Disclosure of utility model
The embodiment of the application provides a stator structure, an in-wheel motor and a vehicle, and aims to solve the problem that a coil winding mode of the existing stator structure is not beneficial to later wiring.
In order to achieve the above purpose, the technical scheme adopted by the embodiment of the application is as follows:
In a first aspect, an embodiment of the present application provides a stator structure, including a winding assembly, the winding assembly including at least one stator body and a coil, the stator body including two ends disposed opposite to each other and a peripheral portion connected to the two ends, the coil having a start end and a terminal end, the coil being wound around the peripheral portion in a thickness direction of the stator body to form a bundle, and the start end and the terminal end being exposed to an outermost layer of the bundle.
The embodiment of the application has the beneficial effects that: the application provides a stator structure, a winding assembly of which comprises at least one stator main body and a coil. When the coil is wound on the peripheral side part of the stator main body, the starting end and the tail end of the coil are exposed, so that the whole coil is wound in a binding mode and is sleeved on the peripheral side part along the thickness direction of the stator main body. Therefore, the starting end and the tail end of the coil after winding are positioned on the outermost layer of the binding, and wiring of subsequent procedures is facilitated.
In some embodiments, when the number of the stator bodies is an odd number, the start end and the end are located on two end sides of the same stator body, respectively;
Or the start end and the end are respectively positioned on the end part side of the stator main body at the start position and the end part side of the stator main body at the tail position, and the start end and the end are oppositely arranged along the thickness direction of the stator main body.
Through adopting above-mentioned technical scheme, when the quantity of stator main part is odd, the initial end and the end of this coil are relative setting, like this, can make the total positive pole wiring of each winding subassembly and total negative pole wiring be located the stator structure relative both sides, then, the positive pole and the negative pole wiring of the follow-up process and peripheral hardware power to and be applicable to the comparatively more service scenario of the number of stator structure.
In some embodiments, when the number of the stator bodies is an even number, the start end and the end are located on the end portion side of the stator body at the start position and the end portion side of the stator body at the end position, respectively, and the start end and the end are disposed on the same side in the thickness direction of the stator body.
Through adopting above-mentioned technical scheme, when the quantity of stator main part is even, the starting end and the end of this coil are homonymy setting, like this, can shorten the wiring route of post-process and peripheral hardware power to and be applicable to the less service scenario of the phase number of stator structure.
In some embodiments, the coil is a flat coil having a broad face that is wound in correspondence with the peripheral side portion.
Through adopting above-mentioned technical scheme, laminate the broad face of flat coil in the week lateral part and wind, can increase the laminating degree of flat coil and stator main part, simultaneously, flat coil's heat dispersion is good, fill factor is high to and can also reduce the axial length and the loss of coil.
In some embodiments, the number of winding assemblies is a plurality, each winding assembly encloses an annular structure, and the circumferential side of the stator body has a trapezoidal cross-sectional shape in a radial cross-sectional plane of the annular structure.
By adopting the technical scheme, the stator main body of each winding assembly is compacter in arrangement, so that a larger number of winding assemblies can be arranged and compacter in arrangement.
In some embodiments, the two ends of the stator body are disposed opposite each other in an axial direction of the annular structure, the stator body includes a plurality of sub-blocks disposed in a stacked manner in a radial direction of the annular structure, and a size of a cross-sectional profile of each of the sub-blocks increases in order from inside to outside in the radial direction of the annular structure.
Through adopting above-mentioned technical scheme, when the two tip of stator main part set up relatively along annular structure's axial, this stator structure is disk stator structure, is applicable to disk motor. Each sub-block of stator main part is stacked along the radial direction of annular structure and the size of the cross-sectional profile of each sub-block increases in proper order along the radial direction of annular structure from inside to outside, then, the vortex flow consumption of individual sub-block is less than the vortex flow consumption of monoblock stator main part, consequently, the vortex flow consumption of stator main part that each sub-block combination formed is also less.
In some embodiments, the stator structure further comprises a bracket for limiting each of the winding assemblies to form the annular structure, the stator structure further comprising an injection molding member, the bracket being connected to each of the winding assemblies by the injection molding member.
By adopting the technical scheme, the glue injection piece can fill the gap between each winding component and the bracket, so that the connection stability between each winding component and the bracket is further improved.
In some embodiments, the bracket comprises a first framework and a second framework which are oppositely arranged, and mounting holes for mounting the winding assemblies are formed in the first framework and the second framework.
Through adopting above-mentioned technical scheme, divide into relative first skeleton and the second skeleton that sets up with the support, be convenient for fix the winding subassembly to and, still accessible skeleton is last to set up the mounting hole, plays corresponding effect of just locating when realizing preinstallation winding subassembly.
In a second aspect, an embodiment of the present application further provides an in-wheel motor, including a rotor structure and the stator structure described above, where the rotor structure rotates around a shaft relative to the stator structure.
In a third aspect, an embodiment of the present application further provides a vehicle, including the hub motor described above.
It will be appreciated that the advantages of the second and third aspects may be found in the relevant description of the first aspect, and are not described here again.
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 and intended to explain the present utility model and should not be construed as limiting the utility model.
In the description of the present utility model, it should be understood that the terms "length," "width," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," and the like indicate orientations or positional relationships based on the orientation or positional relationships shown in the drawings, merely to facilitate describing the present utility model and simplify the description, and do not indicate or imply that the devices or elements referred to must have a specific orientation, be configured and operated in a specific orientation, and therefore should not be construed as limiting the present utility model.
Furthermore, the terms "first," "second," and the like, are used for descriptive purposes only and are not to be construed as indicating or implying a relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defining "a first" or "a second" may explicitly or implicitly include one or more such feature. In the description of the present utility model, the meaning of "a plurality" is two or more, unless explicitly defined otherwise.
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; can be mechanically or electrically connected; can be directly connected or indirectly connected through an intermediate medium, and can be communicated with the inside of two elements or the interaction relationship of the two elements. 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.
Referring to fig. 1 to 3, in a first aspect, a stator structure 100 is provided according to an embodiment of the present application, including a winding assembly 10. The winding assembly 10 includes at least one stator body 11 and a coil 12, the stator body 11 includes two end portions 11a disposed opposite to each other and a peripheral portion 11b connected to the two end portions 11a, the coil 12 has a start end 12a and a terminal end 12b, the coil 12 is wound around the peripheral portion 11b in a thickness direction of the stator body 11 to form a bundle, and the start end 12a and the terminal end 12b are exposed to an outermost layer of the bundle.
It will be appreciated that the stator body 11 is a carrier for winding the coils 12, and that the number of stator bodies 11 may be adjusted according to the use requirements. For example, the number of the stator main bodies 11 is one, and a complete coil 12 is wound on the current stator main body 11; or the number of the stator bodies 11 is two, a complete coil 12 is sequentially wound on the two stator bodies 11, and the like, the number of the stator bodies 11 is increased, the coils 12 also need to be wound on the corresponding stator bodies 11, and the coils 12 on the stator bodies 11 are always complete.
The end 11a of the stator body 11 is the end 11a of the stator body 11 that is designated for facing the rotor structure. When the rotor structure comprises magnets, the end 11a of the stator body 11 is adapted to the magnets of the rotor structure.
For example, when the stator body 11 is applied to a disc motor, the end portions 11a of the stator body 11 are end portions in the axial direction of the annular structure formed by enclosing the respective winding assemblies 10, and at this time, the number of the end portions 11a is two and symmetrically disposed, and at this time, the rotor structure may be selectively disposed on one or both of the end portions 11 a.
For example, when the stator body 11 is applied to a radial motor, the end portions 11a of the stator body 11 are an inner peripheral side and an outer peripheral side in a radial direction of an annular structure formed by enclosing the respective winding assemblies 10, and at this time, the two end portions 11a are arranged in concentric circles, and then the rotor structure may be optionally arranged to be sleeved in the annular structure, that is, on the inner peripheral side of the annular structure; the sleeve can also be arranged outside the annular structure, namely, on the outer peripheral side of the annular structure.
The peripheral side portion 11b of the stator body 11 designates a side wall of the stator body 11 for winding the coil 12.
The start end 12a and the end 12b of the coil 12 refer to two free ends of the coil 12, and are opposite ends of the coil 12 for electrically connecting with the positive and negative poles of an external power source.
The thickness direction of the stator body 11 is a direction designating one end 11a to the other end 11a of the sub-body 11.
The coil 12 is wound around the peripheral portion 11b in the thickness direction of the stator body 11 to form a bundle. The bundling means that the coil 12 is wound around the stator body 11, and the winding manner of the coil 12 is not limited, and may be that a layer is wound around the circumferential side 11b of the stator body 11, and then a second layer is wound until a plurality of layers are wound; alternatively, a plurality of layers may be wound around one region of the peripheral portion 11b of the stator body 11, and then the winding may be continued until the adjacent region continues to be wound around the same number of layers until the entire peripheral portion 11b is covered by the winding.
The outermost layer of the bundle refers to the outer surface of the bundle formed after the coil 12 is completed.
The fact that the start end 12a and the end 12b are exposed to the outermost layer of the bundle means that the start end 12a and the end 12b of the coil 12 are always located at the outermost layer of the bundle. It should be noted that, since the coil 12 has a plurality of layers in the bundling winding, it is ensured that the end 12b is always the outermost layer of the bundling in the case of the naturally sequential layer-by-layer winding, and thus, the starting end 12a is mainly the outermost layer of the bundling.
Then, before winding the coil 12 around the stator body 11, the winding object having the same shape and structure as the stator body 11 is used as a pre-winding carrier, the coil 12 is wound one by one on the winding object under the premise that the starting end 12a and the end 12b of the coil 12 are always located at the outermost layer of the bundle, and after the winding is completed, the wound coil 12 is removed and sleeved on the corresponding stator body 11.
It should be noted that before the coil 12 is sleeved on the corresponding stator main body 11, the coil 12 may be entirely sleeved on the stator main body 11 after completing all winding; the coil 12 may be wound around the stator body only partially, and then the stator body 11 may be wound continuously.
Specifically, the winding method of the coil 12 is as follows: a die is selected, the outline of which is the same as that of the stator body 11, and the peripheral side portion of which has a larger size than the peripheral side portion 11b of the stator body 11, and the peripheral side portion of which is set to be equal to the wound outer size of the coil 12 on the stator body 11, so that the bundle after winding the coil 12 is more fitted to the peripheral side portion 11b of the stator body 11, and the bundle is also easily removed from the die and is fitted to the stator body 11.
Or the coil 12 is wound directly on the peripheral side portion 11b of the stator body 11, i.e., the start end 12a is located at the outermost layer of the wound layer such that the start end 12a is exposed, and then the remaining coils 12 continue to be wound on the peripheral side portion 11b of the stator body 11.
Or the coil 12 is "air wound", that is, the start end 12a is located at the outermost layer of the winding layer, the remaining coils are layered inward layer by layer, then the coil 12 after the current winding is sleeved on the peripheral side 11b of the stator body 11, and then the remaining coils 12 continue to be wound on the peripheral side 11b of the stator body 11.
The above winding methods of the coils 12 may be performed only on the first winding or the first stator body 11, and the other winding 12 may be performed normally from inside to outside, or may be performed continuously from outside to inside to wind the subsequent stator body 11.
The present application provides a stator structure 100, the winding assembly 10 of which comprises at least one stator body 11 and a coil 12. When winding around the peripheral portion 11b of the stator body 11, the coil 12 should be formed by exposing the starting end 12a and the final end 12b, so that the entire coil 12 is wound in a bundle and is fitted around the peripheral portion 11b in the thickness direction of the stator body 11. Thus, the start end 12a and the end 12b of the coil 12 after winding are positioned on the outermost layer of the binding, so that the wiring of the subsequent process is facilitated.
In some embodiments, when the number of the stator bodies 11 is odd, the start end 12a and the end 12b are located on the two end 11a sides of the same stator body 11, respectively;
Or the start end 12a and the end 12b are located on the side of the end 11a of the stator body 11 at the start position and the side of the end 11a of the stator body 11 at the end position, respectively, and the start end 12a and the end 12b are disposed opposite to each other in the thickness direction of the stator body 11.
It will be appreciated that the number of stator bodies 11 is an odd number, and that the number of stator bodies 11 of the present winding assembly 10 may be one, three, five, etc., and that the coils 12 may be wound one by one on the corresponding stator bodies 11.
For example, when the number of the stator bodies 11 is one, the start end 12a of the coil 12 is located at one of the end portions 11a of the stator body 11, and after the completion of winding, the end 12b of the coil 12 is located at the other end portion 11a of the stator body 11.
For example, when the number of the stator bodies 11 is three, the start end 12a of the coil 12 is located at one of the end portions 11a of the stator body 11 of the first position, and after the current winding of the stator body 11 is completed, the end 12b of the coil 12 is located at the other end portion 11a of the stator body 11 of the first position, and for convenience of understanding, it is defined that the coil 12 is wound one by one from the front end portion 11a to the rear end portion 11a of the stator body 11 of the first position; then, for the stator body 11 of the second position, the coils 12 are wound one by one from the rear end 11a to the front end 11a of the stator body 11 of the second position; and, for the stator body 11 of the third position, the coils 12 are wound one by one from the front end 11a to the rear end 11a of the stator body 11 of the third position; finally, the start end 12a of the coil 12 is located at the front end 11a of the stator body 11 at the first position, and the end 12b of the coil 12 is located at the rear end 11a of the stator body 11 at the third position.
Thus, when the number of the stator main bodies 11 is odd, the start ends 12a and the end ends 12b of the coils 12 are located at opposite sides of the stator main bodies 11 in the thickness direction, so that the total positive terminals and the total negative terminals of the winding assemblies 10 are located at opposite sides of the stator structure 100, and the subsequent process is convenient to connect with the positive and negative terminals of the external power source, and the stator structure 100 is suitable for use in a relatively large number of usage scenarios.
In some embodiments, when the number of the stator bodies 11 is even, the start end 12a and the end 12b are located on the side of the end 11a of the stator body 11 at the start position and the side of the end 11a of the stator body 11 at the end position, respectively, and the start end 12a and the end 12b are disposed on the same side in the thickness direction of the stator body 11.
It will be appreciated that the number of stator bodies 11 is even, and that the number of stator bodies 11 of the present winding assembly 10 may be two, four, six, or the like, and that the coils 12 may be wound one by one on the corresponding stator bodies 11.
For example, when the number of the stator bodies 11 is two, the start end 12a of the coil 12 is located at one of the end portions 11a of the stator body 11 of the first position, and after the current winding of the stator body 11 is completed, the end 12b of the coil 12 is located at the other end portion 11a of the stator body 11 of the first position, and for convenience of understanding, it is defined that the coil 12 is wound one by one from the front end portion 11a to the rear end portion 11a of the stator body 11 of the first position; then, for the stator body 11 of the second position, the coils 12 are wound one by one from the rear end 11a to the front end 11a of the stator body 11 of the second position; finally, the start end 12a of the coil 12 is located at the front end 11a of the stator body 11 of the first position, and the end 12b of the coil 12 is located at the front end 11a of the stator body 11 of the second position.
Thus, when the number of the stator main bodies 11 is even, the start end 12a and the end 12b of the coil 12 are disposed on the same side, that is, the start end 12a and the end 12b of the coil 12 are disposed on the same side of the stator main body 11 in the thickness direction, so that the total positive terminal and the total negative terminal of each winding assembly 10 are disposed on the same side of the stator structure 100, which shortens the wiring path between the subsequent process and the external power source, and is suitable for use in a use scenario with a smaller number of phases of the stator structure 100.
Referring to fig. 4, in some embodiments, the coil 12 is a flat coil 12, the flat coil 12 has a wide surface 12c, and the wide surface 12c of the flat coil 12 is wound corresponding to the peripheral portion 11 b.
It will be appreciated that the cross section of the flat coil 12 is rectangular or approximately rectangular, the broad face 12c of the flat coil 12 then corresponds to the long side of the rectangular cross section, and that the broad face 12c of the flat coil 12 is always facing the peripheral side 11b or the broad face 12c of the flat coil 12 that has been wound during winding.
Here, the flat coil 12 has a larger surface area than the circular coil, is more advantageous for heat dissipation, and the filling factor of the flat coil 12 (the proportion of the coil 12 occupying the slot area of the mounting slot of the stator body 11) is generally higher than that of the circular coil, that is, the flat coil 12 can accommodate more turns at the same mounting slot size to improve the electrical performance of the stator coil 12; meanwhile, the cross-sectional area of the flat coil 12 is larger, so that the axial length of the coil 12 can be reduced to a certain extent, and the coil is particularly suitable for a scene with limited size of the peripheral side part 11b of the stator main body 11; furthermore, the flat coil 12 has a relatively large cross-sectional area, and the ac resistance of the coil 12 can be reduced to reduce winding losses.
In this way, the flat coil 12 is wound with the wide surface 12c thereof being bonded to the peripheral portion 11b, so that the bonding degree between the flat coil 12 and the stator body 11 can be increased, the flat coil 12 can be provided with a good heat radiation performance and a high filling factor, and the axial length and loss of the coil 12 can be reduced.
Referring to fig. 1, in some embodiments, the number of winding assemblies 10 is plural, each winding assembly 10 encloses an annular structure, and a cross-sectional shape of a peripheral side portion 11b of the stator body 11 in a radial cross-sectional plane of the annular structure is trapezoidal.
It will be appreciated that the number of winding assemblies 10 may be plural, and each winding assembly 10 encloses a ring structure corresponding to the rotor structure and driving the rotor structure to rotate around the shaft.
Since the inner diameter and the outer diameter of the annular structure are correspondingly different, the sectional shape of the peripheral portion 11b of each stator body 11 is trapezoidal, so that the entire annular structure can be arranged more closely.
In this way, the stator body 11 of each winding assembly 10 is arranged more compactly, so that a greater number of winding assemblies 10 can be provided and arranged more compactly.
Referring to fig. 5, in some embodiments, both end portions 11a of the stator body 11 are disposed opposite to each other in an axial direction of the annular structure, the stator body 11 includes a plurality of sub-blocks 111 stacked in a radial direction of the annular structure, and a size of a cross-sectional profile of each sub-block 111 increases sequentially from inside to outside in the radial direction of the annular structure.
As can be appreciated, the stator structure 100 is a disc-type stator structure suitable for a disc-type motor when both end portions 11a of the stator body 11 are disposed opposite to each other in the axial direction of the ring-shaped structure. The stator body 11 includes a plurality of sub-blocks 111 arranged in a stacked manner in the radial direction of the annular structure, and then the cross-sectional intercepting direction of each sub-block 111 is perpendicular to the axial direction of the annular structure, and thus the size of the cross-sectional profile of each sub-block 111 increases in order from inside to outside in the radial direction of the annular structure.
Meanwhile, the thickness of each sub-block 111 can be adjusted according to the actual use requirement. For example, the thickness of each sub-block 111 may be the same; or any one or several of the sub-blocks 111 may have a thickness greater than or less than the thickness of the other sub-blocks 111; or the thickness of each sub-block 111 is incrementally arranged, decrementally arranged, etc. in the radial direction of the annular structure.
Meanwhile, the eddy current consumption of the individual sub-blocks 111 is smaller than that of the whole stator body, and thus, the eddy current consumption of the stator body 11 formed by combining the sub-blocks 111 is also smaller.
Referring to fig. 6, in some embodiments, the stator structure 100 further includes a bracket 20, the bracket 20 is used to limit each winding assembly 10 to form a ring structure, the stator structure 100 further includes a glue injection member 30, and the bracket 20 is connected to each winding assembly 10 through the glue injection member 30.
It should be understood that the bracket 20 is used to fix each winding assembly 10, and the specific structural form of the bracket 20 is not limited herein, so long as each winding assembly 10 can be fixed and limited.
Illustratively, as shown in fig. 6, the bracket 20 includes a first frame 21 and a second frame 22 disposed opposite to each other, and mounting holes for mounting the winding assemblies 10 are provided on each of the first frame 21 and the second frame 22, that is, each winding assembly 10 is restrained and fixed by the clamping action of the first frame 21 and the second frame 22.
As can be appreciated, when the stator body 11 is applied to a disc motor, the first and second bobbins 21 and 22 may be oppositely disposed in the axial direction of the ring structure; when the stator body 11 is applied to a radial motor, the first and second bobbins 21 and 22 may be disposed opposite to each other in a radial direction of the ring structure, i.e., the first and second bobbins 21 and 22 are disposed in concentric circles at this time.
The glue injection member 30 is fluid, i.e. has a certain fluidity, for example, it may be resin, glue, etc. before the winding assemblies 10 are not fixed, and after a period of time of covering the winding assemblies 10, the fluid starts to cure to connect the winding assemblies 10 with a space or gap into a whole for fixing connection.
Illustratively, the glue injection 30 is an epoxy resin, and its fixing process is as follows: after the bracket 20 pre-fixes the winding assemblies 10, the glue injection member 30 fills and connects the gaps between the bracket 20 and the winding assemblies 10, and also fills and connects the spaces or gaps between the winding assemblies 10.
The glue injection member 30 may also be a glue.
The winding assemblies 10 are fixed in a glue injection mode, the space or the gap between the winding assemblies 10 can be filled to improve the overall connection stability of the stator structure 100, moreover, the thickness of glue injection can be adaptively adjusted to enable the overall volume of the stator structure 100 to be smaller, the glue injection piece 30 also plays a certain role in protecting the winding assemblies 10, risks caused by the fact that the winding assemblies 10 are exposed out of the stator main body 11 or the coil 12 can be reduced, and the safety of the stator structure 100 in the use process is further improved.
In this way, the glue injection member 30 can fill the gap between each winding assembly 10 and the bracket 20, thereby further improving the connection stability between each winding assembly 10 and the bracket 20.
In a second aspect, an embodiment of the present application further provides an in-wheel motor, including a rotor structure and the stator structure 100 described above, where the rotor structure rotates around a shaft relative to the stator structure 100.
In a third aspect, an embodiment of the present application further provides a vehicle, including the above-mentioned in-wheel motor.
It will be appreciated that the advantages of the second and third aspects may be found in the relevant description of the first aspect, and are not described here again.
The foregoing description of the preferred embodiments of the utility model is not intended to be limiting, but rather is intended to cover all modifications, equivalents, and alternatives falling within the spirit and principles of the utility model.