WO2024001020A1 - 定子绕组连接头、定子绕组及电机 - Google Patents

定子绕组连接头、定子绕组及电机 Download PDF

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Publication number
WO2024001020A1
WO2024001020A1 PCT/CN2022/134929 CN2022134929W WO2024001020A1 WO 2024001020 A1 WO2024001020 A1 WO 2024001020A1 CN 2022134929 W CN2022134929 W CN 2022134929W WO 2024001020 A1 WO2024001020 A1 WO 2024001020A1
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WIPO (PCT)
Prior art keywords
conductor
connector
escape
connector body
stator winding
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PCT/CN2022/134929
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English (en)
French (fr)
Inventor
郝秀峰
虞兴翔
蒋大千
朱思衡
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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 WO2024001020A1 publication Critical patent/WO2024001020A1/zh

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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • H02K3/12—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors arranged in slots
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • H02K3/28—Layout of windings or of connections between windings
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/46—Fastening of windings on the stator or rotor structure
    • 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

Definitions

  • the invention relates to the field of motor technology, and in particular to a stator winding connector, a stator winding and a motor.
  • the drive motor on an electric vehicle is one of the cores of the entire power drive system of the vehicle. Its service life and reliability are directly related to the life and safety of the entire vehicle. The reliability and compactness of motor winding design are particularly important for the development of automotive drive motors. Flat wire motors are currently the mainstream application in electric vehicles due to their high slot fill rate and high power density;
  • the current mainstream stator winding manufacturing process for flat wire motors is divided into two technical routes.
  • One is the Hair-PIN process route in which one end is integrally bent and formed, also known as the hairpin winding process, and the other is the I-PIN process route; among which the hairpin process route is
  • the winding is essentially a section of conductor that is bent and twisted to form an integrated U-shaped hairpin structure.
  • This hairpin structure acts as a conductor group alone. It is difficult and slow to insert conductors into the stator slot under the Hair-PIN process route; while I-PIN
  • Each conductor group in the process route includes a first conductor and a second conductor. The first conductor and the second conductor are independent of each other before being inserted into the stator slot.
  • the first conductor and the second conductor can be individually inserted into the stator slot, and then the first conductor is inserted into the stator slot.
  • the conductor is connected to the head of the second conductor, and its insertion into the stator slot is relatively simple and fast;
  • the purpose of the present invention is to provide a stator winding connector, a stator winding and a motor, which increase the electrical gap between adjacent conductor groups by improving the conductor head structure, so that the winding structure meets the creepage distance requirements of the motor.
  • the stator winding connector in this embodiment is used to solve the technical problem of not meeting the creepage distance requirements caused by the existing winding conductor connection process
  • the stator winding connector is used to be arranged on the conductor of the winding and includes a connector body.
  • the connector body is provided with a connecting surface and a first escape surface.
  • the first escape surface is located opposite to the connection surface. side, the first escape surface is configured such that after the first conductor and the second conductor in the same conductor group are installed in the stator slot of the stator and positioned relatively, the connector body of any one of the conductors does not exceed the other conductor. of insulation layer.
  • the connector body also has a first side wall and a second escape surface, the second escape surface is located on the first side wall, and the second escape surface is configured as:
  • the first side wall of the connector body of the first conductor and the connector body of the second conductor are opposite in the radial direction, and the second escape surface allows the first side wall of the connector body of any one of the conductors to be in contact with the other conductor on the side close to the free end of the connector.
  • the connector body also has an end face, the end face is located at the free end of the connector body, and the second escape surface is connected to the end face.
  • the second escape surface is connected between the connection surface and the first escape surface.
  • the second escape surface is an arc-shaped surface, and the second escape surface is further configured such that the bending direction of the second escape surface makes any one of the first conductor and the second conductor When the middle part of the second escape surface of the connector body of the conductor approaches the end surface of the connector body, the corresponding radial gap gradually becomes larger.
  • first escape surface is connected to the end surface.
  • connecting surface is connected to the end surface.
  • first escape surface is an arc-shaped surface, and the first escape surface is further configured such that the bending direction of the first escape surface is such that the distance between the first escape surface and the connection surface is closer to The end face gradually becomes smaller.
  • the present invention also provides a stator winding, which includes a plurality of conductors, and the above-mentioned stator winding connectors are provided on the conductors.
  • the present invention also provides a motor, which is installed with the above-mentioned stator winding.
  • the stator winding connector provided by the present invention includes a connector body.
  • the connector body is provided with a connecting surface and a first escape surface.
  • the first escape surface is located on the opposite side of the connection surface.
  • the first avoidance surface is configured such that after the connector body is connected to the connector body of an adjacent conductor, the connector body does not exceed the insulation layer of the adjacent conductor.
  • Figure 1 is a schematic diagram of the existing stator winding connection structure
  • FIG. 2 is a schematic diagram of the stator winding connection structure of the present invention.
  • FIG. 3 is a schematic structural diagram of the stator winding connector according to Embodiment 1 of the present invention.
  • Figure 4 is a schematic diagram of the structure of Figure 3 viewed from above;
  • FIG. 5 is a schematic diagram 1 of the stator winding connection structure in Embodiment 1 of the present invention.
  • FIG. 6 is a schematic diagram 2 of the stator winding connection structure in Embodiment 1 of the present invention.
  • FIG. 7 is a schematic structural diagram of the stator winding connector in Embodiment 2 of the present invention.
  • Figure 8 is a schematic diagram of the structure of Figure 7 viewed from above;
  • FIG. 9 is a schematic structural diagram of the stator winding connector in Embodiment 3 of the present invention.
  • FIG. 10 is a schematic structural diagram of the stator winding connector in Embodiment 4 of the present invention.
  • FIG 11 is a schematic structural diagram of the stator winding connector in Embodiment 5 of the present invention.
  • connection, coupling, or connection between the two elements.
  • Cooperation or transmission relationship, and the connection, coupling, cooperation or transmission between the two elements can be direct or indirect through an intermediate element, and it cannot be understood as indicating or implying the spatial positional relationship between the two elements, that is, one element can be in another Any orientation inside, outside, above, below, or to one side of a component, unless the content clearly indicates otherwise.
  • the specific meanings of the above terms in the present invention can be understood according to specific circumstances.
  • directional terms such as above, below, up, down, up, down, left, right, etc. are used with respect to the exemplary embodiments as they are shown in the figures, with the upward or upward direction being toward the top of the corresponding figure, The downward or downward direction is towards the bottom of the corresponding figure.
  • each conductor group includes a first conductor 41 and a second conductor 42, where the heads of the first conductor 41 and the second conductor 42 are bent, so that the first conductor 41 and the second conductor 42 are bent.
  • the heads After the first conductor 41 and the second conductor 42 are inserted into the stator slot, their heads form an approximately parallel relationship, and then the two heads are connected through laser welding.
  • This connection method requires the position of the conductor heads to be adjusted. Secondary bending, resulting in more bending processes, and the connection structure causes the winding end to be too high;
  • the connector of the first conductor and the connector of the second conductor in the conductor group form an approximate X-shaped cross structure, then the free end of one connector will extend beyond the insulation layer of the other conductor, which will lead to the first
  • the electrical gap between the conductor group 20 and the second conductor group 30 is small, which makes it difficult to meet the requirements of the motor creepage distance. On the other hand, it is easy to cause damage to the insulation layer.
  • the first conductor group 20 as an example, as shown in Figure 2 shows that the free end of the connector corresponding to the first conductor 41 in the first conductor set 20 exceeds the insulation layer 421 of the second conductor 42, which will result in a smaller electrical gap between the first conductor set 20 and the second conductor set 30.
  • the heads of the first conductor 41 and the second conductor 42 are likely to be over-twisted, which may easily lead to one of the connectors being easily connected to
  • the insulation layers of another conductor are in radial contact with each other, which can easily cause damage to the insulation layer;
  • the stator winding connector in this embodiment is used to solve the technical problem of not meeting the creepage distance requirements caused by the existing winding conductor connection process
  • a stator winding connector used to be arranged on the conductor of the winding, including a connector body 10.
  • the connector body is provided with a connecting surface 11 and a first escape surface 12.
  • the first escape surface 12 is located on the On the opposite side of the connection surface 11, the first escape surface 12 is configured such that after the first conductor 41 and the second conductor 42 in the same conductor group are installed in the stator slot of the stator and positioned relatively, such that the The connector body does not extend beyond the insulation of the other conductor.
  • the first conductor and the second conductor here refer to two conductors in the same conductor group; please refer to Figure 2.
  • the first conductor and the second conductor have the same structure.
  • the second conductor 42 is taken as an example for explanation.
  • the second conductor 42 has a flat rod-shaped structure.
  • An insulation layer 421 is provided on the outside of the second conductor 42.
  • the insulation layer is removed from the head of the second conductor 42 and processed to form the connector 10.
  • the second conductor 42 is inserted into the stator slot. When, its tail end is first inserted into the stator slot and passes through the other end of the stator slot to the outside.
  • the connector of the second conductor 42 is not inserted into the stator slot.
  • the connector of the second conductor 42 is used to connect to the connector located in the same conductor group.
  • the shape of the connecting surface 11 and the first escape surface 12 is not limited here.
  • it can be set as a plane.
  • it can be configured as an arc surface.
  • the connecting surface and the first escape surface can be A single plane or a complex composite surface composed of multiple surfaces;
  • the first avoidance surface is arranged opposite to the connection surface, where the first avoidance surface serves as an avoidance structure and can form an avoidance for the adjacent conductors, so that the first conductor 41 and the second conductor 42 are installed in the stator slot and positioned. , the connector body of the first conductor 41 does not exceed the insulation layer of the second conductor 42, and correspondingly, the connector body of the second conductor 42 does not exceed the insulation layer of the first conductor 41;
  • the distance between the connector body of the first conductor 41 and the insulation layer of the second conductor 42 is a, so that the electrical gap between the first conductor group 20 and the second conductor group 30 becomes larger. , which will help meet the creepage distance requirements of the motor;
  • connection surface 11 and the first escape surface 12 are non-up-and-down symmetrical structures.
  • the connection surface 11 and the first escape surface 12 are both arc-shaped surfaces.
  • the length of the surface is longer to ensure sufficient welding length, while the slope of the first avoidance surface is small, which is conducive to just meeting the avoidance requirements and does not affect the length of the connection surface;
  • connection surface 11 and the first escape surface 12 are symmetrical structures up and down, and the connection surface 11 and the first escape surface 12 are both arc-shaped surfaces, which facilitates processing;
  • the connecting surface 11 is an arc-shaped surface
  • the first escape surface 12 is a plane formed by bevel cutting.
  • the first escape surface 12 is a planar structure.
  • connection surface 11 is an arc surface
  • first escape surface 12 is a angled composite surface formed after removing materials. Then the first escape surface 12 is essentially made of The composite surface formed by the first plane 121 and the second plane 122;
  • connection surface and the first escape surface can be selectively adjusted according to the specific size of the connector and the requirements of the motor's operating conditions, and will not be detailed here;
  • a first avoidance surface is provided on the opposite side of the connection surface to form an avoidance relationship between adjacent conductor groups, thereby increasing the electrical gap between adjacent conductor groups, so that the winding structure meets the creepage distance requirements of the motor. , and because the first avoidance surface avoids the insulation layer of the adjacent conductor, during the bending and twisting process of the conductor at the connector position, the connector does not contact the insulation layer of the adjacent conductor, thereby avoiding damage to the insulation layer.
  • the setting of the connector changes the connection structure of the two conductors in the conductor group, and then develops the X-PIN process route in the I-PIN process route, which solves the problem that the winding end is too high in the existing I-PIN process route.
  • the connector body 10 also has a first side wall 16 and a second escape surface 13.
  • the second escape surface 13 is located on the first side wall 16.
  • the second escape surface 13 is configured for:
  • the first side wall of the connector body of the first conductor 41 and all the surfaces of the second conductor 42 are opposite in the radial direction, and the second escape surface makes the first side wall of the connector body of any one of the conductors on the side close to the free end of the connector.
  • the free end here refers to the end of the connector body extending along the length direction of the conductor.
  • the connector body is essentially a cantilever structure connected to the end of the conductor, so the free end naturally refers to the cantilever end of the connector body;
  • the second escape surface 13 is formed by removing material from the first side wall 16 .
  • the second escape surface is arranged so that the thickness L1 at the free end of the connector body 10 is smaller than the thickness L1 in the middle of the connector body 10 .
  • the thickness dimension L2 as shown in FIG. 6 , allows a first avoidance to be formed between the first side wall 16 on the connector body of the first conductor 41 and the first side wall 16 on the connector body of the second conductor 42 Area 17 and second escape area 18.
  • the first escape area 17 and the second escape area 18 are two radial gaps formed.
  • the first avoidance area 17 makes the first side wall on the connector body of the first conductor 41 close to the free end of the connector and the connector body on the second conductor 42 close to the insulation layer.
  • One end of the connector is not in contact;
  • the corresponding second avoidance area 18 also makes the first side wall on the connector body of the second conductor 42 close to the free end of the connector and the connector body on the first conductor 41 close to the insulation
  • One end of the layer is not in contact; then it can also avoid the contact between the connector body and the adjacent conductor insulation layer due to over-torsion, positioning error or manufacturing error, which will help protect the insulation layer from damage;
  • the opposite side of the second escape surface is not modified.
  • the third escape surface 15 can be adaptively processed on the opposite side of the second escape surface 13.
  • the second avoidance surface 13 and the third avoidance surface 15 are mirror-symmetric structures, used to form an avoidance relationship with other adjacent conductors in the corresponding directions.
  • the relative positioning of the first conductor 41 and the second conductor 42 when installed in the stator slot means that after the first conductor 41 and the second conductor 42 are installed in the stator slot, the connector body of the first conductor 41 and the second conductor
  • the positioning of the connector body 42 before connection is to meet the position requirements for the mutual connection of the two connector bodies; usually, the first conductor 41 and the second conductor 42 are inserted into the corresponding stator slots, and the two conductor heads are twisted to each other. Position, and then connect the two connector bodies through laser welding;
  • the shape of the second avoidance surface is not limited here.
  • it can be set as a plane.
  • it can be set as an arcuate surface.
  • the second avoidance surface can be a separate plane, or it can be A composite surface composed of multiple planes;
  • the connector body 10 also has an end face 14 , the end face 14 is located at the free end of the connector body 10 , and the second escape surface 13 is connected to the end face 14 .
  • the second escape surface and the end surface can be connected through an arc transition.
  • the end surface 14 is essentially the surface corresponding to the cantilever end of the connector body 10.
  • the avoidance area formed by the second escape surface 13 can be lengthened as much as possible, and the avoidance area is adjacent to the end surface.
  • the first conductor 41 and the second conductor 42 in the conductor group are formed and After positioning, the end surface 14 of the connector body of the second conductor 42 is closest to the insulating layer of the first conductor 41, and the structure connecting the second escape surface 13 to the end surface makes the second escape area 18 just facing the first conductor.
  • the position of the connector body of 41 close to the insulating layer will help the connector body of the second conductor 42 to accurately avoid the insulation layer of the first conductor 41. Similarly, it will also help the connector body of the first conductor 41 to accurately avoid the insulating layer of the first conductor 41. Forming an avoidance for the insulation layer of the second conductor 42 facilitates precise avoidance of the insulation layer through a smaller removal processing area.
  • the second escape surface 13 is connected between the connection surface 11 and the first escape surface 12.
  • the connecting surface 11 is usually located on the side away from the positioning core along the axial direction of the stator core, so that The connection surface is outward to facilitate the welding operation; taking the first conductor 41 as an example, corresponding to Figure 5, the connection surface 11 is located in the generally upward direction of the connector body 10 in Figure 5, and the first escape surface 12 is located on the connector body. 10 is generally downward, then the inward side of the connector body 10 of the first conductor 41 perpendicular to the paper surface in Figure 5 is where the first side wall 16 and the second escape surface 13 of the connector body are located.
  • the second escape surface 13 is connected to the connecting surface 11 and the first escape surface 12 so that the connector body 10 has a first side wall 16 inward perpendicular to the paper surface in Figure 5 with a third
  • the two avoidance surfaces 13 form an avoidance area that runs from top to bottom; it can be seen from FIG. 5 that the coverage of the avoidance area formed by the second avoidance surface 13 is larger, which is beneficial to the insulation layer of the second conductor 42 in the same conductor group.
  • the structure of the second escape surface 13 connected to the connecting surface 11 and the first escape surface 12 is also easy to process and form.
  • the second escape surface 13 is an arc-shaped surface, and the second escape surface 13 is further configured such that the bending direction of the second escape surface 13 makes the first conductor 41 and the second conductor When the middle part of the second escape surface of the connector body of any one of the conductors 42 approaches the direction of the end surface of the connector body, the corresponding radial gap gradually becomes larger.
  • the distance between the second escape surface 13 and its opposite surface gradually changes from L2 to L1 ; continue to refer to FIG. 6 , so that the second escape surface 13 of the connector body of the second conductor 42
  • the radial gap between the connector bodies is the largest at the end surface of the connector body and away from the first conductor 41. Even if the middle positions of the two connector bodies are in radial contact due to manufacturing errors or installation errors, then based on The arrangement of the curved structure of the second escape surface 13 can also ensure that a radial gap is maintained between the connection position between the second escape surface and the end surface of the second conductor 42 and the connector body of the first conductor 41, thereby effectively avoiding the insulation layer. Got scratched.
  • first escape surface 12 is connected to the end surface 14 .
  • the end face mentioned here has the same meaning as the above-mentioned end face.
  • the first escape surface 12 is set up in this way. On the one hand, it can lengthen the escape area formed by the first escape surface 12 as much as possible. On the other hand, it ensures that the first escape surface 12
  • the setting does not affect the connection surface 11 to ensure a longer welding length of the connection surface; Please refer to Figure 11, if the first avoidance surface 12 is directly beveled to the connection surface 11, it will easily cause the length of the connector body 10 to be If it is too short, the welding length of the connection surface 11 will be insufficient.
  • connecting surface 11 is connected to the end surface 14 .
  • connection surface 11 and the end surface 14 are connected so that the length of the connection surface is longer, ensuring a longer welding length of the connection surface.
  • first escape surface 12 is an arc-shaped surface, and the first escape surface is also configured such that the bending direction of the first escape surface 12 is such that the distance between the first escape surface 12 and the connecting surface 11 The distance gradually becomes smaller as it approaches the end surface 14 .
  • the curved structure of the first escape surface 12 is arranged to help ensure that the connector body of one of the conductors in the same conductor group does not exceed another insulating layer of said conductor.
  • This embodiment also provides a stator winding, which includes a plurality of conductors, and the above-mentioned stator winding connectors are provided on the conductors.
  • the connectors of the two conductors are connected to form a conductor group.
  • This conductor group has the same function as the hairpin winding.
  • the stator winding formed by this conductor is derived from the I-PIN process route.
  • the X-PIN process route, the installation of the conductor in the stator slot and the connection of the conductor head and tail are all existing technologies and will not be described in detail here;
  • This embodiment also provides a motor, which is installed with the above-mentioned stator winding.
  • the motor also includes a stator assembly and a rotor assembly arranged inside the stator assembly, wherein the above-mentioned stator winding is installed in the stator assembly; so that the X-PIN process route is derived from the I-PIN process route in the motor, and the creep of each conductor
  • the electrical distance meets the requirements, and during the assembly process, it is relatively simple and fast to insert the conductor into the stator slot, and the size of the motor is effectively reduced, making it suitable for more compact applications, and the power density and torque density are effectively improved. It also simplifies the molding tooling and saves costs.

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  • Power Engineering (AREA)
  • Insulation, Fastening Of Motor, Generator Windings (AREA)

Abstract

本发明提供了一种定子绕组连接头、定子绕组及电机；定子绕组连接头用于设置于绕组的导体上，包括连接头本体，所述连接头本体上设置有连接面和第一避让面，所述第一避让面位于所述连接面的相对侧，所述第一避让面配置为：同一导体组中的第一导体和第二导体安装于定子的定子槽内相对定位后，使得其中任意一个导体的所述连接头本体不超过另一个导体的绝缘层。通过在连接面相对侧设置第一避让面，形成相邻导体组之间的避让关系，进而增大相邻导体组之间的电气间隙，使得绕组结构满足电机的爬电距离要求，而且由于第一避让面对相邻导体绝缘层的避让，则使得导体在连接头位置处弯折扭转过程中，连接头不与相邻导体的绝缘层接触，可避免对绝缘层的损伤。

Description

定子绕组连接头、定子绕组及电机 技术领域
本发明涉及电机技术领域，特别涉及一种定子绕组连接头、定子绕组及电机。
背景技术
电动汽车上的驱动电机是汽车整套动力驱动系统的核心之一，它的使用寿命和可靠性直接关系着整车的寿命和安全。而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。扁线电机基于其槽满率和功率密度较高为目前电动汽车的应用主流；
扁线电机目前主流的定子绕组生产制造工艺分成两个技术路线，一种是一端整体折弯成型的Hair-PIN工艺路线，也称发卡绕组工艺，另一种是I-PIN工艺路线；其中发卡绕组实质上一段导体弯折扭转后形成一体的类似U形的发卡结构，该发卡结构单独作为一个导体组，Hair-PIN工艺路线下的导体插入定子槽内较为困难且节拍慢；而I-PIN工艺路线中每个导体组中包括第一导体和第二导体，第一导体和第二导体在插入定子槽之前相互独立，第一导体和第二导体可单独插入定子槽内，然后将第一导体和第二导体的头部连接，其插入定子槽内较为简单、节拍较快；
现有的I-PIN工艺路线中第一导体的连接头与第二导体的连接头连接后，相邻的导体组之间的电气间隙较小，那么导致爬电距离不足，而且也使得导体端部过高。
发明内容
本发明的目的在于提供一种定子绕组连接头、定子绕组及电机，通过对导体头部结构的改进增大相邻导体组之间的电气间隙，进而使得绕组结构满足电机的爬电距离要求。
本实施例中的定子绕组连接头，用于解决现有绕组导体连接工艺导致的 不满足爬电距离要求的技术问题；
所述定子绕组连接头，用于设置于绕组的导体上，包括连接头本体，所述连接头本体上设置有连接面和第一避让面，所述第一避让面位于所述连接面的相对侧，所述第一避让面配置为：同一导体组中的第一导体和第二导体安装于定子的定子槽内相对定位后，使得其中任意一个导体的所述连接头本体不超过另一个导体的绝缘层。
进一步的，所述连接头本体上还具有第一侧壁和第二避让面，所述第二避让面位于所述第一侧壁上，所述第二避让面被配置为：
所述第一导体和所述第二导体安装于定子槽内相对定位后，所述第一导体的所述连接头本体的所述第一侧壁与所述第二导体的所述连接头本体的所述第一侧壁沿径向方向相对，所述第二避让面使得其中任意一个导体的所述连接头本体的所述第一侧壁在靠近该连接头自由端一侧与另一个导体沿所述定子的径向之间具有径向间隙。
进一步的，所述连接头本体上还具有端面，所述端面位于所述连接头本体的自由端，所述第二避让面与所述端面连接。
进一步的，所述第二避让面连接于所述连接面与所述第一避让面之间。
进一步的，所述第二避让面为弧形面，所述第二避让面还被配置为：所述第二避让面的弯曲方向使得所述第一导体和所述第二导体中的任意一个导体的所述连接头本体的所述第二避让面的中部向该连接头本体的端面的方向靠近时，对应的所述径向间隙逐渐变大。
进一步的，所述第一避让面与所述端面连接。
进一步的，所述连接面与所述端面连接。
进一步的，所述第一避让面为弧形面，所述第一避让面还被配置为：所述第一避让面的弯曲方向使得所述第一避让面距离连接面之间的距离在靠近所述端面时逐渐变小。
本发明还提供了一种定子绕组，包括若干个导体，所述导体上设置有上述所述的定子绕组连接头。
本发明还提供了一种电机，所述电机安装有上述所述的定子绕组。
综上所述，在本发明提供的定子绕组连接头，包括连接头本体，所述连接头本体上设置有连接面和第一避让面，所述第一避让面位于所述连接面的相对侧，所述第一避让面配置为：所述连接头本体与相邻导体的连接头本体连接后，使得所述连接头本体不超过所述相邻导体的绝缘层。
如此配置，通过在连接面相对侧设置第一避让面，形成相邻导体组之间的避让关系，进而增大相邻导体组之间的电气间隙，使得绕组结构满足电机的爬电距离要求，而且由于第一避让面对相邻导体绝缘层的避让，则使得导体在连接头位置处弯折扭转过程中，连接头不与相邻导体的绝缘层接触，可避免对绝缘层的损伤；上述的定子绕组连接头应用于绕组导体上时，可以使得相邻导体的连接头形成近似的X形交叉连接结构，同时也解决了导体端部过高的技术问题。
附图说明
图1为现有的定子绕组连接结构示意图；
图2为本发明定子绕组连接结构示意图；
图3为本发明实施例1的定子绕组连接头的结构示意图；
图4为图3的仰视结构示意图；
图5为本发明实施例1的定子绕组连接结构示意图1；
图6为本发明实施例1的定子绕组连接结构示意图2；
图7为本发明实施例2的定子绕组连接头的结构示意图；
图8为图7的仰视结构示意图；
图9为本发明实施例3的定子绕组连接头的结构示意图；
图10为本发明实施例4的定子绕组连接头的结构示意图；
图11为本发明实施例5的定子绕组连接头的结构示意图；
其中，附图标记如下：
10-连接头本体；11-连接面；12-第一避让面；13-第二避让面；14-端面；
15-第三避让面；16-第一侧壁；17-第一避让区；18-第二避让区；
20-第一导体组
30-第二导体组；
41-第一导体；42-第二导体；421-绝缘层。
具体实施方式
以下结合附图和具体实施例对本发明提出的定子绕组连接头作进一步详细说明。根据下面说明，本发明的优点和特征将更清楚。需说明的是，附图均采用非常简化的形式且均使用非精准的比例，仅用以方便、明晰地辅助说明本发明实施例的目的。
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。此外，如在本发明中所使用的，“安装”、“相连”、“连接”，一元件“设置”于另一元件，应做广义理解，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置关系，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。此外，诸如上方、下方、上、下、向上、向下、左、右等的方向术语相对于示例性实施方案如它们在图中所示进行使用，向上或上方向朝向对应附图的顶部，向下或下方向朝向对应附图的底部。
请参考图1所示，现有的I-PIN工艺路线中，每个导体组包括第一导体41和第二导体42，其中第一导体41和第二导体42的头部弯折，使得第一导体41和第二导体42在插入定子槽内后，二者的头部形成近似的平行关系，然后 通过激光焊接将二者的头部位置连接，该连接方式需要对导体头部位置进行二次弯折，使得弯折工序较多，而且该连接结构导致绕组端部过高；
基于此，提出了如图2所示的一种不同于上述工艺路线的一种全新的连接工艺，此时在导体组中的第一导体和第二导体的头部加工形成裸露的连接头，该连接头不需要如图1所示弯折形成近似平行结构，可减少一次弯折工序，而且也可以解决导体端部过高的问题；图2中，连接头中只考虑了连接面的设置，导体组中第一导体的连接头和第二导体的连接头形成近似的X形交叉结构，那么其中一个连接头的自由端延伸位置会超过另一个导体的绝缘层，一方面会导致第一导体组20与第二导体组30之间的电气间隙较小，难以满足电机爬电距离的要求，另一方面容易导致绝缘层的损伤；以第一导体组20为例说明，如图2所示，第一导体组20中第一导体41对应的连接头的自由端超过第二导体42的绝缘层421，那么会导致第一导体组20与第二导体组30之间的电气间隙较小，而且第一导体41和第二导体42的头部在扭转工序的过程中，为了保证两个连接头对应的连接面对齐，容易存在过扭的现象，则容易导致其中一个连接头容易与另一个导体的绝缘层径向相互接触，那么容易导致绝缘层的破损；
本实施例中的定子绕组连接头，用于解决现有绕组导体连接工艺导致的不满足爬电距离要求的技术问题；
一种定子绕组连接头，用于设置于绕组的导体上，包括连接头本体10，所述连接头本体上设置有连接面11和第一避让面12，所述第一避让面12位于所述连接面11的相对侧，所述第一避让面12配置为：同一导体组中的第一导体41和第二导体42安装于定子的定子槽内相对定位后，使得其中任意一个导体的所述连接头本体不超过另一个导体的绝缘层。
此处的第一导体和第二导体是指同一导体组中的两个导体；请参考图2所示，第一导体和第二导体的结构相同，以第二导体42为例进行说明，第二导体42为扁状的杆状结构，第二导体42的外部设置有绝缘层421，在第二导体42的头部去除绝缘层并加工形成了连接头10，第二导体42在插入定子槽时，其尾端首先插入定子槽内并经过定子槽另一端穿至外部，第二导体42的连接 头并未插入定子槽内，第二导体42的连接头用于与位于同一导体组内的第一导体41的连接头连接，请参考图5和图6所示，第一导体41和第二导体42在插入定子槽内并定位后，第一导体41和第二导体42对应的两个连接面11大致呈共面结构，激光焊接时，焊层覆盖于两个连接面上将两个所述导体头连为一体；
其中连接面11和第一避让面12的形状此处不做限定，例如可以设置为平面，在另一可替代的实施例中，可以设置为弧形面，连接面和第一避让面可以为一个单独的平面，也可以由多个面构成的复杂复合面；
第一避让面与连接面相对设置，其中第一避让面作为避让结构，可以对所述相邻导体形成避让，使得所述第一导体41和所述第二导体42安装于定子槽内定位后，所述第一导体41的连接头本体不超过所述第二导体42的绝缘层，相应的，所述第二导体42的连接头本体也不超过所述第一导体41的绝缘层；
请参考图5所示，第一导体41的连接头本体与第二导体42的绝缘层之间的距离为a，那么使得第一导体组20与第二导体组30之间的电气间隙变大，进而利于满足电机的爬电距离要求；
请参考图3所示，连接面11和第一避让面12为非上下对称结构，连接面11和第一避让面12均为弧形面，连接面11的斜度较大，则利于使得连接面的长度较长，保证足够的焊接长度，而第一避让面的斜度较小，利于刚好满足避让要求，且不影响连接面的长度；
请参考图7所示，在一个可替代的实施例中，连接面11和第一避让面12为上下对称结构，连接面11和第一避让面12均为弧形面，利于加工；
请参考图9所示，在另一个可替代的实施例中，连接面11为弧形面，第一避让面12为斜切去料后形成的平面，此时第一避让面12为平面结构；
请参考图10所示，在另一个可替代的实施例中，连接面11为弧形面，第一避让面12为去料后形成的折角复合面，那么第一避让面12实质上是由第一平面121和第二平面122构成的复合面；
连接面和第一避让面的具体结构形式可依据连接头的具体尺寸以及电机 使用工况的要求选择性的调整，此处不在赘述；
本发明中，通过在连接面相对侧设置第一避让面，形成相邻导体组之间的避让关系，进而增大相邻导体组之间的电气间隙，使得绕组结构满足电机的爬电距离要求，而且由于第一避让面对相邻导体绝缘层的避让，则使得导体在连接头位置处弯折扭转过程中，连接头不与相邻导体的绝缘层接触，可避免对绝缘层的损伤。
另外该连接头的设置，改变导体组中两个导体的连接结构，进而在I-PIN工艺路线中发展形成了X-PIN工艺路线，解决了现有I-PIN工艺路线中绕组端部过高的技术问题，且进一步简化了电机的装配工艺；
进一步的，所述连接头本体10上还具有第一侧壁16和第二避让面13，所述第二避让面13位于所述第一侧壁16上，所述第二避让面13被配置为：
所述第一导体41和所述第二导体42安装于定子槽内相对定位后，所述第一导体41的所述连接头本体的所述第一侧壁与所述第二导体42的所述连接头本体的所述第一侧壁沿径向方向相对，所述第二避让面使得其中任意一个导体的所述连接头本体的所述第一侧壁在靠近该连接头自由端一侧与另一个导体沿所述定子的径向之间具有径向间隙。
此处的自由端是指连接头本体沿着导体的长度方向延伸的一端，连接头本体实质上是连接于导体端部的悬臂结构，那么自由端自然是指接头本体的悬臂端；
请参考图4所示，第二避让面13是在第一侧壁16基础上去料加工形成，第二避让面的设置使得连接头本体10自由端处的厚度尺寸L1小于连接头本体10中部的厚度尺寸L2，结合图6所示，那么使得第一导体41的连接头本体上的第一侧壁16与第二导体42的连接头本体上的第一侧壁16之间形成了第一避让区17和第二避让区18，第一避让区17和第二避让区18即为形成的两处径向间隙，当该导体组内的所述第一导体41和所述第二导体42插入定子槽内被定位后，第一避让区17使得第一导体41的连接头本体上的第一侧壁在靠近该连接头自由端一侧与第二导体42上的连接头本体在靠近绝缘层的一端不接触；相应的第二避让区18也使得第二导体42的连接头本体上的第 一侧壁在靠近该连接头自由端一侧与第一导体41上的连接头本体在靠近绝缘层的一端不接触；那么也可以避免由于过扭、定位误差或者制造误差导致的连接头本体与相邻导体绝缘层接触的现象，利于保护绝缘层不被损伤；
图4中第二避让面的相对侧未做改进，如图8所示，在另一可替代的实施例中，可在第二避让面13的相对侧适应性的加工形成第三避让面15，第二避让面13和第三避让面15为镜像对称结构，用于在相应的方向上与相邻的其他的导体形成避让关系。
第一导体41和第二导体42安装于定子槽内相对定位是指所述第一导体41和所述第二导体42安装于定子槽内后，第一导体41的连接头本体和第二导体42的连接头本体在连接前的定位，以满足两个连接头本体相互连接的位置要求；通常，第一导体41和第二导体42插入相应的定子槽内，两个导体头部扭转后相互定位，然后通过激光焊接使得两个连接头本体连接；
其中第二避让面的形状此处不不做限定，例如可以设置为平面，在另一可替代的实施例中，可以设置为弧形面，第二避让面可以为一个单独的平面，也可以由多个平面构成的复合面；
进一步的，所述连接头本体10上还具有端面14，所述端面14位于所述连接头本体10的自由端，所述第二避让面13与所述端面14连接。
第二避让面与端面可以通过圆弧过渡连接，请结合图4所示，端面14实质上就是连接头本体10的悬臂端对应的面，那么第二避让面13与连接头本体10的悬臂端连接，可以尽可能的加长由于第二避让面13形成的避让区域，且使得该避让区域与端面相邻，则如图6所示，导体组中第一导体41和第二导体42成型且被定位后，第二导体42的连接头本体的端面14距离第一导体41的绝缘层的位置最近，第二避让面13与端面连接的结构则使的第二避让区18刚好正对第一导体41的连接头本体靠近绝缘层的位置处，那么利于第二导体42的连接头本体精确的对第一导体41的绝缘层形成避让，同理，也利于第一导体41的连接头本体精确的对第二导体42的绝缘层形成避让，利于通过较小的去料加工区域达到对绝缘层的精确避让。
进一步的，所述第二避让面13连接于所述连接面11与所述第一避让面 12之间。
请参考图5所示，导体组中，当第一导体41和第二导体42插入定子槽内被定位后，通常连接面11位于沿定子铁芯的轴向方向远离定位铁芯一侧，使得连接面向外，便于焊接操作；以第一导体41为例，对应于图5中，则连接面11位于图5中连接头本体10大致向上的方向，而第一避让面12则位于连接头本体10大致向下的方向一侧，那么图5中第一导体41的连接头本体10垂直于纸面向内的一侧即为该连接头本体的第一侧壁16和第二避让面13的所在位置；第二避让面13与所述连接面11以及所述第一避让面12连接的设置，使得该连接头本体10在图5中垂直于纸面向内的第一侧壁16上具有由第二避让面13形成的由上至下贯通的避让区域；则结合图5可知，使得第二避让面13形成的避让区域的覆盖范围较大，利于对同一导体组中第二导体42的绝缘层的避让，而且第二避让面13与连接面11以及第一避让面12连接的结构也便于加工成型。
进一步的，所述第二避让面13为弧形面，所述第二避让面13还被配置为：所述第二避让面13的弯曲方向使得所述第一导体41和所述第二导体42中的任意一个导体的所述连接头本体的所述第二避让面的中部向该连接头本体的端面的方向靠近时，对应的所述径向间隙逐渐变大。
请参考图4所示，第二避让面13距离其相对面之间的距离由L2逐渐变为L1；继续参考图6所示，则使得第二导体42的连接头本体的第二避让面13与该连接头本体端面相接的部位距离第一导体41的连接头本体之间的径向间隙最大，那么即使两个连接头本体中部位置由于制造误差或安装误差径向相接触了，那么基于第二避让面13弯曲结构的设置，也可保证第二导体42上第二避让面与端面的连接位置处与第一导体41的连接头本体之间保持径向间隙，则可有效避免绝缘层被划伤。
进一步的，所述第一避让面12与所述端面14连接。
该处所述的端面与上述端面的含义相同，第一避让面12如此设置，一方面是可以尽可能的加长由于第一避让面12形成的避让区域，另外一方面是保证第一避让面12的设置不影响到连接面11，以保证连接面较长的焊接长度； 请参考图11所示，若第一避让面12直接斜切至连接面11上，则容易导致连接头本体10的长度过短，那么使得连接面11的焊接长度不足。
进一步的，所述连接面11与所述端面14连接。
请参考图3所示，连接面11与端面14连接使得连接面的长度较长，保证连接面较长的焊接长度。
进一步的，所述第一避让面12为弧形面，所述第一避让面还被配置为：所述第一避让面12的弯曲方向使得所述第一避让面12距离连接面11之间的距离在靠近所述端面14时逐渐变小。
请参考图5所示，导体组内的两个导体插入定子槽内被定位时，第一避让面12弯曲结构的设置，利于使得同一导体组中，其中一个导体的所述连接头本体不超过另一个所述导体的绝缘层。
本实施例中还提供了一种定子绕组，包括若干个导体，所述导体上设置有上述所述的定子绕组连接头。
请参考图5所示，两个导体的连接头连接后形成了导体组，该导体组与发卡式的绕组的作用相同，通过该导体形成的定子绕组属于基于I-PIN工艺路线衍生而形成的X-PIN工艺路线，导体安装于定子槽内以及导体头部和尾部的连接均为现有技术，此处不在赘述；
本实施例中还提供了一种电机，所述电机安装有上述所述的定子绕组。
电机还包括定子组件以及布置于所述定子组件内侧的转子组件，其中定子组件中安装有上述所述的定子绕组；使得电机中在I-PIN工艺路线衍生X-PIN工艺路线，各导体的爬电距离满足要求，且装配过程中，导体插入定子槽内较为简单、节拍快，且电机的尺寸得到有效的减小，适合更紧密的应用场合，而且功率密度和转矩密度得到有效的提升，也简化了成型工装，节省了成本。
本说明书中各个实施例采用递进的方式描述，每个实施例重点说明的都是与其他实施例的不同之处，各个实施例之间相同相似部分互相参见即可。
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 (10)

  1. 一种绕组连接头，用于设置于绕组的导体上，其特征在于：包括连接头本体，所述连接头本体上设置有连接面和第一避让面，所述第一避让面位于所述连接面的相对侧，所述第一避让面配置为：同一导体组中的第一导体和第二导体安装于定子的定子槽内相对定位后，使得其中任意一个导体的所述连接头本体不超过另一个导体的绝缘层。
  2. 如权利要求1所述定子绕组连接头，其特征在于：所述连接头本体上还具有第一侧壁和第二避让面，所述第二避让面位于所述第一侧壁上，所述第二避让面被配置为：
    所述第一导体和所述第二导体安装于定子槽内相对定位后，所述第一导体的所述连接头本体的所述第一侧壁与所述第二导体的所述连接头本体的所述第一侧壁沿径向方向相对，所述第二避让面使得其中任意一个导体的所述连接头本体的所述第一侧壁在靠近该连接头自由端一侧与另一个导体沿所述定子的径向之间具有径向间隙。
  3. 如权利要求2所述定子绕组连接头，其特征在于：所述连接头本体上还具有端面，所述端面位于所述连接头本体的自由端，所述第二避让面与所述端面连接。
  4. 如权利要求2所述定子绕组连接头，其特征在于：所述第二避让面连接于所述连接面与所述第一避让面之间。
  5. 如权利要求3所述定子绕组连接头，其特征在于：所述第二避让面为弧形面，所述第二避让面还被配置为：所述第二避让面的弯曲方向使得所述第一导体和所述第二导体中的任意一个导体的所述连接头本体的所述第二避让面的中部向该连接头本体的端面的方向靠近时，对应的所述径向间隙逐渐变大。
  6. 如权利要求3所述定子绕组连接头，其特征在于：所述第一避让面与所述端面连接。
  7. 如权利要求6所述定子绕组连接头，其特征在于：所述连接面与所述 端面连接。
  8. 如权利要求3所述的定子绕组连接头，其特征在于：所述第一避让面为弧形面，所述第一避让面还被配置为：所述第一避让面的弯曲方向使得所述第一避让面距离连接面之间的距离在靠近所述端面时逐渐变小。
  9. 一种定子绕组，其特征在于：包括若干个导体，所述导体上设置有如权利要求1至权利要求8任意一项权利要求所述的定子绕组连接头。
  10. 一种电机，其特征在于：所述电机安装有如权利要求9所述的定子绕组。
PCT/CN2022/134929 2022-06-30 2022-11-29 定子绕组连接头、定子绕组及电机 WO2024001020A1 (zh)

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN103904790A (zh) * 2012-12-26 2014-07-02 现代摩比斯株式会社 发针式绕组电机的定子总成
JP2018117469A (ja) * 2017-01-19 2018-07-26 本田技研工業株式会社 回転電機のステータ
CN109586445A (zh) * 2017-09-29 2019-04-05 比亚迪股份有限公司 导体段及具有其的定子组件、电机
CN109586448A (zh) * 2017-09-29 2019-04-05 比亚迪股份有限公司 导体段及具有其的定子组件、电机
CN213484604U (zh) * 2020-10-30 2021-06-18 比亚迪股份有限公司 定子组件和电机
CN213661299U (zh) * 2020-10-30 2021-07-09 比亚迪股份有限公司 定子组件和电机

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN103904790A (zh) * 2012-12-26 2014-07-02 现代摩比斯株式会社 发针式绕组电机的定子总成
JP2018117469A (ja) * 2017-01-19 2018-07-26 本田技研工業株式会社 回転電機のステータ
CN109586445A (zh) * 2017-09-29 2019-04-05 比亚迪股份有限公司 导体段及具有其的定子组件、电机
CN109586448A (zh) * 2017-09-29 2019-04-05 比亚迪股份有限公司 导体段及具有其的定子组件、电机
CN213484604U (zh) * 2020-10-30 2021-06-18 比亚迪股份有限公司 定子组件和电机
CN213661299U (zh) * 2020-10-30 2021-07-09 比亚迪股份有限公司 定子组件和电机

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