CN221305593U - Flat wire stator and motor - Google Patents

Abstract

The utility model provides a flat wire stator and a motor. The flat wire stator includes: the inner wall of the outer ring is provided with a plurality of outer ring connecting parts which are circumferentially distributed; the outer periphery of the inner ring is provided with a plurality of inner ring tooth parts which are distributed along the circumferential direction, the space between the adjacent inner ring tooth parts forms an inner ring groove part, the outer side surface of the inner ring tooth part is provided with an inner ring connecting part, and the inner ring connecting part is used for being fixedly connected with the outer ring connecting part; a flat wire continuous wave winding is mounted in the inner ring slot. According to the utility model, the auxiliary coil inserting tool in the prior art is replaced by the inner ring, so that the investment of the tool mold is reduced, and the step of pushing the winding into the iron core is reduced, therefore, the winding copper wire is not scratched, and the assembling step of the flat wire stator is simpler and more convenient.

Description

Flat wire stator and motor

Technical Field

The utility model relates to the technical field of motors, in particular to a flat wire stator and a motor.

Background

With the technical progress of electric vehicles, the power density of the electric vehicle is also improved, and an electric drive system is required to be efficient, lightweight and low in cost, so that the flat wire motor is more widely applied due to higher power density.

The flat wire motor comprises a rotor and a flat wire stator, wherein the flat wire stator comprises an iron core and a flat wire winding. The winding manner of the flat wire winding has an influence on the manufacturing process and performance of the flat wire motor. The existing flat wire winding forms comprise a hairpin winding and a continuous wave winding. In the manufacturing process of the flat wire stator with the continuous wave winding, the flat wire continuous wave winding needs to be woven into the stator core, but cannot be directly woven into the stator core. In actual production, an auxiliary wire inserting tool is needed to be utilized, the inner ring of the auxiliary wire inserting tool is provided with a sliding block which can be radial, and the outer ring of the auxiliary wire inserting tool is close to the outer diameter of the rotor. When the flat wire stator is used, the flat wire continuous wave winding is wound into the auxiliary wire inserting tool, then the auxiliary wire inserting tool is placed into the inner hole of the iron core, the sliding block is pushed to push the flat wire continuous wave winding into the stator iron core groove, and the auxiliary wire inserting tool is taken out, so that the assembly of the flat wire stator is completed.

In carrying out the utility model, the inventors have found that at least the following problems exist in the prior art: the auxiliary wire inserting tool is needed to be used for installing the flat wire continuous wave winding, the installation time is long, and when the flat wire stator is assembled by using the existing auxiliary wire inserting tool, the winding copper wire is easily scratched by the iron core groove when the flat wire continuous wave winding is pushed into the iron core in the radial direction.

Disclosure of utility model

The present utility model aims to solve at least one of the technical problems in the related art to a certain extent.

The utility model aims to provide a flat wire stator, a motor and a manufacturing method of the flat wire stator, and solves the problems that the installation time of a flat wire continuous wave winding is long and the flat wire continuous wave winding is easily scratched by an iron core slot.

To achieve the above object, a first aspect of the present utility model provides a flat wire stator, comprising:

the inner wall of the outer ring is provided with a plurality of outer ring connecting parts which are circumferentially distributed;

The inner ring is provided with a plurality of inner ring tooth parts circumferentially arranged at the periphery, the space between the adjacent inner ring tooth parts forms an inner ring groove part, the outer side surface of the inner ring tooth part is provided with an inner ring connecting part, and the inner ring connecting part is used for being fixedly connected with the outer ring connecting part;

And the flat wire continuous wave winding is arranged in the inner ring groove part.

According to the flat wire stator, the flat wire stator is manufactured into the inner ring and the outer ring, the flat wire continuous wave winding is wound on the inner ring, and the inner ring and the outer ring are fixedly connected, so that the flat wire stator can be assembled, the operation steps are simple and convenient, and the installation time is short. According to the utility model, the auxiliary coil inserting tool in the prior art is replaced by the inner ring, so that the investment of the tool mold is reduced, and the step of pushing the winding into the iron core is reduced, and therefore, the winding copper wire cannot be scratched.

According to one embodiment of the utility model, the inner ring connecting portion is adapted to the outer shape of the outer ring connecting portion to form an interference fit.

According to one embodiment of the utility model, the inner ring connecting portion is a gear shaping and the outer ring connecting portion is a groove.

According to one embodiment of the present utility model, the spline-fit cross-sectional shapes of the inner ring connecting portion and the outer ring connecting portion are each semicircular, triangular or quadrangular.

According to one embodiment of the utility model, the width of the inner ring teeth increases gradually radially outwards.

According to one embodiment of the present utility model, the cross-sectional shape of the inner ring groove portion is rectangular.

According to one embodiment of the utility model, the width of the inner ring connection portion is smaller than the minimum width of the inner ring groove portion.

A second aspect of the present utility model proposes an electric machine comprising a flat wire stator according to the first aspect and a rotor arranged in an inner bore of the flat wire stator.

The third aspect of the present utility model provides a method for manufacturing a flat wire stator, including:

processing an outer ring, wherein the inner wall of the outer ring is provided with a plurality of outer ring connecting parts which are distributed along the circumferential direction;

Processing an inner ring, wherein the periphery of the inner ring is provided with a plurality of inner ring tooth parts distributed along the circumferential direction, the space between adjacent inner ring tooth parts forms an inner ring groove part, and the outer side surface of the inner ring tooth part is provided with an inner ring connecting part;

braiding a flat wire continuous wave winding in the inner ring groove part;

And heating the outer ring, pressing the outer ring into the inner ring, wherein the outer ring connecting part and the inner ring connecting part are fixed in an interference fit manner.

According to the manufacturing method of the flat wire stator, the flat wire stator is manufactured into the inner ring and the outer ring, the inner ring and the outer ring are respectively processed, the flat wire continuous wave winding is wound on the groove part of the inner ring, and then the inner ring and the outer ring are fixedly connected, so that the flat wire stator can be assembled, the operation steps are simple and convenient, and the installation time is short. According to the utility model, the auxiliary coil inserting tool in the prior art is replaced by the inner ring, so that the investment of the tool mold is reduced, and the step of pushing the winding into the iron core is reduced, and therefore, the winding copper wire cannot be scratched.

According to one embodiment of the utility model, before the flat wire continuous wave winding is woven in the inner ring groove part, the method further comprises sleeving an insulating paper groove in the inner ring groove part.

Additional aspects and advantages of the utility model will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the utility model.

Drawings

Various other advantages and benefits will become apparent to those of ordinary skill in the art upon reading the following detailed description of the preferred embodiments. The drawings are only for purposes of illustrating the preferred embodiments and are not to be construed as limiting the utility model. Also, like reference numerals are used to designate like parts throughout the figures. Wherein:

Fig. 1 is a schematic structural view of a flat wire continuous wave winding.

Fig. 2 is a plan-view expanded schematic of a single coil of a flat wire continuous wave winding.

Fig. 3 is a schematic structural view of an iron core of a flat wire stator according to an embodiment of the present utility model.

Fig. 4 is a schematic structural view of an inner ring of an iron core of a flat wire stator according to an embodiment of the present utility model.

Fig. 5 is a schematic structural view of an outer ring of an iron core of a flat wire stator according to an embodiment of the present utility model.

Fig. 6 is a schematic view of an embodiment of the present utility model involving braiding of a flat wire continuous wave winding on an inner coil.

Fig. 7 is a schematic structural view of a flat wire stator according to an embodiment of the present utility model.

Fig. 8 is a flowchart of a method for manufacturing a flat wire stator according to an embodiment of the utility model.

Reference numerals illustrate:

The flat wire continuous wave winding comprises a 1-flat wire continuous wave winding, a 2-outer ring, a 3-inner ring, an 11-continuous wave wire, a 21-yoke part, a 22-outer ring connecting part, a 23-outer ring tooth part, a 31-inner cylinder, a 32-inner ring tooth part, a 33-inner ring connecting part and a 34-inner ring groove part.

Detailed Description

Embodiments of the present utility model are described in detail below, examples of which are illustrated in the accompanying drawings, wherein like or similar reference numerals refer to like or similar elements or elements having like or similar functions throughout. The embodiments described below by referring to the drawings are illustrative only and are not to be construed as limiting the utility model. On the contrary, the embodiments of the utility model include all alternatives, modifications and equivalents as may be included within the spirit and scope of the appended claims.

As shown in fig. 1 to 7, a first aspect of an embodiment of the present utility model proposes a flat wire motor including a flat wire continuous wave winding 1, an outer ring 2, and an inner ring 3.

The inner wall of the outer ring 2 is provided with a plurality of outer ring connecting parts 22 which are distributed along the circumferential direction, the outer ring 2 can be made by bonding silicon steel sheet lamination, the two ends of the outer ring connecting parts 22 in the axial direction are flush with the two ends of the outer ring 2 in the axial direction, and the outermost part of the outer ring 2 is a yoke part 21. The outer periphery of the inner ring 3 is provided with a plurality of inner ring teeth 32 arranged in the circumferential direction. The inner ring 3 may be made of laminated sheets of silicon steel. The space between adjacent inner ring teeth 32 forms an inner ring groove 34. An inner ring connecting portion 33 is arranged on the outer side face of the inner ring tooth portion 32, and the inner ring connecting portion 33 is used for being fixedly connected with the outer ring connecting portion 22. Both ends of the inner ring tooth portion 32 and the inner ring connecting portion 33 in the axial direction are flush with both ends of the inner ring 3 in the axial direction. The innermost part of the inner ring 3 is an inner cylinder 31, the inner cylinder 31 needs to be made thinner and lighter, and the influence on the magnetic flux generated by the flat wire continuous wave winding 1 is reduced.

The flat wire continuous wave winding 1 is mounted in the inner ring groove 34. The flat wire continuous wave winding 1 comprises a plurality of continuous wave wires 11. The continuous wave wires 11 are processed into a circular ring shape having a plurality of layers in the radial direction. The continuous wave wire 11 is mounted in the inner ring groove 34 in the same manner as the integral iron core in the prior art, and the specific method can refer to the prior art, and will not be described herein.

The inner ring teeth 32 are circumferentially equally spaced, and the number and period of the arrangement are designed according to actual needs, and are not particularly limited herein.

Alternatively, the lamination of the inner ring connecting portion 33 and the inner ring tooth portion 32 is integrally formed, having a high hardness and strength. When the inner ring connecting portion 33 and the outer ring connecting portion 22 are connected, adjacent faces are in contact with each other without leaving a gap, forming a stable structure and reducing an unnecessary air gap.

According to the flat wire stator provided by the embodiment of the utility model, the flat wire stator is manufactured into the inner ring and the outer ring, the flat wire continuous wave winding is wound on the inner ring, and the inner ring and the outer ring are fixedly connected, so that the assembly of the flat wire stator can be completed, the operation steps are simple and convenient, and the installation time is short. According to the embodiment of the utility model, the inner ring is used for replacing an auxiliary coil inserting tool in the prior art, so that the investment of the tool and the die is reduced, and the step of pushing the winding into the iron core is reduced, and therefore, the winding copper wire cannot be scratched.

In some embodiments, the inner race connection portion 33 is adapted to the shape of the outer race connection portion 22, forming an interference fit. The interference fit utilizes outer lane connecting portion 22 to stretch into in the inner circle connecting portion 33 after being heated and enlarged, and after outer lane connecting portion 22 resumes normal atmospheric temperature, makes both close connection together, has higher bearing capacity, can bear impact vibration, has higher operational reliability.

In one example, the inner race connection 33 is a gear shaping and the outer race connection 22 is a groove. In specific implementation, the cross-sectional shapes of the tooth grooves of the inner ring connecting portion 33 and the outer ring connecting portion 22 may be semicircular, triangular or quadrilateral, or other shapes may be adopted. Preferably, the cross-sectional shape is quadrilateral and easy to process. The width of the inner race tooth portion 32 increases radially outwardly, and the cross-sectional shape of the inner race groove portion 34 is rectangular. At this time, the portion between the outer ring connecting portions 22 is the outer ring tooth portion 23, and the width of the outer ring tooth portion 23 is larger than the width of the inner ring groove portion 34. Because the winding wire is the flat wire, rectangular can be better hold the flat wire, promotes the groove full rate. The width of the inner ring connection portion 33 is smaller than the minimum width of the inner ring groove portion 34, so that the flat wire continuous wave winding 1 is conveniently wound.

Based on the same inventive concept, a second aspect of the embodiment of the present utility model provides an electric machine, which includes the flat wire stator of the first aspect and a rotor, wherein the rotor is disposed in an inner hole of the flat wire stator. The motor can be applied to vehicles such as electric vehicles, hybrid electric vehicles, extended range electric vehicles, plug-in hybrid electric vehicles and the like.

Referring to fig. 1 to 8, a third aspect of the embodiment of the present utility model provides a method for manufacturing a flat wire stator, including the following steps:

Step S102, machining the outer ring 2, wherein the inner wall of the outer ring 2 is provided with a plurality of outer ring connecting portions 22 arranged along the circumferential direction.

In this embodiment, the outer ring 2 is made of metal, optionally silicon steel. The outer ring 2 may be manufactured by conventional machining methods. The outer ring 2 is formed by bonding a plurality of lamination sheets. The outer ring connecting parts 22 are uniformly distributed, and the outer shape of the outer ring connecting parts 22 is designed according to actual needs.

Step S104, machining the inner ring 3, wherein the outer periphery of the inner ring 3 is provided with a plurality of inner ring teeth 32 arranged along the circumferential direction, the space between adjacent inner ring teeth 32 forms an inner ring groove 34, and the outer side surface of the inner ring teeth 32 is provided with an inner ring connecting portion 33.

In this embodiment, the inner ring 3 is made of metal, optionally silicon steel. The outer ring 2 may be manufactured by conventional machining methods. The inner ring 3 is also composed of a multi-layered laminate. It should be noted that, the innermost portion of the inner ring 3 is the inner cylinder 31, and the inner cylinder 31 needs to be made relatively thin and light, so each lamination of the inner ring 3 is glued, and welding cannot be adopted, so that deformation caused by welding is avoided.

Step S106, braiding the flat wire continuous wave winding 1 in the inner ring groove portion 34.

In the present embodiment, the flat wire continuous wave winding 1 is woven in the inner ring groove portion 34 in the same manner as the integral core in the related art. Alternatively, the flat wire continuous wave winding 1 includes 12 continuous wave wires 11, with each inner ring slot 34 accommodating 8 continuous wave wires 11.

Step S108, the outer ring 2 is heated, and the outer ring 2 is pressed into the inner ring 3, wherein the outer ring connecting part 22 and the inner ring connecting part 33 are fixed in an interference fit.

In the embodiment, during the crimping process, the inner ring 3 and the flat wire continuous wave winding 1 are fixed and kept still, and the outer ring 2 is pressed into the inner ring 3 by a press to form a flat wire stator.

According to the manufacturing method of the flat wire stator, the flat wire stator is manufactured into the inner ring and the outer ring, the inner ring and the outer ring are respectively processed, the flat wire continuous wave winding is wound on the groove part of the inner ring, and then the inner ring and the outer ring are fixedly connected, so that the flat wire stator can be assembled, the operation steps are simple and convenient, and the installation time is short. According to the embodiment of the utility model, the inner ring is used for replacing an auxiliary coil inserting tool in the prior art, so that the investment of the tool and the die is reduced, and the step of pushing the winding into the iron core is reduced, and therefore, the winding copper wire cannot be scratched.

In one embodiment, prior to step S106, step S105 is further included, where an insulation paper slot is nested in the inner ring slot 34.

In this embodiment, the insulating paper grooves function as insulation between the wires of the out-of-phase flat wire and between the wires and the core. The shape of the insulating paper groove is various, such as O-type and C-type.

It should be noted that in the description of the present utility model, the terms "first," "second," and the like are used for descriptive purposes only and are not to be construed as indicating or implying relative importance. Furthermore, in the description of the present utility model, unless otherwise indicated, the meaning of "a plurality" is two or more.

In the present utility model, unless explicitly specified and limited otherwise, the terms "mounted," "connected," "secured," and the like are to be construed broadly, and may be, for example, fixedly connected, detachably connected, or integrally formed; may be mechanically connected, may be electrically connected or may be in communication with each other; either directly or indirectly, through intermediaries, or both, may be in communication with each other or in interaction with each other, unless expressly defined otherwise. The specific meaning of the above terms in the present utility model can be understood by those of ordinary skill in the art according to the specific circumstances.

In the present utility model, unless expressly stated or limited otherwise, a first feature "up" or "down" a second feature may be the first and second features in direct contact, or the first and second features in indirect contact via an intervening medium. Moreover, a first feature being "above," "over" and "on" a second feature may be a first feature being directly above or obliquely above the second feature, or simply indicating that the first feature is level higher than the second feature. The first feature being "under", "below" and "beneath" the second feature may be the first feature being directly under or obliquely below the second feature, or simply indicating that the first feature is less level than the second feature.

In the description of the present utility model, the azimuth or positional relationship indicated by the terms "left", "right", "front", "rear", etc., are based on the azimuth or positional relationship shown in the drawings, are merely for convenience of description of the present utility model and to simplify the description, and do not indicate or imply that the apparatus or element referred to must have a specific azimuth, be constructed and operated in a specific azimuth, and thus should not be construed as limiting the present utility model.

Any process or method descriptions in flow charts or otherwise described herein may be understood as representing modules, segments, or portions of code which include one or more executable instructions for implementing specific logical functions or steps of the process, and further implementations are included within the scope of the preferred embodiment of the present utility model in which functions may be executed out of order from that shown or discussed, including substantially concurrently or in reverse order, depending on the functionality involved, as would be understood by those reasonably skilled in the art of the present utility model.

In the description of the present specification, a description referring to terms "one embodiment," "some embodiments," "examples," "specific examples," or "some examples," etc., means that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the present utility model. In this specification, schematic representations of the above terms do not necessarily refer to the same embodiments or examples. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.

While embodiments of the present utility model have been shown and described above, it will be understood that the above embodiments are illustrative and not to be construed as limiting the utility model, and that variations, modifications, alternatives and variations may be made to the above embodiments by one of ordinary skill in the art within the scope of the utility model.

Claims (8)

1. A flat wire stator, comprising:

The outer ring (2), the inner wall of the outer ring (2) is provided with a plurality of outer ring connecting parts (22) which are circumferentially distributed;

The inner ring (3), the periphery of the inner ring (3) is provided with a plurality of inner ring tooth parts (32) distributed along the circumferential direction, the space between the adjacent inner ring tooth parts (32) forms an inner ring groove part (34), the outer side surface of the inner ring tooth part (32) is provided with an inner ring connecting part (33), and the inner ring connecting part (33) is used for being fixedly connected with the outer ring connecting part (22);

And the flat wire continuous wave winding (1) is arranged in the inner ring groove part (34).

2. The flat wire stator according to claim 1, characterized in that the inner ring connection (33) is adapted to the outer ring connection (22) profile, forming an interference fit.

3. The flat wire stator according to claim 2, characterized in that the inner ring connection (33) is a gear shaping and the outer ring connection (22) is a groove.

4. A flat wire stator according to claim 3, characterized in that the cogging cross-section of the inner ring connection (33) and the outer ring connection (22) is semicircular, triangular or quadrilateral.

5. The flat wire stator according to claim 1, wherein the width of the inner ring teeth (32) increases gradually radially outwards.

6. The flat wire stator according to claim 1, wherein the cross-sectional shape of the inner ring groove portion (34) is rectangular.

7. The flat wire stator according to claim 5, characterized in that the width of the inner ring connection portion (33) is smaller than the minimum width of the inner ring groove portion (34).

8. An electric machine comprising the flat wire stator of any one of claims 1 to 7 and a rotor disposed in an inner bore of the flat wire stator.