiation direction of the laser to avoid welding through.
  • the connecting surface 14 includes a slope section and/or a curved section.
  • the axial angle arrangement between the connection surface 14 and the iron core 20 can be realized in many ways.
  • Fig. 5f shows one example, in which the heads of the conductors 10 are thinned in a wedge shape, so that the heads of two opposite conductors 10 form slope sections with the same inclination direction.
  • the head of the conductor 10 on the right presents a wedge shape with a large size on the top
  • the head of the conductor 10 on the left presents a wedge shape with a small top and a large bottom.
  • the connection surfaces 14 of the two conductors 10 are still in contact with each other, but both connection surfaces 14 are inclined relative to the axial direction of the iron core 20 .
  • the connecting surfaces 14 of the two opposite conductors 10 may also include curved surface sections that are adapted to each other, for example, the two are ground into a matching wave shape or arc shape, etc., which can be Reduce the possibility of weld penetration.
  • the head of the conductor 10 may also be twisted to form the connection surface 14 which is angled to the axial direction of the iron core 20 , and the present invention is not limited thereto.
  • the conductor 10 is a flat wire, the longer direction of the flat wire in the radial direction is the width direction, and the shorter direction in the radial direction is the thickness direction; bending direction; the connection surface 14 is located in the thickness direction of the flat wire.
  • connection surface 14 and the body of the conductor 10 form a height difference in the direction of the conductor 10 to be connected, and the connection surface 14 is lower than the body of the conductor 10 .
  • the direction to be connected of the conductor 10 is the normal direction of the connection surface 14, and for the flat wire as shown in FIG. 5e, it is the thickness direction of the flat wire.
  • the connecting surface 14 and the body of the conductor 10 form a height difference such as a stepped drop.
  • the connecting surface 14 being lower than the body of the conductor 10 means that the distance between the connecting surface 14 and the other conductor 10 to be connected is greater than the distance between the body of the conductor 10 and the other conductor 10 to be connected.
  • Such configuration after the two conductors 10 to be connected are bonded and connected to each other at the connection surface 14 , is beneficial to reduce the thickness in the direction to be connected, and avoid affecting another group of adjacent conductors 10 to be connected.
  • connection face 14 is preferably carried out before the conductor 10 is inserted into the core 20 .
  • the head of the conductor 10 before penetrating into the iron core 20, the head of the conductor 10 is subjected to a pretreatment step; The direction of the conductors 10 to be connected is thinned to form the connecting surface 14 .
  • the connection surface 14 is lower than the body of the conductor 10, forming a height difference in the direction to be connected.
  • the thinning process can be performed not only in the direction toward the conductor 10 to be connected, but also in the direction away from the conductor 10 to be connected.
  • the conductor 10 is common in the thickness direction, which is convenient for random selection during assembly, and is not limited by the connection sequence of the conductor 10, that is, in the thickness direction, the A conductor can be connected to the B conductor, or the B conductor can be connected. on the A conductor.
  • the step of applying a pushing force to the conductor 10 that protrudes after penetrating the iron core 20, so that the conductor 10 is bent at the root includes: applying a pushing force to the head of the conductor 10, The conductor 10 is bent at the root until it is formed.
  • applying a pushing force to the head of the conductor 10 does not refer to applying a force to the head end of the conductor 10 in a narrow sense, but should be broadly understood as applying a pushing force to a region close to the head.
  • the action point of the thrust on the head can be abstracted as the first force application point 31 .
  • the first force application point 31 is relatively close to the head end of the conductor 10 .
  • the thrusting direction is mainly along the width direction of the conductor 10, so that the conductor 10 is bent along the width direction at the root.
  • the scheme of directly applying thrust to the first force application point 31 of the head is easy to operate, but since the force is only applied to the first force application point 31 close to the head, it is easy to make the conductor 10 bend at the root, and it is also easy to form a certain shape on the whole. of the bend.
  • the step of causing the conductor 10 to bend at the root includes: applying a pushing force to the root of the conductor 10 so that the The conductor 10 is initially bent at the root, and then a pushing force is applied to the head of the conductor 10, so that the conductor 10 continues to bend at the root until it is formed.
  • applying a pushing force to the head or root of the conductor 10 here does not refer to applying force to the head or root of the conductor 10 in a narrow sense, but should be broadly understood as being able to push against the head or root of the conductor 10 in a broad sense.
  • a section of the area to apply thrust For example, in the example shown in FIG.
  • the action point of thrust on the head can be abstracted as a first force application point 31
  • the action point of thrust on the root can be abstracted as a second force application point 32 .
  • Applying thrust to the second force application point 32 at the root can make the conductor 10 initially bend at the root, and then apply thrust to the first force application point 31 at the head to make the conductor 10 continue to bend at the root.
  • the step-by-step bending method can reduce the overall bending of the conductor 10 and keep the conductor 10 in a relatively straight shape.
  • the step of causing the conductor 10 to bend at the root includes: applying a pushing force to the root of the conductor 10 so that the The conductor 10 is initially bent at the root, and then the point of application of force gradually moves along the root to the head.
  • a thrust is applied to the conductor 10, so that the conductor 10 continues to bend at the root until it is formed.
  • the point of action of thrust on the head can be abstracted as a first point of force application 31, and the point of action of thrust on the root can be abstracted as a second point of force application 32, and the point of action of thrust on the head can gradually move toward the head along the root
  • the track of is the force track 33.
  • the exemplary way of applying force can also reduce the overall bending of the conductor 10 and keep the conductor 10 in a relatively straight shape.
  • the conductor 10 that protrudes after penetrating the iron core 20
  • only a pushing force is applied to the conductor 10, so as to keep the conductor 10 in the In the portion protruding from one end of the iron core 20 in the axial direction, there is no reverse bend relative to the bending direction of the root, that is, the conductor 10 does not have a reverse bend in the portion protruding from one end of the iron core 20 in the axial direction.
  • Reverse bend in the direction of the bend at the root Compared with the existing pull-type force application method, only the push force application method can ensure that the conductor 10 will not form a reverse bend relative to the bending direction of the root.
  • the formation of the reverse bend will increase the height of the winding head, wasting space and material.
  • the method of only applying thrust can ensure that no reverse bending is formed on the one hand, and on the other hand, it also reduces the torque required for force application, and at the same time reduces problems such as the insulation layer falling off caused by pulling force application.
  • the winding end processing method further includes: setting an auxiliary limit body (not shown) at the root of the conductor 10, so that the auxiliary limit The body abuts against the conductor 10 along the radial direction of the conductor 10 .
  • the auxiliary limiter can be cylindrical, which can limit the root of the conductor 10 and make the bending of the conductor 10 closer to the root.
  • the winding end structure further includes a header coating 15 , and the header coating 15 covers the head of the conductor 10 ; the header coating 15 is an electrical insulator.
  • the head of the conductor 10 here is not defined as the head end of the conductor 10 in a narrow sense, but should be broadly understood as a region close to the head.
  • the head coating 15 can be coated on several parts such as the aforementioned welding surface 12 and the back surface opposite to the connecting surface 14 .
  • the head coating 15 is an electrical insulator, for example, it may be impregnated varnish of polymer material or epoxy resin.
  • the head coat layer 15 can be formed by, for example, a coating process, or a low pressure overmolding process.
  • the winding end processing method further includes: step S4: coating the head of the conductor 10 Or low-pressure overmolding treatment to form the head coating 15 .
  • the setting of the head coating 15, on the one hand, can physically protect the welding surface 12 at the end of the winding to prevent the separation of the welded conductors 10, and on the other hand, it can also insulate the welding surface 12 to prevent the winding and the shell from being damaged. A short circuit occurs.
  • the winding end structure is applied to the IPIN winding, the axial ends of the conductor 10 of the IPIN winding are bent at the root of the core 20, and the same conductor
  • the bending directions of the two axial ends of the 10 are opposite.
  • the upper end of a certain conductor 10 protruding from the iron core 20 is bent towards the clockwise direction around the iron core 20, and the lower end of the conductor 10 protruding out of the iron core 20 is bent towards the surrounding iron core 20.
  • the core 20 is bent in the counterclockwise direction, and the bending directions of the two axial ends of the same conductor 10 are opposite.
  • the winding end processing method is applied to the IPIN winding, and both axial ends of the conductor 10 of the IPIN winding are processed using the winding end processing method.
  • the axial ends of the conductor 10 of the IPIN winding are processed by the twisting process, and after the winding end processing method provided in this embodiment is used for both ends, the height of the two ends of the winding can be equal. get lowered.
  • the winding end processing method and winding end structure provided in this embodiment are also applicable to the HAIRPIN winding.
  • One end of the HAIRPIN winding in the axial direction is formed by pre-bending, and the other end also needs to be processed by the twisting process, so it can also be The winding end processing method and winding end structure provided in this embodiment are applicable.
  • this embodiment also provides a stator assembly, which includes: an iron core 20 and a winding 21 arranged on the iron core 20; the conductor 10 of the winding 21 adopts the above-mentioned winding end department structure.
  • a stator assembly is exemplarily described below.
  • a plurality of conductors 10 are distributed circumferentially around the iron core 20 on the same radius to form a conductor group, that is, a circle of conductors 10 located on the same circumference in FIG. 3 .
  • the stator assembly includes at least two conductor groups arranged inside and outside in the radial direction of the iron core 20; all the conductors 10 in the same conductor group have the same bending direction, and the inner and outer adjacent conductor groups The bending directions of the conductors 10 in the conductor group are opposite; the two conductors 10 to be connected are respectively located in the inner and outer adjacent conductor groups.
  • the stator assembly includes 8 conductor groups.
  • each conductor 10 has its fixed circumferential distribution position.
  • the circumferential distribution position of the conductors 10 distributed in the 12 o'clock direction is 0°, and the circumferential distribution positions of different conductors 10 gradually increase in the clockwise direction until they circle around one circle.
  • the same circumferential distribution position of the conductors 10 means that the circumferential distribution positions of the conductors 10 in different conductor groups around the iron core 20 are the same.
  • the circumferential distribution positions of the conductors 10 are respectively 0°, 60°, 120°, 180°, 240° and 300° .
  • the circumferential distribution position of conductor 10 is also 0°, 60°, 120°, 180°, 240° and 300°, which is called the circumferential distribution of conductor 10 in different conductor groups same location.
  • the conductors 10 of different conductor groups are actually arranged radially around the center, and the conductors 10 in the same circumferential distribution position in all conductor groups are arranged in a linear row along the radial direction of the iron core 20 .
  • the number of conductors 10 in the above-mentioned conductor group is only an example and not a limitation to the number of conductors 10 . Those skilled in the art can set the number of conductors 10 in the conductor set according to the actual situation.
  • the conductors 10 to be connected are spaced apart from five other conductors 10 in the circumferential distribution position.
  • the stator assembly has three phases, each phase includes conductors 10 arranged at two adjacent circumferential positions, and the three phases are arranged in turn.
  • the conductors 10 arranged on the circumferential distribution positions sa and sb are all phase A
  • the conductors 10 arranged on the circumferential distribution positions sc and sd are all B phases
  • the conductors 10 arranged on the circumferential distribution positions se and sf are all phase A.
  • the conductors 10 arranged are all C-phase, and the conductors 10 arranged on the circumferential distribution positions sg and sh are all A-phase, and the cycle is repeated sequentially.
  • the conductors 10 to be connected are of the same phase, and since the conductors 10 of the three phases are arranged in turn, the circumferential distribution positions of the conductors 10 of the same phase are separated by 5 circumferential distribution positions of other conductors 10 .
  • the conductor 10a in the conductor group whose circumferential distribution position sa is in the innermost circle is bent counterclockwise, and is connected to the conductor 10b in the conductor group whose circumferential distribution position sg is in the second circle from the inside to the outside.
  • the conductor 10a and the conductor 10b are separated by five circumferential distribution positions of other conductors 10 , that is, the circumferential distribution positions sb, sc, sd, se, and sf.
  • the stator assembly further includes lead wires, which can be connected to the conductors 10 of the windings according to conventional arrangements in the field, which will not be described in this embodiment.
  • the winding end processing method includes: chamfering the head of the conductor to form a welding surface; the welding surface It is at an angle to the axial direction of the conductor; a pushing force is applied to the conductor protruding after penetrating the iron core, so that the conductor is bent at the root; after bending, the two conductors to be connected
  • the welding surfaces are adjacent to form a welding line; the two conductors to be connected are connected by laser welding at the welding surfaces.
  • the winding end structure adopts a thrust method to process the conductor, and the conductor head does not need to be pulled to apply force, so the head does not retain the pulling head, which reduces the height of the winding end and the outer envelope size .
  • the welding surface is connected by laser welding, which will not damage the insulating layer other than the welding surface, effectively improving the winding performance. reliability.

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Abstract

本发明提供一种绕组端部加工方法、绕组端部结构及定子组件，所述绕组端部加工方法包括：对导体的头部进行切角以形成焊接面；所述焊接面与所述导体的轴向成角度；对穿入铁芯后伸出的所述导体施加推力，使所述导体在根部产生弯折；在弯折后，待连接的两根所述导体的所述焊接面相邻接形成焊接线；将待连接的两根所述导体于所述焊接面处通过激光焊连接。如此配置，绕组端部结构采用推力的方式对导体进行加工，导体头部不需拉拽施力，因此头部不会留存拉拽头，降低了绕组端部高度，减小了外包络尺寸。另一方面，由于对导体的头部具有通过切角形成焊接面，进而在导体折弯后在焊接面处采用激光焊连接，不会对焊接面以外部位的绝缘层产生损伤。

Description

绕组端部加工方法、绕组端部结构及定子组件 技术领域
本发明涉及电机技术领域，特别涉及一种绕组端部加工方法、绕组端部结构及定子组件。
背景技术
电动汽车上的驱动电机是整车的核心之一，它的使用寿命和可靠性直接关系着整车的寿命和安全。因此，电机绕组设计的可靠性和紧凑性，对车用驱动电机的开发尤为重要。新型扁线绕组大大提高了电机的槽满率，并具有良好的散热效果，使电机的峰值和持续性能都得到了极大的提高。
尤其是IPIN绕组具有很高的生产便利性，具有较高的可靠性和容错能力，因此在国内率先得到了广泛的应用。
如图1和图2所示，现有的IPIN绕组的绕组端部01主要采用扭头工艺加工，一般采用工装夹住位于头部的拉拽端02施加拉拽力F，每个导体均形成两个折弯点03、04。一方面由于折弯点03以上的拉拽端02的存在，使得整个IPIN绕组端部高度较高，材料浪费大，外包络尺寸较大，另一方面在施加拉拽力F时，折弯点03处的绝缘层容易出现脱落，从而易产生缺陷。
因此IPIN绕组受到其他类型的扁线电机的强烈挑战，并逐渐地限制其应用的范围。
发明内容
本发明的目的在于提供一种绕组端部加工方法、绕组端部结构及定子组件，以解决现有的绕组端部包络尺寸较大，且对绝缘层存在伤害的问题。
为解决上述技术问题，本发明提供一种绕组端部加工方法，其包括：对 导体的头部进行切角以形成焊接面；所述焊接面与所述导体的轴向成角度；
对穿入铁芯后伸出的所述导体施加推力，使所述导体在根部产生弯折；在弯折后，待连接的两根所述导体的所述焊接面相邻接形成焊接线；
将待连接的两根所述导体于所述焊接面处通过激光焊连接。
可选的，在弯折后，待连接的两根所述导体的所述焊接面位于同一平面上；和/或；所述焊接线垂直于所述铁芯的轴向。
可选的，在穿入所述铁芯前，所述导体的头部经预处理步骤处理；所述预处理步骤包括：对所述导体的头部朝向待连接的导体的方向进行打薄处理，以形成连接面。
可选的，所述连接面的延伸方向与所述铁芯的轴向成角度布置。
可选的，沿所述焊接线的延伸方向，所述激光焊的能量分布为中间大于两端。
可选的，对穿入铁芯后伸出的所述导体施加推力，使所述导体在根部产生弯折的步骤包括：
对所述导体的头部施加推力，使所述导体于根部产生弯折，直至成型。
可选的，对穿入铁芯后伸出的所述导体施加推力，使所述导体在根部产生弯折的步骤包括：
对所述导体的根部施加推力，使所述导体于根部产生初步弯折，进而对所述导体的头部施加推力，使所述导体在根部继续弯折，直至成型。
可选的，对穿入铁芯后伸出的所述导体施加推力，使所述导体在根部产生弯折的步骤包括：
对所述导体的根部施加推力，使所述导体于根部产生初步弯折，进而施力点沿根部向头部逐渐移动，在所述施力点移动的同时对所述导体施加推力，使所述导体于根部继续弯折，直至成型。
可选的，在对所述导体的根部施加推力前，所述绕组端部加工方法还包括：于所述导体的根部设置辅助限位体，使所述辅助限位体沿所述导体的径向与所述导体相抵靠。
可选的，在将待连接的两根所述导体于所述焊接面处通过激光焊连接后，所述绕组端部加工方法还包括：
对所述导体的头部进行涂敷处理或低压包塑处理，以形成头部涂层。
可选的，对穿入铁芯后伸出的所述导体施加推力，使所述导体在根部产生弯折的过程中，仅对所述导体施加推力，以保持所述导体在所述铁芯轴向一端伸出的部分中，不形成相对所述根部弯折方向的反弯。
可选的，所述绕组端部加工方法应用于IPIN绕组，所述IPIN绕组的导体的轴向两端均应用所述绕组端部加工方法进行加工。
为解决上述技术问题，本发明还提供一种绕组端部结构，其包括：待连接的两根导体；
所述导体于伸出铁芯的根部形成弯折，所述导体的头部具有在穿入所述铁芯前通过切角形成的焊接面，所述焊接面与所述导体的轴向成角度，待连接的两根所述导体的所述焊接面相邻接形成焊接线；待连接的两根所述导体于所述焊接面处通过激光焊连接。
可选的，所述导体的头部具有连接面，所述连接面朝向待连接的另一所述导体；待连接的两根所述导体的所述连接面相互贴合连接。
可选的，所述连接面与所述导体的本体在所述导体的待连接方向上形成高低差，所述连接面低于所述导体的本体。
可选的，所述导体为扁线，所述扁线在径向上较长的方向为宽度方向，在径向上较短的方向为厚度方向；所述导体于根部沿宽度方向弯折；所述连接面位于所述扁线的厚度方向上。
可选的，所述导体在所述铁芯轴向一端伸出的部分中，不具有相对所述根部弯折方向的反弯。
可选的，所述绕组端部结构应用于IPIN绕组，所述IPIN绕组的导体的轴向两端于伸出铁芯的根部均形成弯折，且同一所述导体的轴向两端的弯折方向相反。
可选的，所述绕组端部结构还包括头部涂层，所述头部涂层包覆于所述导体的头部；所述头部涂层为电绝缘体。
可选的，所述连接面的延伸方向与所述铁芯的轴向成角度布置。
可选的，所述连接面包括斜面区段和/或曲面区段。
为解决上述技术问题，本发明还提供一种定子组件，其包括：铁芯以及设置于所述铁芯上的绕组；所述绕组的导体采用如上所述的绕组端部结构。
可选的，多根所述导体围绕所述铁芯于同一半径上周向分布，形成导体组；所述定子组件包括至少两个在所述铁芯的径向上内外排布的所述导体组；同一所述导体组中的所有所述导体的弯折方向相同，内外相邻的所述导体组中的所述导体的弯折方向相反；待连接的两根所述导体分别位于内外相邻的所述导体组中。
可选的，在不同的所述导体组中，所述导体的周向分布位置相同；待连接的所述导体于周向分布位置上间隔5个其它导体。
综上所述，本发明提供的绕组端部加工方法、绕组端部结构及定子组件中，所述绕组端部加工方法包括：对导体的头部进行切角以形成焊接面；所述焊接面与所述导体的轴向成角度；对穿入铁芯后伸出的所述导体施加推力，使所述导体在根部产生弯折；在弯折后，待连接的两根所述导体的所述焊接面相邻接形成焊接线；将待连接的两根所述导体于所述焊接面处通过激光焊连接。
如此配置，绕组端部结构采用推力的方式对导体进行加工，导体头部不需拉拽施力，因此头部不会留存拉拽头，降低了绕组端部高度，减小了外包络尺寸。另一方面，由于对导体的头部具有通过切角形成焊接面，进而在导体折弯后在焊接面处采用激光焊连接，不会对焊接面以外部位的绝缘层产生损伤，有效提高了绕组的可靠性。
附图说明
本领域的普通技术人员将会理解，提供的附图用于更好地理解本发明，而不对本发明的范围构成任何限定。其中：
图1是一种采用扭头工艺加工的定子组件的整体示意图；
图2是一种采用扭头工艺加工的绕组端部结构的示意图；
图3是本发明实施例的定子组件的整体示意图；
图4是本发明实施例的绕组端部结构的示意图；
图5a是本发明实施例的绕组端部结构的典型单元的示意图，其中焊接面位于同一平面，形成焊接线；
图5b是本发明实施例焊接面无法形成焊接线的示意图；
图5c是本发明实施例的绕组端部结构的典型单元的示意图，其中焊接面内凹成角度，形成焊接线；
图5d是本发明实施例的绕组端部结构的典型单元的示意图，其中焊接面外凸成角度，形成焊接线；
图5e是本发明实施例的绕组端部结构的导体连接前的示意图；
图5f是本发明实施例的绕组端部结构的典型单元的示意图，其中连接面与铁芯的轴向成角度布置。
附图中：
01-绕组端部；02-拉拽端；03、04-折弯点；10-导体；11-弯折；12-焊接面；13-焊接线；14-连接面；15-头部涂层；20-铁芯；21-绕组；31-第一施力点；32-第二施力点；33-施力轨迹。
具体实施方式
为使本发明的目的、优点和特征更加清楚，以下结合附图和具体实施例对本发明作进一步详细说明。需说明的是，附图均采用非常简化的形式且未按比例绘制，仅用以方便、明晰地辅助说明本发明实施例的目的。此外，附图所展示的结构往往是实际结构的一部分。特别的，各附图需要展示的侧重点不同，有时会采用不同的比例。
如在本发明中所使用的，单数形式“一”、“一个”以及“该”包括复数对象，术语“或”通常是以包括“和/或”的含义而进行使用的，术语“若干”通常是以包括“至少一个”的含义而进行使用的，术语“至少两个”通常是以包括“两个或两个以上”的含义而进行使用的，此外，术语“第一”、“第二”、“第三”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”、“第三”的特征可以明示或者隐含地包括一个或者至少两个该特征，术语“头部”通常是指导体伸出定子铁芯且远离定子铁芯的一端部，术语“根部”通常是指导体伸出定子铁芯而靠近定子铁芯的一端部；术语“一端”与“另一端”以及“近端”与“远端”通常是指相对应的两部分，其不仅包括端点，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，或成一体；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或两个元件的相 互作用关系。此外，如在本发明中所使用的，一元件设置于另一元件，通常仅表示两元件之间存在连接、耦合、配合或传动关系，且两元件之间可以是直接的或通过中间元件间接的连接、耦合、配合或传动，而不能理解为指示或暗示两元件之间的空间位姿关系，即一元件可以在另一元件的内部、外部、上方、下方或一侧等任意方位，除非内容另外明确指出外。对于本领域的普通技术人员而言，可以根据具体情况理解上述术语在本发明中的具体含义。
本发明的目的在于提供一种绕组端部加工方法、绕组端部结构及定子组件，以解决现有的绕组端部包络尺寸较大，且对绝缘层存在伤害的问题。
下面结合附图进行描述。
发明人研究发现，如图1和图2所示的扭头工艺所加工的绕组端部结构中，由于拉拽端02的存在，虽然对减小外包络尺寸不利，但是客观上，较长的拉拽端02对焊接提供了一定的便利性。具体的，由于夹住拉拽端02对导体施加拉拽力时，容易使导体的绝缘层(如漆皮)爆裂，一般拉拽端02的导体是无漆皮的区域，折弯点03处为有漆皮和无漆皮区域的交接处，因此在拉拽端02的头部(即图2的上部)按照现有常规的焊接方式进行焊接，由于拉拽端02较长的过渡，不至于对折弯点03以下的漆皮产生影响。因此虽然现有的扭头工艺在加工中，容易使折弯点03处的漆皮脱落，但其焊接时并不会对漆皮产生较大的影响。
为了降低绕组端部结构的高度，请参考图3至图5f，本实施例提出了通过对绕组端部结构采用推力的方式对导体10进行加工，导体10的头部不需拉拽施力，因此头部不会留存拉拽头，由此降低了绕组端部高度，减小了外包络尺寸。由于不存在拉拽头，导体10的绝缘层一般是延伸至头部的，以避免形成绕组时产生短路等问题。然而若按照现有普通的焊接方式(如钎焊或 电阻焊等)对导体头部进行焊接时，容易对靠近导体头部的绝缘层产生影响，导致靠近焊接部位的漆皮产生脱离等缺陷。针对该问题，发明人研究发现，可通过对导体10的头部进行切角形成焊接面12，进而在导体10折弯后使待连接的导体10的焊接面12相邻接形成焊接线13，在焊接面12处采用激光焊连接，这样即不会对焊接面12以外部位的绝缘层产生损伤，有效提高了绕组的可靠性。
基于上述研究，请参考图3至图5f，本发明实施例提供一种绕组端部结构，其包括：待连接的两根导体10；所述导体10于伸出铁芯20的根部形成弯折11，所述导体10的头部具有在穿入所述铁芯20前通过切角形成的焊接面12，所述焊接面12与所述导体10的轴向成角度，待连接的两根所述导体10的所述焊接面12相邻接形成焊接线13；待连接的两根所述导体10于所述焊接面12处通过激光焊连接。请参考图4，这里待连接的两根所述导体10是指根据绕组的排布方式，需要连接起来的两根导体10。在实际中，待连接的两根导体10常为同一相的导体10。图5a示出了绕组端部结构的一个典型单元的示例，其中的两根导体10即为弯折后待连接的导体10。可以理解的，待连接的两根导体10的弯折方向是相反的，以使两根导体10能够相交并连接起来。另外需要说明的，焊接线13指两个焊接面12相邻接的且重合的边缘。具体的，两个焊接面12相对于各自导体10之轴向的角度应合理地配置，使得两根导体10在弯折后，两个焊接面12相邻接的边缘能够重合以形成焊接线13。若两个焊接面12相邻接的边缘相互成角度，如图5b所示，则无法形成焊接线13，进而难以对其进行激光焊。
为实现上述绕组端部结构的加工制造，本发明实施例提供一种绕组端部加工方法，其包括：
步骤S1：对导体10的头部进行切角以形成焊接面12；所述焊接面12与 所述导体10的轴向成角度；
步骤S2：对穿入铁芯后伸出的导体10施加推力，使所述导体10在根部产生弯折11；在弯折后，待连接的两根所述导体10的所述焊接面12相邻接形成焊接线13；
步骤S3：将待连接的两根所述导体10于所述焊接面12处通过激光焊连接。
由于导体10在穿入铁芯20后再进行切角时，一方面难以进行加工，另一方面也难以控制切角的准确角度，难以使焊接面12相邻接形成焊接线13。因此对导体10的头部进行切角以形成焊接面12的步骤优选在导体10穿入铁芯20之前执行。
优选的，在弯折后，待连接的两根所述导体10的所述焊接面12位于同一平面上；和/或；所述焊接线13垂直于所述铁芯20的轴向。在一个示范例中，如图5a所示，在弯折后，待连接的两根导体10的焊接面12位于同一平面上，两个焊接面12相邻接形成焊接线13，此时可以方便地对焊接面12进行激光焊，使待连接的两根导体10形成可靠的电连接。进而由于激光焊的能量主要分布在焊接线13附近，能有效地减少对导体10的漆皮产生影响，有效提高了绕组的可靠性。优选的，如图4所示，位于同一平面上的两个焊接面12可以同时垂直于铁芯20的轴向(即图中的竖直方向)，由此焊接线13亦垂直于铁芯20的轴向，便于进行激光焊。当然在一些实施例中，焊接线13也可以与铁芯20的轴向成一定的角度，不限于必须垂直，焊接线13只要能够完整地向激光焊机暴露出即可。
在另一些实施例中，如图5c和5d所示，在弯折后，待连接的两根导体10的焊接面12并不位于同一平面上，该两个焊接面12相对各自导体10呈斜面状，但两个焊接面12相邻接的边缘还是保持重合，形成焊接线13。在这些 实施例种，同样可以对焊接面12进行激光焊。需要说明的，前述所列举的示范例中，焊接面12均为平面，可以理解的，在其它的一些实施例中，焊接面12也可以是曲面，焊接线13也不限于为直线形，也可以是弧线形，本领域技术人员可根据实际进行改变，本发明对此不限。
优选的，沿所述焊接线13的延伸方向，所述激光焊的能量分布为中间大于两端。发明人研究发现，若激光焊的能量分布沿着焊接线13的延伸方向均匀分布，则容易对靠近焊接线13两端的绝缘层产生影响。并且实际中，待连接的两根导体10也并不需要沿着整个焊接线13都进行焊接，只要在焊接线13的中间部分保证可靠的焊接，即可有效地保证待连接的两根导体10的电连接的可靠性。由此，本实施例提出激光焊的能量分布为中间大于两端，使待连接的两根导体10在焊接线13的中间部位保证可靠的电连接，而焊接线13的两端部分由于中间部位传递过来的热量，只需少量的激光焊能量即可完成焊接，如此配置也不会对靠近焊接线13两端的绝缘层产生影响。
可选的，请继续参考图5e，所述导体10的头部具有连接面14，所述连接面14朝向另一待连接的所述导体10；待连接的两根所述导体10的所述连接面14相互贴合连接。图5e示出了待连接的两根导体10在连接前的状态，两根导体10的头部相对的一面均具有连接面14。待连接的两根导体10在连接后，如图5a所示，两者的连接面14相互贴合连接，这样在焊接后，可以保证两根导体10可靠的电连接。
可选的，请参考图5f，在一些实施例中，所述连接面14的延伸方向与所述铁芯20的轴向成角度布置。为了便于施焊，激光焊的激光一般沿着铁芯20的轴向照射，其大致垂直于焊接面12。发明人发现，若连接面14的延伸方向平行于激光的照射方向，一些情况下容易焊穿。由此，可将连接面14的延伸方向配置为与铁芯20的轴向成角度布置，这样两个导体10的连接面14即与 激光的照射方向形成角度，可避免焊穿。
优选的，所述连接面14包括斜面区段和/或曲面区段。连接面14与铁芯20的轴向成角度布置可以有多种实现方式。图5f示出了其中一个示范例，其通过对导体10的头部进行楔形地打薄，使得相对的两个导体10的头部形成相同倾斜方向的斜面区段。图5f示出的示范例中，右侧的导体10的头部呈现上大小小的楔形，左侧的导体10的头部则呈现上小下大的楔形，可以理解的，此时相对的两个导体10的连接面14依然是相互贴靠的，但两个连接面14均相对于铁芯20的轴向呈倾斜状。
在其它的一些实施例中，相对的两个导体10的连接面14还可以包括相互适配的曲面区段，例如两者被磨合呈相配合的波浪形或圆弧形等形状，其均可减少焊穿的可能。另一些实施例中，也可以将导体10的头部扭转，来形成与铁芯20的轴向成角度的连接面14，本发明对此不限。
优选的，请参考图4，所述导体10为扁线，所述扁线在径向上较长的方向为宽度方向，在径向上较短的方向为厚度方向；所述导体10于根部沿宽度方向弯折；所述连接面14位于扁线的厚度方向上。
进一步的，请参考图5e，所述连接面14与所述导体10的本体在所述导体10的待连接方向上形成高低差，所述连接面14低于所述导体10的本体。导体10的待连接方向即连接面14的法向，对于如图5e示出的扁线而言，即扁线的厚度方向。在导体10的待连接方向上，连接面14与导体10的本体形成如台阶式跌落的高低差。连接面14低于导体10的本体是指，连接面14相对于待连接的另一导体10的距离大于导体10的本体相对于待连接的另一导体10的距离。如此配置，待连接的两个导体10在连接面14相互贴合连接后，有利于减小在待连接方向上的厚度，避免对相邻的另一组待连接的导体10产生影响。
对连接面14的加工优选在导体10穿入铁芯20之前执行。具体的，在绕组端部加工方法中，在穿入所述铁芯20前，所述导体10的头部经预处理步骤处理；所述预处理步骤包括：对所述导体10的头部朝向待连接的导体10的方向进行打薄处理，以形成连接面14。打薄处理后，连接面14低于导体10的本体，在待连接方向上形成高低差。
在一些实施例中，不仅可以对朝向待连接的导体10的方向进行打薄处理，还可以在背离待连接的导体10的方向也进行打薄处理。这样导体10在厚度方向上是通用的，便于在装配时随机选择，可不受导体10的连接次序的限制，即在厚度方向上，可以是A导体连接在B导体上，也可以是B导体连接在A导体上。
请参考图4，下面结合若干示范例，对穿入铁芯20后伸出的所述导体10施加推力，使所述导体10在根部产生弯折的步骤进行说明。
在第一个示范例中，对穿入铁芯20后伸出的所述导体10施加推力，使所述导体10在根部产生弯折的步骤包括：对所述导体10的头部施加推力，使所述导体10于根部产生弯折，直至成型。需要说明的，这里对所述导体10的头部施加推力，并非狭义地指对导体10的头端部施力，而应广义地理解为可以对靠近头部的一段区域施加推力。例如在图4示出的示例中，推力于头部的作用点可以抽象为第一施力点31。该第一施力点31较为靠近导体10的头端部。可以理解的，施加推力的方向主要是沿导体10的宽度方向，这样导体10于根部沿宽度方向弯折。直接对头部的第一施力点31施加推力的方案操作简便，但由于仅对靠近头部的第一施力点31施力，容易使导体10除了在根部产生弯折，整体上也容易形成一定的弯曲。
在第二个示范例中，对穿入铁芯20后伸出的所述导体10，使所述导体10在根部产生弯折的步骤包括：对所述导体10的根部施加推力，使所述导体 10于根部产生初步弯折，进而对所述导体10的头部施加推力，使所述导体10在根部继续弯折，直至成型。同样需要说明的，这里对所述导体10的头部或根部施加推力，并非狭义地指对导体10的头端部或根端部施力，而应广义地理解为可以对靠近头部或根部的一段区域施加推力。例如在图4示出的示例中，推力于头部的作用点可以抽象为第一施力点31，推力于根部的作用点可以抽象为第二施力点32。先对根部的第二施力点32施加推力，可使导体10于根部产生初步弯折，进而再对头部的第一施力点31施加推力，可以使导体10在根部继续弯折。分步弯折的方式可以减少导体10在整体上形成弯曲，使导体10保持较为平直的形态。
在第三个示范例中，对穿入铁芯20后伸出的所述导体10，使所述导体10在根部产生弯折的步骤包括：对所述导体10的根部施加推力，使所述导体10于根部产生初步弯折，进而施力点沿根部向头部逐渐移动，在所述施力点移动的同时对所述导体10施加推力，使所述导体10于根部继续弯折，直至成型。例如在图4示出的示例中，推力于头部的作用点可以抽象为第一施力点31，推力于根部的作用点可以抽象为第二施力点32，施力点沿根部向头部逐渐移动的轨迹为施力轨迹33。该示范例的施力方式，也可以减少导体10在整体上形成弯曲，使导体10保持较为平直的形态。
优选的，对穿入铁芯20后伸出的所述导体10，使所述导体10在根部产生弯折的过程中，仅对所述导体10施加推力，以保持所述导体10在所述铁芯20轴向一端伸出的部分中，不形成相对所述根部弯折方向的反弯，即所述导体10在所述铁芯20轴向一端伸出的部分中，不具有相对所述根部弯折方向的反弯。相较于现有拉拽式的施力方式，仅施加推力的方式可以确保导体10不会形成相对所述根部弯折方向的反弯。可以理解的，反弯的形成将会增大绕组端部高度，浪费空间和材料。而仅施加推力的方式，一方面可以保证 不会形成反弯，另一方面也减小了施力所需的扭矩，同时也减少了因拉拽式施力而引起的绝缘层脱落等问题。
可选的，在对所述导体10的根部施加推力前，所述绕组端部加工方法还包括：于所述导体10的根部设置辅助限位体(未图示)，使所述辅助限位体沿所述导体10的径向与所述导体10相抵靠。辅助限位体如可为圆柱状，其可以对导体10的根部施加限制，使导体10的弯折更靠近根部。
进一步的，所述绕组端部结构还包括头部涂层15，所述头部涂层15包覆于所述导体10的头部；所述头部涂层15为电绝缘体。需要说明的，这里导体10的头部，并非狭义地指导体10的头端部，而应广义地理解为靠近头部的一段区域。例如头部涂层15可以包覆于前述的焊接面12、连接面14相对的背面等若干部位。头部涂层15为电绝缘体，例如可以是高分子材料的浸渍漆或环氧树脂等。头部涂层15如可通过涂敷处理形成，或通过低压包塑处理形成。基于此，在将待连接的所述导体10于所述焊接面12处通过激光焊连接后，所述绕组端部加工方法还包括：步骤S4：对所述导体10的头部进行涂敷处理或低压包塑处理，以形成头部涂层15。头部涂层15的设置，一方面可对绕组端部的焊接面12进行物理保护，防止焊接后的导体10产生分离，另一方面也对焊接面12进行绝缘，避免绕组与壳体等部位产生短路。
请参考图3，较佳的，所述绕组端部结构应用于IPIN绕组，所述IPIN绕组的导体10的轴向两端于伸出铁芯20的根部均形成弯折，且同一所述导体10的轴向两端的弯折方向相反。如图3所示出的示范例中，某一根导体10伸出铁芯20的上端朝向围绕铁芯20的顺时针方向弯折，而该根导体10伸出铁芯20的下端朝向围绕铁芯20的逆时针方向弯折，同一导体10的轴向两端的弯折方向是相反的。
相适配的，所述绕组端部加工方法应用于IPIN绕组，所述IPIN绕组的 导体10的轴向两端均应用所述绕组端部加工方法进行加工。在现有技术中，IPIN绕组的导体10的轴向两端均采用扭头工艺加工，对其两端均改用本实施例提供的绕组端部加工方法后，可使其绕组两端的高度均能得到降低。可以理解的，本实施例提供的绕组端部加工方法和绕组端部结构也适用于HAIRPIN绕组，HAIRPIN绕组轴向的一端通过预弯折成型，其另一端也需要通过扭头工艺加工，因此同样可以适用本实施例提供的绕组端部加工方法和绕组端部结构。
基于上述绕组端部结构，本实施例还提供一种定子组件，其包括：铁芯20以及设置于所述铁芯20上的绕组21；所述绕组21的导体10采用如上所述的绕组端部结构。下面请参考图3和图4，示范性地对一个定子组件进行说明。
在图3示出的示范例中，多根所述导体10围绕铁芯20于同一半径上周向分布，形成导体组，即图3中位于同一圆周上的一圈导体10。所述定子组件包括至少两个在所述铁芯20的径向上内外排布的所述导体组；同一所述导体组中的所有所述导体10的弯折方向相同，内外相邻的所述导体组中的所述导体10的弯折方向相反；待连接的两根所述导体10分别位于内外相邻的所述导体组中。具体的，在图3示出的示范例中，定子组件包括8个导体组，从最外圈往最内圈排布的各导体组中，处于奇数圈的导体组中所有的导体10在上端伸出铁芯后均顺时针弯折，在下端伸出铁芯后均逆时针弯折。处于偶数圈的导体组中所有的导体10在上端伸出铁芯后均逆时针弯折，在下端伸出铁芯后均顺时针弯折。如此配置，内外相邻的导体组中的导体10的弯折方向相反，两者能够相互连接。
请参考图4，优选的，在不同的所述导体组中，所述导体10的周向分布位置相同；这里对导体10的周向分布位置相同进行说明。每一根导体10在 穿设在铁芯20中后，均具有其固定的周向分布位置。例如以俯视图观察一个定子组件，以分布于12点方向的导体10的周向分布位置为0°，沿着顺时针方向，不同的导体10的周向分布位置逐渐增加，直至环绕一周。导体10的周向分布位置相同是指，不同导体组中的导体10围绕于铁芯20的周向分布位置的分布是相同的。例如以一个简化的仅包括6个导体10的导体组为例进行说明，一个导体组中，导体10的周向分布位置分别为0°、60°、120°、180°、240°和300°。那么其它不同的导体组中，导体10的周向分布位置也为0°、60°、120°、180°、240°和300°，这样就称为不同的导体组中导体10的周向分布位置相同。如此配置，不同导体组的各导体10实际上呈围绕中心的放射状排布，所有导体组中位于同一周向分布位置的导体10沿铁芯20的径向排列成直线状的一列。需要说明的，上述导体组中导体10的数量仅为示例而非对导体10数量的限定。本领域技术人员可根据实际对导体组中导体10的数量进行设定。
进一步的，待连接的所述导体10于周向分布位置上间隔5个其它导体10的周向分布位置。优选的，所述定子组件具有三相，每相均包括相邻的两个周向分布位置上所排布的导体10，三相依次轮流排布。如图4所示，周向分布位置sa、sb上排布的导体10均为A相，周向分布位置sc、sd上排布的导体10均为B相，周向分布位置se、sf上排布的导体10均为C相，周向分布位置sg、sh上排布的导体10均为A相，依次循环。一般的，待连接的导体10为同一相，由于三相的导体10轮流排布，因此同相的导体10周向分布位置之间间隔5个其它导体10的周向分布位置。例如周向分布位置sa于最内圈的导体组中的导体10a逆时针弯折，与其连接的是周向分布位置sg于由内向外第二圈的导体组中的导体10b。导体10a和导体10b之间间隔5个其它导体10的周向分布位置，即周向分布位置sb、sc、sd、se、sf。
可选的，定子组件还包括引出线，引出线可根据本领域常规的设置方式与绕组的导体10进行连接，本实施例对此不再展开说明。
综上所述，本发明提供的绕组端部加工方法、绕组端部结构及定子组件中，所述绕组端部加工方法包括：对导体的头部进行切角以形成焊接面；所述焊接面与所述导体的轴向成角度；对穿入铁芯后伸出的所述导体施加推力，使所述导体在根部产生弯折；在弯折后，待连接的两根所述导体的所述焊接面相邻接形成焊接线；将待连接的两根所述导体于所述焊接面处通过激光焊连接。
如此配置，绕组端部结构采用推力的方式对导体进行加工，导体头部不需拉拽施力，因此头部不会留存拉拽头，降低了绕组端部高度，减小了外包络尺寸。另一方面，由于对导体的头部具有通过切角形成焊接面，进而在导体折弯后在焊接面处采用激光焊连接，不会对焊接面以外部位的绝缘层产生损伤，有效提高了绕组的可靠性。
需要说明的，上述若干实施例之间可相互组合。上述描述仅是对本发明较佳实施例的描述，并非对本发明范围的任何限定，本发明领域的普通技术人员根据上述揭示内容做的任何变更、修饰，均属于权利要求书的保护范围。

Claims (24)

  1. 一种绕组端部加工方法，其特征在于，包括：
    对导体的头部进行切角以形成焊接面；所述焊接面与所述导体的轴向成角度；
    对穿入铁芯后伸出的所述导体施加推力，使所述导体在根部产生弯折；在弯折后，待连接的两根所述导体的所述焊接面相邻接形成焊接线；
    将待连接的两根所述导体于所述焊接面处通过激光焊连接。
  2. 根据权利要求1所述的绕组端部加工方法，其特征在于，在弯折后，待连接的两根所述导体的所述焊接面位于同一平面上；和/或；所述焊接线垂直于所述铁芯的轴向。
  3. 根据权利要求1所述的绕组端部加工方法，其特征在于，在穿入所述铁芯前，所述导体的头部经预处理步骤处理；所述预处理步骤包括：对所述导体的头部朝向待连接的导体的方向进行打薄处理，以形成连接面。
  4. 根据权利要求3所述的绕组端部加工方法，其特征在于，所述连接面的延伸方向与所述铁芯的轴向成角度布置。
  5. 根据权利要求1所述的绕组端部加工方法，其特征在于，沿所述焊接线的延伸方向，所述激光焊的能量分布为中间大于两端。
  6. 根据权利要求1所述的绕组端部加工方法，其特征在于，对穿入铁芯后伸出的所述导体施加推力，使所述导体在根部产生弯折的步骤包括：
    对所述导体的头部施加推力，使所述导体于根部产生弯折，直至成型。
  7. 根据权利要求1所述的绕组端部加工方法，其特征在于，对穿入铁芯后伸出的所述导体施加推力，使所述导体在根部产生弯折的步骤包括：
    对所述导体的根部施加推力，使所述导体于根部产生初步弯折，进而对所述导体的头部施加推力，使所述导体在根部继续弯折，直至成型。
  8. 根据权利要求1所述的绕组端部加工方法，其特征在于，对穿入铁芯后伸出的所述导体施加推力，使所述导体在根部产生弯折的步骤包括：
    对所述导体的根部施加推力，使所述导体于根部产生初步弯折，进而施力点沿根部向头部逐渐移动，在所述施力点移动的同时对所述导体施加推力，使所述导体于根部继续弯折，直至成型。
  9. 根据权利要求6～8中任一项所述的绕组端部加工方法，其特征在于，在对所述导体的根部施加推力前，所述绕组端部加工方法还包括：于所述导体的根部设置辅助限位体，使所述辅助限位体沿所述导体的径向与所述导体相抵靠。
  10. 根据权利要求1所述的绕组端部加工方法，其特征在于，在将待连接的两根所述导体于所述焊接面处通过激光焊连接后，所述绕组端部加工方法还包括：
    对所述导体的头部进行涂敷处理或低压包塑处理，以形成头部涂层。
  11. 根据权利要求1所述的绕组端部加工方法，其特征在于，对穿入铁芯后伸出的所述导体施加推力，使所述导体在根部产生弯折的过程中，仅对所述导体施加推力，以保持所述导体在所述铁芯轴向一端伸出的部分中，不形成相对所述根部弯折方向的反弯。
  12. 根据权利要求1所述的绕组端部加工方法，其特征在于，所述绕组端部加工方法应用于IPIN绕组，所述IPIN绕组的导体的轴向两端均应用所述绕组端部加工方法进行加工。
  13. 一种绕组端部结构，其特征在于，包括：待连接的两根导体；
    所述导体于伸出铁芯的根部形成弯折，所述导体的头部具有在穿入所述铁芯前通过切角形成的焊接面，所述焊接面与所述导体的轴向成角度，待连接的两根所述导体的所述焊接面相邻接形成焊接线；待连接的两根所述导体 于所述焊接面处通过激光焊连接。
  14. 根据权利要求13所述的绕组端部结构，其特征在于，所述导体的头部具有连接面，所述连接面朝向待连接的另一所述导体；待连接的两根所述导体的所述连接面相互贴合连接。
  15. 根据权利要求14所述的绕组端部结构，其特征在于，所述连接面与所述导体的本体在所述导体的待连接方向上形成高低差，所述连接面低于所述导体的本体。
  16. 根据权利要求13所述的绕组端部结构，其特征在于，所述导体为扁线，所述扁线在径向上较长的方向为宽度方向，在径向上较短的方向为厚度方向；所述导体于根部沿宽度方向弯折；所述连接面位于所述扁线的厚度方向上。
  17. 根据权利要求13所述的绕组端部结构，其特征在于，所述导体在所述铁芯轴向一端伸出的部分中，不具有相对所述根部弯折方向的反弯。
  18. 根据权利要求13所述的绕组端部结构，其特征在于，所述绕组端部结构应用于IPIN绕组，所述IPIN绕组的导体的轴向两端于伸出铁芯的根部均形成弯折，且同一所述导体的轴向两端的弯折方向相反。
  19. 根据权利要求13所述的绕组端部结构，其特征在于，所述绕组端部结构还包括头部涂层，所述头部涂层包覆于所述导体的头部；所述头部涂层为电绝缘体。
  20. 根据权利要求13所述的绕组端部结构，其特征在于，所述连接面的延伸方向与所述铁芯的轴向成角度布置。
  21. 根据权利要求20所述的绕组端部结构，其特征在于，所述连接面包括斜面区段和/或曲面区段。
  22. 一种定子组件，其特征在于，包括：铁芯以及设置于所述铁芯上的 绕组；所述绕组的导体采用根据权利要求13～20中任一项所述的绕组端部结构。
  23. 根据权利要求22所述的定子组件，其特征在于，多根所述导体围绕所述铁芯于同一半径上周向分布，形成导体组；所述定子组件包括至少两个在所述铁芯的径向上内外排布的所述导体组；同一所述导体组中的所有所述导体的弯折方向相同，内外相邻的所述导体组中的所述导体的弯折方向相反；待连接的两根所述导体分别位于内外相邻的所述导体组中。
  24. 根据权利要求23所述的定子组件，其特征在于，在不同的所述导体组中，所述导体的周向分布位置相同；待连接的所述导体于周向分布位置上间隔5个其它导体。
PCT/CN2022/134931 2021-12-31 2022-11-29 绕组端部加工方法、绕组端部结构及定子组件 WO2023124701A1 (zh)

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