The present application claims the benefit of priority to Chinese Application No. 202311413910.8, filed on Oct. 30, 2023, the contents of which are incorporated herein by reference in their entireties for all purposes.
The present disclosure relates to the field of motors, and in particular to a flat wire motor and a vehicle using the flat wire motor.
Drive motors are a part of the core three-electric system of new energy vehicles, and the performance of the drive motors directly determines the driving performance of new energy vehicles. A slot full rate of the motors influences the operational efficiency of the motor.
According to a first aspect of the present disclosure, a motor includes: a stator. The stator includes a stator core and an end winding. The stator core has a central hole configured for assembly of a rotor. The end winding is arranged at an end of the stator core, and the end winding includes an inner flat wire conductor adjacent to the central hole. The inner flat wire conductor includes a bridging segment, and a first coupling segment and a second coupling segment embedded in the stator core, and the bridging segment is coupled between the first coupling segment and the second coupling segment. An extension dimension of the first coupling segment of the inner flat wire conductor and an extension dimension of the second coupling segment of an adjacent inner flat wire conductor have an axial length difference in an axial direction of the stator core, so that an overlapped part of two adjacent inner flat wire conductors form staggered approach avoidance in the axial direction and reduce radial intrusion into the central hole.
According to a second aspect of the present disclosure, a vehicle includes a motor and the motor includes a stator. The stator includes a stator core and an end winding. The stator core has a central hole configured for assembly of a rotor. The end winding is arranged at an end of the stator core, and the end winding includes an inner flat wire conductor adjacent to the central hole. The inner flat wire conductor includes a bridging segment, and a first coupling segment and a second coupling segment embedded in the stator core, and the bridging segment is coupled between the first coupling segment and the second coupling segment. An extension dimension of the first coupling segment of the inner flat wire conductor and an extension dimension of the second coupling segment of an adjacent inner flat wire conductor have an axial length difference in an axial direction of the stator core, so that an overlapped part of two adjacent inner flat wire conductors form staggered approach avoidance in the axial direction and reduce radial intrusion into the central hole.
Embodiments of the present disclosure will be described in detail below, examples of which are illustrated in the accompanying drawings. Embodiments described below by referring to the drawings are exemplary and are intended to explain the present disclosure, but not to be construed as limiting the present disclosure.
At present, in order to achieve a higher slot full rate, a winding of the motors is also evolving from round wires to flat wires. However, in the related art, PIN wires (flat wires) of the winding bridged in the same layer occupy an inner diameter space of a stator core, which may lead to the problem of making a motor rotor interfere and collide with the PIN wires when it is assembled to the inner space of the motor stator, reducing the assemblability.
As illustrated in
In
The motor according to embodiments of the present disclosure includes a stator.
The stator may have two end windings 2, and the two end windings 2 are respectively arranged at two ends of the stator core 1 in an axial direction.
During assembly, a part of the first coupling segment 222a and a part of the second coupling segment 222b may be embedded in the stator core 1, and the bridging segment 221 may substantially extend along the circumferential direction of the stator core 1, so that the first coupling segment 222a and the second coupling segment 222b may be bridged in the circumferential direction of the stator core 1.
In the axial direction of the stator core 1, a first extension dimension of the first coupling segment 222a extending to an outside of the stator core 1 and a second extension dimension of the second coupling segment 222b extending to the outside of the stator core 1 are different. For example, the first extension dimension may be larger than the second extension dimension, and in other embodiments, the first extension dimension may also be smaller than the second extension dimension.
Therefore, when all the inner flat wire conductors 22 are assembled on the stator core 1, the first coupling segment 222a and the second coupling segment 222b of an overlapped part 23 of two adjacent inner flat wire conductors 22 in the circumferential direction of the stator core 1 will form an axial length difference L. Specifically, as illustrated in
Due to the axial length difference L between the first coupling segment 222a and the second coupling segment 222b of the two inner flat wire conductors 22 at the overlapped part 23, the overlapped part 23 of the two inner flat wire conductors 22 will form a staggered approach avoidance in the axial direction, thus avoiding the situation that when the overlapped part 23 of the two inner flat wire conductors 22 are located at the same extension dimension in the axial direction and have the same extension size, it is easy to cause an overall dimension of the stator core 1 in the radial direction to be larger, thus reducing the intrusion into the central hole.
Secondly, the axial length difference may provide a deformation space in an up-and-down direction (axial direction) for bending deformation of the bridging segment 221, thus avoiding the situation that the bending deformation of the bridging segment 221 may only occur in the radial direction of the stator core 1, which easily causes the bridging segment 221 to intrude into the central hole 11 due to a large width dimension in the radial direction of the stator core 1. That is, the intrusion deformation of the bridging segment 221 into the central hole 11 may be converted into an axial deformation of the bridging segment 221 along the axial direction of the stator core 1, which further reduces the intrusion of the stator core 1 into the central hole 11. The motor of embodiments of the present disclosure improves the situation that the inner flat wire conductor 22 of the end winding 2 intrudes into the inner diameter space (i, e. central hole 11) of the stator core 1, avoids the situation that the rotor is easily interfered with the inner flat wire conductor 22 when it is assembled from the end of the stator core 1 into the central hole 11, facilitates the assembly of the rotor into the stator core, and improves the assemblability.
Within this range, the situation that the intrusion of the bridging segment 221 into the central hole 11 may be improved, and the axial length difference L may be limited within a reasonable range, thus ensuring the structural strength and stability of the three-dimensional inner flat wire conductor 22 and facilitating the molding of a three-dimensional shape of the inner flat wire conductor 22.
In some embodiments, the first coupling segment 222a is higher than the second coupling segment 222b, and two end faces of the stator core 1 may be provided with an insulating paper. The insulating paper has an extension dimension along the axial direction of the stator core 1, and the extension dimension of the second coupling segment 222b located outside the stator core 1 is identical to the extension dimension of the insulating paper at the end of the motor in the axial direction. Therefore, a better insulation protection effect may be achieved. In some embodiments, as illustrated in
In some embodiments, as illustrated in
As illustrated in
In some embodiments, as illustrated in
The extending directions of the first coupling segment 222a and the second coupling segment 222b may be arranged perpendicular to the end face of the stator core 1, and a part of the first coupling segment 222a and a part of the second coupling segment 222b are respectively embedded in different assembly slots 12. Furthermore, the embedded part of the first coupling segment 222a and the embedded part of the second coupling segment 222b may be located at a same slot depth in different assembly slots 12, so that the inner flat wire conductors 22 in the same layer may be bridged.
Sizes of the angle β and the angle γ are positively correlated with the number of assembly slots 12. That is, the more the number of assembly slots 12 in the stator core 1, the larger the angle β and the angle γ are. Specifically, when the number of assembly slots 12 increases, a corresponding central angle between two adjacent assembly slots 12 will be smaller, and spacing between two adjacent assembly slots 12 will be shortened accordingly. At this time, the increase of angle β and angle γ is beneficial to the arrangement of the bridging segment 221, which avoids the situation that the bridging segment 221 is not easy to bend within a small range, improving the machining adaptability.
In some embodiments, as illustrated in
Similarly, the second segment 221b is coupled to the second coupling segment 222b, and the size of the angle γ is positively correlated with the extension dimension of the second coupling segment 222b located outside the stator core 1. For example, when the extension dimension of the extension part of the second coupling segment 222b located outside the stator core 1 is large, the angle γ is also large.
In some embodiments, as illustrated in
It should be noted that since a joint of the first segment 221a and the second segment 221b forms a part of the overlapped part, and the part of the first segment 221a corresponding to the overlapped part 23 is easy to produce radial intrusion into the central hole 11, when assembling, the inner peripheral wall of the part of the first segment 221a corresponding to the overlapped part 23 may be constrained to a position which is flush with the hole wall of the central hole 11 or located outside of the hole wall of the central hole 11, to realize the overall constraint on the inner peripheral wall of the first segment 221a, thereby avoiding the radial intrusion of the first segment 221a into the central hole 11.
In some examples, the distance between the first segment 221a and the hole wall of the central hole 11 is not less than 0.4 mm.
In some embodiments, the sizes of the angle β and the angle γ are positively correlated with the width dimension M of the inner flat wire conductor 22. The larger the width dimension M, the less likely the inner flat wire conductor 22 is be bent and shaped. At this time, the angle β and the angle γ reduce the requirements for bending and shaping of the inner flat wire conductor 22 and reduce the machining difficulty.
In some embodiments, as illustrated in
In some embodiments, as illustrated in
In some embodiments, the angles formed between any two adjacent flat wire conductors 241 are all equal, thus ensuring the consistency of heat dissipation effect of each flat wire conductor 241.
A vehicle according to embodiments of the present disclosure will be described below.
The vehicle according to embodiments of the present disclosure includes a motor, and the motor may be the motor as described in any of the above embodiments. The vehicle is a new energy vehicle, specifically a car, a SUV, a truck or other vehicles.
The motor of embodiments of the present disclosure includes: a stator. The stator includes a stator core and an end winding. The stator core has a central hole configured for assembly of a rotor. The end winding is arranged at an end of the stator core, and the end winding includes an inner flat wire conductor adjacent to the central hole. The inner flat wire conductor includes a bridging segment, and a first coupling segment and a second coupling segment embedded in the stator core, and the bridging segment is coupled between the first coupling segment and the second coupling segment. An extension dimension of the first coupling segment of the inner flat wire conductor and an extension dimension of the second coupling segment of an adjacent inner flat wire conductor have an axial length difference in an axial direction of the stator core, so that an overlapped part of two adjacent inner flat wire conductors form staggered approach avoidance in the axial direction and reduce radial intrusion into the central hole.
In some embodiments, a ratio of the axial length difference L between a part of the first coupling segment located outside the stator core and a part of the second coupling segment located outside the stator core to a width dimension M of the inner flat wire conductor is 0.25 to 4.
In some embodiments, the first coupling segment is higher than the second coupling segment, and the axial length difference L is 3 mm to 5 mm.
In some embodiments, the bridging segment includes a first segment and a second segment, and the first segment and the second segment having opposite inclination directions; an extending direction of the first segment and an end face of the stator core form an angle β, and an extending direction of the second segment and the end face of the stator core form an angle γ, and the angle β and the angle γ are acute angles.
In some embodiments, the stator core is provided with a plurality of assembly slots arranged at intervals along a circumferential direction of the stator core, the first coupling segment and the second coupling segment are respectively embedded in different assembly slots, and sizes of the angle β and the angle γ are positively correlated with a number of the assembly slots.
In some embodiments, the first segment is coupled to the first coupling segment, and a size of the angle β is positively correlated with an extension dimension of the first coupling segment located outside the stator core; and/or, the second segment is coupled to the second coupling segment, and a size of the angle γ is positively correlated with an extension dimension of the second coupling segment located outside the stator core.
In some embodiments, the first segment and the second segment are arranged in a staggered manner in a radial direction of the stator core, a distance between the first segment and a hole wall of the central hole is smaller than a distance between the second segment and the hole wall of the central hole, and an inner peripheral wall of the first segment is flush with or located outside the hole wall of the central hole.
In some embodiments, the angle β and the angle γ are positively correlated with a width dimension M of the inner flat wire conductor.
In some embodiments, the end winding includes a plurality of conductor groups arranged at intervals along a circumferential direction of the stator core, and each conductor group includes a plurality of flat wire conductors arranged at intervals along a radial direction of the stator core, and a flat wire conductor located at an innermost side of a same conductor group is the inner flat wire conductor.
The vehicle of embodiments of the present disclosure includes a motor as described in any of the above embodiments.
In the description of the present disclosure, it should be understood that, the azimuth or positional relationship indicated by terms “center”, “length”, “width”, “up”, “down”, “left”, “right”, “vertical”, “horizontal”, “inside”, “outside”, “axial”, “radial” and “circumferential” is based on the azimuth or positional relationship illustrated in the attached drawings, which is only for the convenience of describing the present disclosure and simplifying the description, and does not indicate or imply that the device or element must have a specific orientation, be constructed and operated in a specific orientation, so it cannot be understood as a limitation of the present disclosure.
In addition, the terms “first” and “second” are only used for descriptive purposes, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of indicated technical features. Therefore, the features defined as “first” and “second” may explicitly or implicitly include at least one of these features. In the description of the present disclosure, “plural” means at least two, such as two, three, etc., unless otherwise specifically defined.
In the present disclosure, unless otherwise specified and limited, the terms “install”, “couple”, “connect” and “fix” should be broadly understood, for example, which may be fixed connected, detachable connected or integrated; which may be mechanically connected, electrically connected or communicated with each other; which may be directly connected or indirectly connected through an intermediary, and may be the internal connection of two elements or the interaction between two elements, unless otherwise specified. For those skilled in the art, the specific meanings of the above terms in the present disclosure may be understood according to specific situations.
In the present disclosure, unless otherwise specified and limited, the first feature “above” or “below” the second feature may be that the first and second features are in direct contact, or the first and second features are in indirect contact through an intermediary. Moreover, the first feature is “upon”, “above” and “on” the second feature, which may mean that the first feature is directly above or obliquely above the second feature, or just means that the horizontal height of the first feature is higher than the second feature. The first feature is “down”, “below” and “under” the second feature, which may mean that the first feature is directly or obliquely below the second feature, or just means that the horizontal height of the first feature is smaller than the second feature.
In the description of this specification, descriptions referring to the terms “an embodiment”, “some embodiments”, “an example”, “a specific example”, or “some examples” mean that specific features, structures, materials or characteristics described in connection with this embodiment or example are included in at least one embodiment or example of this disclosure. In this specification, the schematic expressions of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described may be combined in any one or more embodiments or examples in a suitable manner. In addition, those skilled in the art may combine and combine different embodiments or examples and features of different embodiments or examples described in this specification without contradicting each other.
Although the above-mentioned embodiments have been illustrated and described, it may be understood that the above-mentioned embodiments are exemplary and cannot be understood as limitations of the present disclosure, and changes, modifications, substitutions and variations made to the above-mentioned embodiments by those skilled in the art are within the protection scope of the present disclosure.
Number | Date | Country | Kind |
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202311413910.8 | Oct 2023 | CN | national |