WO2019062915A1 - 定子组件及其制备方法 - Google Patents

定子组件及其制备方法 Download PDF

Info

Publication number
WO2019062915A1
WO2019062915A1 PCT/CN2018/108641 CN2018108641W WO2019062915A1 WO 2019062915 A1 WO2019062915 A1 WO 2019062915A1 CN 2018108641 W CN2018108641 W CN 2018108641W WO 2019062915 A1 WO2019062915 A1 WO 2019062915A1
Authority
WO
WIPO (PCT)
Prior art keywords
phase
stator
slot
line
slots
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/CN2018/108641
Other languages
English (en)
French (fr)
Inventor
林焕炜
游斌
齐文明
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
BYD Co Ltd
Original Assignee
BYD Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by BYD Co Ltd filed Critical BYD Co Ltd
Publication of WO2019062915A1 publication Critical patent/WO2019062915A1/zh
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Images

Classifications

    • 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
    • H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/30—Manufacture of winding connections
    • H02K15/33—Connecting winding sections; Forming leads; Connecting leads to terminals

Definitions

  • the present disclosure relates to the field of electric machines, and in particular to a stator assembly suitable for a drive motor of a vehicle, a method of manufacturing the stator assembly, and a stator assembly obtained by the post-processing using the preparation method.
  • the one-way access and the two-way access respectively adopt different winding methods, and the number of roads is not adjustable, and it is difficult to match the requirements of different vehicle high-efficiency zones.
  • the present disclosure is intended to address at least one of the technical problems existing in the prior art. To this end, the present disclosure proposes a method of fabricating a stator assembly that is simple in construction, on the basis of which machining can be performed to obtain stator assemblies of different numbers of paths.
  • the present disclosure also proposes a stator assembly prepared using the above preparation method.
  • the stator assembly includes: a cylindrical stator core having a plurality of stator slots arranged in a circumferential direction of the stator core; a stator winding, the stator The winding includes a plurality of U-shaped conductor segments, each of the U-shaped conductor segments including a bent portion and a first in-slot portion and a second in-slot portion respectively connected to the bent portion, the U-shaped conductor segment
  • the first in-slot portion passes through one of the one of the stator slots
  • the second in-slot portion passes through one of the other slot slots
  • the inner portion of the slot passes through the stator slot
  • the preparation method comprises: connecting one of the outgoing lines of any phase to the different road star points of the phase.
  • the star point line and the lead line of each phase of each phase are different in the circumferential direction by 3q stator slots, and the multiplexed star point lines of any phase are in the circumferential direction.
  • the two phases are different from one stator slot, and the multiplexed leads of either phase are different from each other by one stator slot in the circumferential direction.
  • one of the outgoing lines of any phase differs from the different star-shaped dotted lines of the phase by 3q-1 stator slots in the circumferential direction.
  • Dividing the parallel branches in each phase into n groups, and the lead lines of one of the at least one group of the n groups are connected with the star point lines of the other of the groups, and the star point and the neutral line of one of the groups Connected, the other lead wire in the group is connected to the terminal block to form a stator assembly with a parallel branch number a 2n.
  • star point line and the lead line of each U phase are different from each other by 6 stator slots;
  • the two channels of each phase differ by one stator slot in the circumferential direction
  • star-point lines corresponding to the adjacent phases in the U phase, the V phase, and the W are different in the circumferential direction by 4 stator slots;
  • the lead lines corresponding to the adjacent phases in the U phase, the V phase, and the W phase are different in the circumferential direction by 4 stator slots;
  • the preparation method comprises: connecting a second way lead line of any phase to a first road star point line of the phase to form a stator assembly having a parallel branch number of 1.
  • star point line and the lead line of each U phase are different from each other by 9 stator slots;
  • the two phases of the U phase are different from each other in the circumferential direction by one stator slot;
  • the two phases of the V phase are separated by one stator slot in the circumferential direction;
  • the two phases of the W phase are separated by one stator slot in the circumferential direction;
  • the adjacent star-point lines in the U phase, the V phase, and the W phase are different in the circumferential direction by 6 stator slots;
  • the adjacent corresponding lead lines in the U phase, the V phase, and the W phase are different in the circumferential direction by 6 stator slots;
  • the preparation method includes: connecting a second way lead line of any phase to a first road star point line of the phase, and connecting a third way lead line of any phase to a second road star point line of the phase, A stator assembly having a number of parallel branches of one is formed.
  • the first in-slot portion and the second in-slot portion of the plurality of U-shaped conductor segments located in different layers are soldered on the soldering end to enable the The winding direction of the windings is configured to be in each phase of each phase:
  • first direction and the second direction are opposite directions on the circumference of the stator core.
  • the cross section of the U-shaped conductor segment perpendicular to the extending direction thereof is a rectangular shape.
  • the U-shaped conductor segments have equal cross-sectional areas in the extending direction of the U-shaped conductor segments.
  • the stator assembly according to the second aspect of the present disclosure is prepared using the method of preparing the stator assembly according to the above-described first aspect of the present disclosure.
  • FIG. 1 is a schematic view of a stator core in a stator assembly in accordance with an embodiment of the present disclosure
  • FIG. 2 is a schematic illustration of a U-shaped conductor segment in a stator assembly in accordance with an embodiment of the present disclosure
  • Figure 3 is a schematic view showing the welded connection between the U-shaped conductor segments shown in Figure 2;
  • FIG. 4 is a schematic view of a stator assembly as an initial arrangement according to an embodiment of the first aspect of the present disclosure, wherein an 8-pole 48-slot 3 phase is illustrated;
  • FIG. 5 is a schematic view showing the winding manner of the stator assembly of FIG. 4, wherein the U-phase 1 road is taken as an example;
  • Figure 6 is a final stator assembly of the stator assembly of Figure 4 after being processed to form a 2-way connection;
  • Figure 7 is a final stator assembly of the stator assembly of Figure 4 after being machined to form a 1-way connection.
  • Stator assembly 100 stator core 1, stator slot 11,
  • Stator winding 2 U-shaped conductor segment 20, bent portion 201, first in-slot portion 202, second in-slot portion 203,
  • U phase 1 road star point line U1A U phase 2 road star point line U2B;
  • V phase 1 road star point line V1A V phase 2 road star point line V2B;
  • W phase 1 way lead line W1A; W phase 2 way lead line W2A;
  • connection In the description of the present disclosure, it should be noted that the terms “installation”, “connected”, and “connected” are to be understood broadly, and may be fixed or detachable, for example, unless otherwise explicitly defined and defined. Connected, or integrally connected; can be mechanical or electrical; can be directly connected, or indirectly connected through an intermediate medium, can be the internal communication of the two components.
  • Connected, or integrally connected can be mechanical or electrical; can be directly connected, or indirectly connected through an intermediate medium, can be the internal communication of the two components.
  • the specific meanings of the above terms in the present disclosure can be understood in the specific circumstances by those skilled in the art.
  • the stator assembly includes: a cylindrical stator core and a stator winding, wherein the stator core has a plurality of stator slots arranged in a circumferential direction along the stator core;
  • the stator slot 11 has a plurality of slot layers therein. Specifically, after the stator windings are inserted into the stator slots 11, the stator slots have a plurality of layers formed by stator windings.
  • the slot layers include sequential arrangements. Each of the layers a, b, c, d, e, and f is a layer located in the innermost layer in the radial direction of the stator core 1 and a layer f in the outermost layer.
  • the stator winding includes a plurality of U-shaped conductor segments, each U-shaped conductor segment including a bent portion, a first in-slot portion and a second in-slot portion, the first in-slot portion and the second in-slot portion being respectively connected to the bent portion .
  • the first slot portion of the U-shaped conductor segment passes through one of the slot slots in one of the stator slots, and the second slot portion passes through one of the slot slots in the other stator slot, the first slot inner portion and the second slot portion After the inner portion passes through the stator slot, its end portion extends beyond the stator core to form a welded end, and the first slot inner portion of the plurality of U-shaped conductor segments located in the adjacent layer and the second slot inner portion are weldedly connected at the soldering end.
  • the preparation method comprises: connecting one of the outgoing lines of any phase to the different road star points of the phase.
  • the number of windings of the stator assembly can be adjusted, and the adjustment mode is simple and quick; and the vehicle requirements of different motor voltage levels can be matched, and the vehicle requirements of different high-efficiency zones can also be matched.
  • the star point line of each phase of each phase is located in the radially outer outer layer, and the lead line of each phase of each phase is located at the outermost radial direction;
  • the star point line and the lead line of each phase of each phase are different from each other by 3q stator slots in the circumferential direction, and the multi-way star point line of any phase differs by one stator slot in the circumferential direction, either phase
  • the multi-channel lead wires are separated by one stator slot in the circumferential direction.
  • one of the outgoing lines of any phase differs from the different star-shaped dotted lines of the phase by 3q-1 stator slots in the circumferential direction.
  • Dividing the parallel branches in each phase into n groups, and the lead lines of one of the at least one group of the n groups are connected with the star point lines of the other of the groups, and the star point and the neutral line of one of the groups Connected, the other lead wire in the group is connected to the terminal block to form a stator assembly with a parallel branch number a 2n.
  • the number of parallel branches is 2.
  • the star point line and the lead line of each U phase are different from each other by 6 stator slots; the two channels of each phase are different in the circumferential direction by one stator slot; the U phase, the V phase, and the adjacent phase in W correspond to each other.
  • the star-point line differs by four stator slots in the circumferential direction; the adjacent corresponding lead lines in the U-phase, V-phase, and W-phase are different in the circumferential direction by four stator slots.
  • the preparation method comprises: connecting a second way lead line of any phase to a first road star point line of the phase to form a stator assembly having a parallel branch number of 1.
  • the number of parallel branches is 3.
  • stator slots there are 9 stator slots between the star point line and the lead line of each U phase; the two phases of the U phase are different from each other in the circumferential direction by 1 stator slot; One stator slot is different in the upward direction; two stators in the W phase are different in the circumferential direction by one stator slot; the adjacent star-point lines in the U phase, V phase, and W phase are different in the circumferential direction by 6 stator slots.
  • the adjacent corresponding lead lines in the U phase, the V phase, and the W phase are different in the circumferential direction by 6 stator slots.
  • the preparation method includes: connecting a second way lead line of any phase to a first road star point line of the phase, and connecting a third way lead line of any phase to a second road star point line of the phase, A stator assembly having a number of parallel branches of one is formed.
  • the first in-slot portion and the second in-slot portion of the plurality of U-shaped conductor segments located in different layers are soldered on the soldering end to enable the The winding direction of the windings is configured to be in each phase of each phase:
  • first direction and the second direction are opposite directions on the circumference of the stator core.
  • the cross section of the U-shaped conductor segment perpendicular to its direction of extension is a rectangular shape. Thereby, the tank full rate can be improved.
  • the U-shaped conductor segments have equal cross-sectional areas in the direction of extension of the U-shaped conductor segments.
  • the stator assembly according to the second aspect of the present disclosure is prepared using the method of preparing the stator assembly according to the above-described first aspect of the present disclosure.
  • the number of windings can be adjusted, so that the vehicle requirements of different motor voltage levels can be matched, and the vehicles of different high-efficiency zones can also be matched. demand.
  • the number of roads can be adjusted to be different, so that the voltage difference between adjacent layers in each stator slot is different, the requirements for the layer insulation system are different, and thus different roads can be selected according to actual risks and cost control. Number plan.
  • stator assembly and a method of fabricating the same according to embodiments of the present disclosure are described below.
  • FIGS. 1-4 A stator assembly in accordance with an embodiment of the present disclosure may be described in accordance with FIGS. 1-4, which may be used as an initial stator assembly and machined to customer requirements to obtain a final stator assembly in a final form of different numbers of paths.
  • a stator assembly 100 includes a stator core 1 and a stator winding 2.
  • the stator core 1 has a plurality of stator slots 11, each of which has a plurality of slot layers
  • the stator winding 2 includes a plurality of U-shaped conductor segments 20.
  • each U-shaped conductor segment 20 includes a bent portion 201 and a first in-slot portion 202 and a second in-slot portion 203 that are respectively connected to the bent portion 201, and the first in-slot portion 202 Passing through one of the slot slots in one of the stator slots 11, the second in-slot portion 203 passes through one of the slot slots in the other stator slot 11, the first in-slot portion 202 and the second in-slot portion 203 passing through the stator After the groove 11, its end portion is beyond the stator core 1.
  • the cross section of the U-shaped conductor segment 20 perpendicular to its extending direction is a rectangular shape.
  • the U-shaped conductor segment 20 has a rectangular cross section, and the short side of the rectangle is perpendicular to the bottom wall of the stator slot 11. In the direction in which the U-shaped conductor segments 20 extend, the cross-sectional areas of the U-shaped conductor segments 20 are equal.
  • one end of the bent portion 201 in the plurality of U-shaped conductor segments 20 is the card-issuing end I of the stator winding 2, and the end of the end portion of the first in-slot portion 202 and the second in-slot portion 203 is called As the welding end II of the stator winding 2, as shown in Fig. 3, the welding end 2 is a first in-slot portion 202 of a plurality of U-shaped conductor segments 20 and a second in-slot portion of the U-shaped conductor segment 20 adjacent thereto. 203 is formed by welding in sequence.
  • welding end II, the star point line and the lead line of each phase of each phase are different in the circumferential direction by 3q stator slots 11, and the multiplex lines of any phase are different in the circumferential direction by one stator slot 11;
  • z is the number of stator slots
  • m is the number of phases
  • 2p is the number of poles.
  • the stator assembly 100 herein is suitable for a z-slot 2p-stage m-phase motor, where the number of slots z can be 24, 48, 72, etc., the number of phases m can be three-phase, two-phase or single-phase, and the pole-number p can It is 8-pole, 4-pole, etc. It can be set according to the specific motor.
  • phase difference refers to the difference between the two slots. For example, if the initial slot is 1, then the difference is 6 slots and then the 7th slot.
  • the distance between the lead wire and the star point line is the smallest, and can be used as the structure of the initial stator component, for example, the factory structure setting, and the number of winding parallel branches can be separately adjusted according to customer requirements. .
  • the stator assembly of the embodiment of the present disclosure can be processed to adjust it into a stator assembly having a parallel branch number of 1 channel, and then with the rotor, etc.
  • the components are assembled to obtain a motor that is connected all the way; accordingly, when two-way access is required, the stator assembly of the embodiment of the present disclosure is processed to adjust it to a stator assembly having two parallel branches.
  • the stator assembly according to an embodiment of the present disclosure is adjustable in the number of lines, so that the vehicle requirements of different motor voltage levels can be matched, and the vehicle requirements of different high efficiency areas can also be matched.
  • the number of roads can be adjusted to be different, so that the voltage difference between adjacent layers in each stator slot is different, the requirements for the layer insulation system are different, and thus different roads can be selected according to actual risks and cost control. Number plan.
  • the above-described winding coil structure may be wound by the following winding method:
  • the lead wire is led out to the radially outermost groove layer of the initial groove, the initial groove is the stator groove 11 which is inserted for the first time when the lead wire is ready to be wound;
  • terminal slot refers to the last stator slot that passes after the coil is wound.
  • first direction and the second direction are opposite directions on the circumference of the stator core.
  • the six-layer lines include layers a, b, c, d, e, and f which are sequentially arranged, in each of the stator slots 11 In the radial direction of the stator core 1, the inner layer is the a layer, and the outermost layer is the f layer.
  • the star point line and the lead line of each U phase are different from each other by 6 stator slots 11, and the two channels of each phase are different in the circumferential direction by one stator slot 11;
  • U phase The star-point lines corresponding to the adjacent phases in the V phase and the W are different in the circumferential direction by four stator slots 11;
  • the adjacent adjacent lead wires in the U phase, the V phase, and the W phase are different in the circumferential direction by four stator slots 11.
  • the U-phase 1 way lead line U1A and the U-phase 2 way lead line U2A differ by 1 stator slot, and the V-phase 1 way lead line V1A and V phase
  • the two-way lead-out line V2A differs by one stator slot; the W-phase one-way lead-out line W1A and the W-phase two-way lead-out line W2A differ by one stator slot.
  • the U-phase 1 way lead line U1A and the U-phase 1 way star point line U1B are different from each other by 6 stator slots, and the U-phase 2 way lead lines U2A and U-phase 2 way
  • the star-point line U2B differs by 6 stator slots; likewise, the two-way lead-out line V1A and the star-point line V1B, the lead-out line V2A, and the star-point line V2B are also different from each other by 6 stator slots; There are also six stator slots between the two-way lead line W1A and the star point line W1B, the lead line W2A, and the star point line W2B.
  • the adjacent star-point lines in the U-phase, V-phase, and W-phase are different from each other in the circumferential direction by four stator slots.
  • the U-phase 1-way star-point line U1B and V-phase 1 The star point line V1B of the road and the star point line W1B of the W phase 1 road are sequentially different by 4 slots in the circumferential direction.
  • U1B is taken out from the 07 slot e layer
  • V1B is taken out from the 03 slot e layer, W1B. It is taken out from the 47-slot e layer.
  • U2B, V2B, and W2B of the second path are taken out from the 08-slot e-layer, the 04-slot e-layer, and the 48-slot e-layer, respectively, with 4 stator slots in between.
  • the U-phase 1 lead line U1A, the V-phase 1 way lead line V1A, and the W-phase 1 way lead line W1A are sequentially different by four slots in the circumferential direction, for example, in FIG. 2
  • U1A is introduced from the 01-slot f layer
  • V1A is introduced from the 45-slot f-layer
  • W1A is introduced from the 41-slot f-layer
  • the U2A, V2A, and W2A of the second path are introduced from the 02-slot f-layer, the 46-slot f-layer, and the 42-slot-f layer, respectively, with 4 stator slots in between.
  • the winding coil structure can be wound by the following winding method. As shown in FIG. 5 and FIG. 6, taking the A-phase first road as an example, the winding line is as follows:
  • the winding circuit of the second phase of the A phase is different from the first phase of the A phase by one stator slot in the circumferential direction.
  • the adjacent star-point lines in the A phase, the B phase, and the C phase are different in the circumferential direction by 4 stator slots;
  • the adjacent corresponding lead lines in the A phase, the B phase, and the C phase are different in the circumferential direction by four stator slots.
  • each phase includes three paths (not shown), wherein the star points of each of the U phases
  • the difference between the line and the lead line is 9 stator slots 11, and the two sides of the U phase are different from each other by one stator slot 11 in the circumferential direction; the two sides of the V phase are different in the circumferential direction by one stator slot 11
  • the two phases of the W phase are different from each other in the circumferential direction by one stator slot 11, and the star-point lines corresponding to the U phase, the V phase, and the W are circumferentially different from each other by six stator slots 11, U phase, V phase, W
  • the corresponding lead wires are different in the circumferential direction by six stator slots 11.
  • the star point line of each phase of each phase is located in the radially outermost layer, and the lead line of each phase of each phase is located in the radial direction.
  • the outer layer is convenient for the introduction of the lead wire, the extraction of the star point line, and the structure of the entire stator winding is simple.
  • stator assembly 100 is suitable for use in a z-slot 2p-stage m-phase motor.
  • g When q is an odd number, g has 2 choices: q road and 1 road;
  • g When q is an even number, g has q/2+1 choices, q, q/2, q/4, ..., 1;
  • the star point lines of each of the m phases are outwardly bent and connected by the neutral line 3; the lead wires of each of the m phases are fixed by welding and interface with the external controller. Connected.
  • the material in the neutral line 3 herein may conform to the material of the U-shaped conductor segment 20.
  • U-phase 4th lead wire is stretched and then U-phase 3 way
  • the star-point line connection the U-phase 3-way lead-out line is stretched and connected to the U-phase 2-way star-point line
  • the U-phase 2-way lead-out line is stretched and then the U-phase 1 way star-point line Connection, the U-phase 1 way lead wire is fixed and connected to the external controller after welding; in addition, the U-phase 4 way star point line is connected by the first neutral line 3; the U-phase 3 way star point line passes the second neutral Line 3 is connected; the U-phase 2 way star point line is connected by the third neutral line 3.
  • the q channels in each phase are divided into q/2 groups, and the lead wires of one of the at least one group of the q/2 group are stretched and bent and fixed with the star line of the other road, one of which is fixed.
  • the star point lines are bent outward and connected by a neutral line 3, and the other line of leads is soldered and connected to an external controller interface.
  • the U phase in the 4 way is taken as an example. If you want to change it to the second way, you can do it by: 4 ways in the U phase are divided into 2 groups, and the 1st and 2nd roads are the first.
  • One group, the third road and the fourth road are the second group, wherein the lead line of the second road is welded and fixed to the star point line of the first road, and the star point line of the second road is connected with the neutral line 3, the first one The road is connected to the external controller.
  • the lead wire of the 4th road is welded and fixed to the star point line of the 3rd road, the star point line of the 4th road is connected with the neutral line 3, and the 3rd road is connected with the external controller.
  • the number of windings of the stator assembly is adjustable, and the adjustment mode is simple and quick; and the vehicle requirements of different motor voltage levels can be matched, and the vehicle requirements of different high-efficiency zones can also be matched.
  • the number of roads can be adjusted to be different, so that the voltage difference between adjacent layers in each stator slot is different, the requirements for the layer insulation system are different, and thus different roads can be selected according to actual risks and cost control. Number plan.
  • the connection by the neutral wire 3 is a welding.
  • the angle at which the star point line and the lead line are bent outward is 60-150 degrees.
  • the angle of the outward bend may be substantially 90 degrees. It is easy to weld and simple and convenient.
  • a two-way solution or a one-way solution can be selected based on its initial stator assembly 100.
  • the first road star lines U1B, V1B, W1B, and the second road star points U2B, V2B, and W2B of the U, V, and W phases are respectively bent outward and passed.
  • the center line 3 is welded and connected, as shown in Fig. 7, finally, the first lead wires U1A, V1A, W1A of the three phases of U, V, W, and the second lead wires U2A, V2A, W2A are welded and fixed by soldering terminals. Connected to an external controller interface.
  • the U2, V2, and W2A of the U, V, and W phases are stretched and bent, and the first road star line U1B of the three phases of U, V, and W, V1B and W1B are respectively welded and fixed, and the second star point lines U2B, V2B, and W2B are respectively bent outward, and are connected by welding through the center line 3.
  • the first lead wires U1A, V1A, and W1A of the U, V, and W phases are soldered and fixed by soldering terminals, and then connected to an external controller interface.
  • stator assembly 200 according to Embodiment 3 of the present disclosure will be described below, which is obtained by the processing means of the step S2 in the above-described manufacturing method, wherein the same components as those in the stator assembly 100 of the embodiment are given the same reference numerals.
  • the stator assembly includes a stator core 1 and a stator winding 2. As shown in FIG. 2, the stator core 1 has a plurality of stator slots 11 each having a plurality of slot layers therein.
  • the stator winding 2 includes a plurality of U-shaped conductor segments 20, each U-shaped conductor segment 20 including a bent portion 201 and a first in-slot portion 202 and a second in-slot portion 203 that are respectively connected to the bent portion 201, the first groove
  • the inner portion 202 passes through one of the slot slots in one of the stator slots 11, and the second in-slot portion 203 passes through one of the slot layers in the other stator slot 11, the first in-slot portion 202 and the second in-slot portion 203 After passing through the stator slot 11, the end thereof extends beyond the stator core 1.
  • the cross section of the U-shaped conductor segment 20 perpendicular to its extending direction is a rectangular shape.
  • the U-shaped conductor segment 20 has a rectangular cross section, and the short side of the rectangle is perpendicular to the bottom wall of the stator slot 11. In the direction in which the U-shaped conductor segments 20 extend, the cross-sectional areas of the U-shaped conductor segments 20 are equal.
  • one end of the bent portion 201 in the plurality of U-shaped conductor segments 20 is the card-issuing end I of the stator winding 2, and the end of the end portion of the first in-slot portion 202 and the second in-slot portion 203 is called As the welding end II of the stator winding 2, as shown in Fig. 3, the welding end 2 is a first in-slot portion 202 of a plurality of U-shaped conductor segments 20 and a second in-slot portion of the U-shaped conductor segment 20 adjacent thereto. 203 is formed by welding in sequence.
  • welding end II, the star point line and the lead line of each phase of each phase are different in the circumferential direction by 3q stator slots 11, and the multiplex lines of any phase are different in the circumferential direction by one stator slot 11;
  • the corresponding lead lines between the multiple phases are spatially different from each other by 2q stator slots 11;
  • the star point lines of each of the m phases are outwardly bent and connected by a neutral line 3; the lead wires of each of the m phases are soldered and fixed and connected to an external controller interface.
  • the material of the neutral wire 3 is identical to the material of the U-shaped conductor segment 20.
  • the neutral wire 3 is formed in an arc shape and is concentric with the stator core 1, thereby facilitating welding and a good joining effect.
  • the cross section of the neutral wire 3 may also be formed in a rectangular shape, and a cross section equal to the cross-sectional area of the U-shaped conductor segment 20 may also be employed.
  • the stator assembly when the stator assembly is applied to an 8-pole 48-slot 3-phase motor, that is, the number of stator slots is 48, the number of poles is 8, the number of phases is 3, and the U phase, the V phase, and the W phase are included.
  • an 8-pole 48-slot 3-phase 2-way stator assembly 200 is formed.
  • the stator assembly 200 bends the two-point star line of the U phase, the V phase, and the W phase outward, and is connected by the neutral wire 3; the U phase, the V phase After the two leads of the phase and W are soldered and fixed, they are connected to the external controller interface.
  • the two outgoing lines corresponding to the U phase, the V phase, and the W are fixed by welding end II.
  • stator assembly 300 according to Embodiment 4 of the present disclosure will be described below, which is obtained by the processing means of the step S3 in the above-described manufacturing method, wherein the same components as those in the stator assembly 100 of the first aspect embodiment are given the same reference numerals.
  • the stator assembly includes a stator core 1 and a stator winding 2. As shown in FIG. 2, the stator core 1 has a plurality of stator slots 11 each having a plurality of slot layers therein.
  • the stator winding 2 includes a plurality of U-shaped conductor segments 20, each U-shaped conductor segment 20 including a bent portion 201 and a first in-slot portion 202 and a second in-slot portion 203 that are respectively connected to the bent portion 201, the first groove
  • the inner portion 202 passes through one of the slot slots in one of the stator slots 11, and the second in-slot portion 203 passes through one of the slot layers in the other stator slot 11, the first in-slot portion 202 and the second in-slot portion 203 After passing through the stator slot 11, the end thereof extends beyond the stator core 1.
  • the cross section of the U-shaped conductor segment 20 perpendicular to its extending direction is a rectangular shape.
  • the U-shaped conductor segment 20 has a rectangular cross section, and the short side of the rectangle is perpendicular to the bottom wall of the stator slot 11. In the direction in which the U-shaped conductor segments 20 extend, the cross-sectional areas of the U-shaped conductor segments 20 are equal.
  • one end of the bent portion 201 in the plurality of U-shaped conductor segments 20 is the card-issuing end I of the stator winding 2, and the end of the end portion of the first in-slot portion 202 and the second in-slot portion 203 is called As the welding end II of the stator winding 2, as shown in Fig. 3, the welding end 2 is a first in-slot portion 202 of a plurality of U-shaped conductor segments 20 and a second in-slot portion of the U-shaped conductor segment 20 adjacent thereto. 203 is formed by welding in sequence.
  • the star point line and the lead line of each phase of each phase are different from each other by 3q stator slots 11 in the circumferential direction, and the multiplex lines of any one phase are different from each other by one stator slot 11 in the circumferential direction;
  • the corresponding lead lines between the multiple phases are spatially different from each other by 2q stator slots 11;
  • the lead line of the kth channel in each phase is sequentially welded and fixed to the star point line of the k-1th road in the corresponding phase, wherein k is a natural number of 2 to q; and the lead wire of the first channel in each phase is fixed after welding
  • the external controller interface is connected; the star point lines of the other roads except the first one in each phase are connected by the neutral line 3.
  • the lead line of the kth path in each phase is first bent outward, and then sequentially fixed to the star point line of the k-1th road in the corresponding phase.
  • star-point lines of the other roads except the first one in each phase are first bent outward and then connected through the neutral line 3.
  • the material of the neutral wire 3 is identical to the material of the U-shaped conductor segment 20.
  • the neutral wire 3 is formed in an arc shape and is concentric with the stator core 1, thereby facilitating welding and a good joining effect.
  • the cross section of the neutral wire 3 may also be formed in a rectangular shape, and a cross section equal to the cross-sectional area of the U-shaped conductor segment 20 may also be employed.
  • stator assembly 200 is elongated and bent by the second phase lead wires of the U phase, the V phase, and the W phase on the basis of the stator assembly 100 of the first embodiment, respectively, and is respectively U phase, V phase, and W phase.
  • the first road star line is welded and fixed, and the second road star line of the U phase, the V phase and the W phase is bent outward, and is connected by the neutral wire 3 welding; the first phase corresponding to the U phase, the V phase and the W phase After the lead wire is soldered and fixed, it is connected to the external controller interface.
  • the two outgoing lines corresponding to the U phase, the V phase, and the W are fixed by welding end II.
  • the number of parallel branches of the stator assembly 100 is four, if it is to be turned into one way, it can be performed by: the U-phase 4th lead wire is elongated and bent Connected with the U-phase 3 way star point line, the U-phase 3 way lead line is stretched and bent and connected with the U-phase 2 way star point line.
  • the U-phase 2 way lead line is stretched and bent and U-phase 1
  • the star point line of the road is connected, and the lead line of the U phase 1 road is fixed by welding to the external controller; in addition, the star line of the U phase 4 is connected by the first neutral line 3; the star line of the U phase 3 way Connected by the second neutral line 3; the star line of the U phase 2 is connected by the third neutral line 3.
  • stator assembly 400 according to the fifth embodiment of the present disclosure is described below, which is obtained by the processing means of the step S4 in the above-described manufacturing method, wherein the same components as those in the stator assembly 100 of the first aspect embodiment are given the same reference numerals.
  • the stator assembly includes a stator core 1 and a stator winding 2. As shown in FIG. 2, the stator core 1 has a plurality of stator slots 11 each having a plurality of slot layers therein.
  • the stator winding 2 includes a plurality of U-shaped conductor segments 20, each U-shaped conductor segment 20 including a bent portion 201 and a first in-slot portion 202 and a second in-slot portion 203 that are respectively connected to the bent portion 201, the first groove
  • the inner portion 202 passes through one of the slot slots in one of the stator slots 11, and the second in-slot portion 203 passes through one of the slot layers in the other stator slot 11, the first in-slot portion 202 and the second in-slot portion 203 After passing through the stator slot 11, the end thereof extends beyond the stator core 1.
  • one end of the bent portion 201 in the plurality of U-shaped conductor segments 20 is the card-issuing end I of the stator winding 2, and the end of the end portion of the first in-slot portion 202 and the second in-slot portion 203 is called As the welding end II of the stator winding 2, as shown in Fig. 3, the welding end 2 is a first in-slot portion 202 of a plurality of U-shaped conductor segments 20 and a second in-slot portion of the U-shaped conductor segment 20 adjacent thereto. 203 is formed by welding in sequence.
  • the star point line and the lead line of each phase are different in the circumferential direction by 3q stator slots 11, and the multiplex lines of any phase are different in the circumferential direction by one stator slot 11;
  • the corresponding lead lines between the multiple phases are spatially different from each other by 2q stator slots 11;
  • q channels in each phase are divided into q/2 groups, and at least one of the at least one group of the q/2 group is welded to the star line of the other road, and one of the star points passes through The sex line 3 is connected, and the other lead wire is soldered and fixed to be connected to an external controller interface.
  • the lead wires of one of the paths are first stretched and then soldered to the star line of the other road.
  • one of the star-point lines is bent outward and then connected through the neutral line 3.
  • the material of the neutral wire 3 is identical to the material of the U-shaped conductor segment 20.
  • the neutral wire 3 is formed in an arc shape and is concentric with the stator core 1, thereby facilitating welding and a good joining effect.
  • the cross section of the neutral wire 3 may also be formed in a rectangular shape, and a cross section equal to the cross-sectional area of the U-shaped conductor segment 20 may also be employed.
  • stator assembly When the stator assembly is applied to a 6-pole, 72-slot, 3-phase motor, that is, the number of stator slots is 72, the number of poles is 6, the number of phases is 3, and the U-phase, V-phase, and W-phase are included, and the number of paths is 4.
  • the four channels in each phase are divided into two groups, the first group includes the first road and the second road, and the second group includes the third road and the second Four roads, in which the lead wire in the second road is bent and fixed with the star point line of the first road, and the star line of the second road is bent outward and connected through the neutral line 3, the first road After the lead wire is welded and fixed, it is connected to the external controller interface; the lead wire in the fourth road is stretched and bent and fixed with the star point line of the third road, and the star line of the fourth road is bent outward and passes the neutral Line 3 is connected, and the lead wire of the third way is soldered and fixed to be connected to an external controller interface (not shown).
  • the stator assembly 200, 300 of the third, fourth, and fifth embodiments of the present disclosure can be obtained through different steps in the method of manufacturing the stator assembly according to the embodiment of the present disclosure. 400. That is to say, through the stator assembly and the preparation method thereof in the embodiments of the present disclosure, the number of steps of the stator assembly is adjustable, the adjustment mode is simple and quick, and the vehicle requirements of different motor voltage levels can be matched, and the efficiency can also be matched. The overall vehicle demand in the district. In addition, since the number of roads can be adjusted to be different, so that the voltage difference between adjacent layers in each stator slot is different, the requirements for the layer insulation system are different, and thus different roads can be selected according to actual risks and cost control. Number plan.

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Windings For Motors And Generators (AREA)

Abstract

一种定子组件及其制备方法，定子组件(100)的定子绕组(2)包括多个U形导体段(20)，每个U形导体段(20)的第一槽内部分(202)穿过其中一个定子槽(11)中的其中一个槽层，且第二槽内部分(203)穿过另一个定子槽(11)中的其中一个槽层；制备方法包括：将任一相的其中一路引出线与该相的不同路星点线连接。

Description

定子组件及其制备方法
相关申请的交叉引用
本公开基于申请号为201710912471.3，申请日为2017年9月29日的中国专利申请提出，并要求该中国专利申请的优先权，该中国专利申请的全部内容在此引入本公开作为参考。
技术领域
本公开涉及电机领域，尤其涉及一种适用于车辆的驱动电机的定子组件、定子组件的制备方法、以及采用所述制备方法后加工后得到的定子组件。
背景技术
相关技术中，车辆采用的驱动电机的绕组并联支路方面，一路接入和两路接入都分别采用不同的绕线方式，路数不可调，难以匹配不同整车高效区的需求。
发明内容
本公开旨在至少解决现有技术中存在的技术问题之一。为此，本公开提出一种结构简单的定子组件的制备方法，在其基础上可以进行加工以获得不同路数的定子组件。
本公开还提出一种使用上述制备方法进行制备的定子组件。
根据本公开第一方面的一种定子组件的制备方法，适用于z槽2p级m相的电机中，其每极每相槽数为q＝z/m/(2p)，并联支路数为a，a≤q，所述定子组件包括：圆筒形的定子铁芯，所述定子铁芯上具有沿所述定子铁芯的圆周方向间隔排列的多个定子槽；定子绕组，所述定子绕组包括多个U形导体段，每个所述U形导体段包括折弯部和分别连接至所述折弯部的第一槽内部分和第二槽内部分，所述U形导体段的第一槽内部分穿过其中一个定子槽中的其中一个槽层，所述第二槽内部分穿过另一个定子槽中的其中一个槽层，所述第一槽内部分和所述第二槽内部分穿过所述定子槽后其端部超出所述定子铁芯以形成焊接端，在所述焊接端上所述多个U形导体段的位于相邻层的所述第一槽内部分和所述第二槽内部分焊接连接，在所述焊接端上，任一相每一路的星点线位于径向上次外层，且任一相每一路的引出线位于径向上的最外层；
所述制备方法包括：将任一相的其中一路引出线与该相的不同路星点线连接。
根据本公开的一个实施例，在所述焊接端上，任一相每一路的星点线和引出线在周向上相差3q个定子槽，任一相的多路的星点线在周向上两两相差1个定子槽，任一相的多路的引出线在周向上两两相差1个定子槽。
根据本公开的一个实施例，任一相的其中一路引出线与该相的不同路星点线在周向上相差3q-1个定子槽。
根据本公开的一个实施例，当q为偶数时，定子组件的并联支路数为a＝2n或a＝1,其中n为1～q/2的自然数；
将每相中第k路的引出线依次与其该相中第k-1路的星点线连接，其中k为2～q的自然数，将每相中第1路的引出线与接线端子相连接；每相中第q路的星点线与中性线连接，形成并联支路数a＝1的定子组件；
将每相中并联支路划分为n组，所述n组的至少一组中其中一路的引出线与该组中另一路的星点线连接，该组其中一路的星点线与中性线连接，该组中另一路的引出线与接线端子相连接，形成并联支路数a＝2n的定子组件。
根据本公开的一个实施例，当q为奇数时，定子组件的并联支路数为a＝1或者a＝q，
将每相中第k路的引出线依次与其该相中第k-1路的星点线连接，其中k为2～q的自然数；将每相中第1路的引出线与接线端子相连接；每相中第q路的星点线与中性线连接,形成并联支路数a＝1的定子组件；
当a＝q时，将每相每路的星点线与中性线连接；每相每路的引出线与接线端子相连接,形成并联支路数a＝q的定子组件。
根据本公开的一个实施例，所述定子组件的定子槽数为48，所述极数为8，所述相数为3且包括U相、V相和W相，每极每相槽数为q＝2，并联支路数为2，
其中，所述U相每一路的星点线和引出线之间相差6个定子槽；
各相的两路之间在周向上相差1个定子槽；
U相、V相、W中相邻相相对应的星点线在周向上相差4个定子槽；
U相、V相、W中相邻相相对应的引出线在周向上相差4个定子槽；
所述制备方法包括：将任一相的第二路引出线与该相的第一路星点线连接，形成并联支路数为1的定子组件。
根据本公开的一个实施例，所述定子组件的定子槽数为72，所述极数为8，所述相数为3且包括U相、V相和W相，每极每相槽数为q＝3，并联支路数为3，
其中，所述U相每一路的星点线和引出线之间相差9个定子槽；
U相的三路之间两两在周向上相差1个定子槽；
V相的三路之间两两在周向上相差1个定子槽；
W相的三路之间两两在周向上相差1个定子槽；
U相、V相、W相中相邻相对应的星点线在周向上相差6个定子槽；
U相、V相、W相中相邻相对应的引出线在周向上相差6个定子槽；
所述制备方法包括：将任一相的第二路引出线与该相的第一路星点线连接，将任一相的第三路引出线与该相的第二路星点线连接，形成并联支路数为1的定子组件。
根据本公开的一个实施例，在所述焊接端上将所述多个U形导体段的位于不同层的所述第一槽内部分和所述第二槽内部分焊接连接，以使所述绕组的缠绕方向被构造成在每相每路中：
S31、将引出线引出至初始槽的径向最外槽层；
S32、沿第一方向同层跨越y个定子槽；
S33、从跨越y个定子槽后的径向次外槽层起，沿第二方向跨越，每跨越y个定子槽所述槽层的层数变化一层，其中所述层数沿径向从外到内变化直至径向次内槽层；
S34、从跨越y个定子槽后的径向最内槽层起，沿第一方向同层跨越y个定子槽；
S35、从跨越y个定子槽后的径向次内槽层起，沿第一方向跨越，每跨越y个定子槽所述槽层的层数变化一层，其中层数沿径向从内到外变化直至径向次外槽层；
S36、从跨越y个定子槽后的径向最外槽层起，沿第一方向同层跨越y个定子槽；
S37、重复S33-S36，直至绕线到达终止槽的径向最外槽层的相邻层、而后引出该相该路的星点线，其中所述终止槽在在正向上距离所述初始槽y个定子槽；
其中，所述第一方向和第二方向为沿定子铁芯圆周上的相反方向。
根据本公开的一个实施例，所述U形导体段的垂直于其延伸方向的横截面为矩形形状。
根据本公开的一个实施例，在所述U形导体段的延伸方向上，所述U形导体段的横截面面积相等。
根据本公开第二方面的定子组件，使用根据本公开上述第一方面实施例的定子组件的制备方法进行制备。
本公开的附加方面和优点将在下面的描述中部分给出，部分将从下面的描述中变得明显，或通过本公开的实践了解到。
附图说明
本公开的上述和/或附加的方面和优点从结合下面附图对实施例的描述中将变得明 显和容易理解，其中：
图1为根据本公开实施例的定子组件中定子铁芯的示意图；
图2为根据本公开实施例的定子组件中U形导体段的示意图；
图3为图2中所示的U形导体段之间焊接连接的示意图；
图4为根据本公开第一方面实施例的作为初始设置的定子组件的示意图，其中以8极48槽3相为例示出；
图5为图4中的定子组件的绕线方式示意图，其中以U相1路为例示出；
图6为图4中定子组件经过加工后形成2路接线方式的最终定子组件；
图7为图4中定子组件经过加工后形成1路接线方式的最终定子组件。
附图标记：
定子组件100，定子铁芯1，定子槽11，
定子绕组2，U形导体段20，折弯部201，第一槽内部分202，第二槽内部分203，
中性线3，发卡端I，焊接端II；
三相：U相、V相、W相
U相1路引出线U1A；U相2路引出线U2A；
U相1路星点线U1A；U相2路星点线U2B；
V相1路引出线V1A；V相2路引出线V2A；
V相1路星点线V1A；V相2路星点线V2B；
W相1路引出线W1A；W相2路引出线W2A；
W相1路星点线W1A；W相2路星点线W2B
具体实施方式
下面详细描述本公开的实施例，所述实施例的示例在附图中示出，其中自始至终相同或类似的标号表示相同或类似的元件或具有相同或类似功能的元件。下面通过参考附图描述的实施例是示例性的，仅用于解释本公开，而不能理解为对本公开的限制。
在本公开的描述中，需要理解的是，术语“中心”、“轴向”、“径向”、“周向”等指示的方位或位置关系为基于附图所示的方位或位置关系，仅是为了便于描述本公开和简化描述，而不是指示或暗示所指的装置或元件必须具有特定的方位、以特定的方位构造和操作，因此不能理解为对本公开的限制。此外，术语“第一”、“第二”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”的特征可以明示或者隐含地包括一个或者更多个该特征。在本公开的描述中，除非另有说明，“多个”的含义是两个或两个以上。
在本公开的描述中，需要说明的是，除非另有明确的规定和限定，术语“安装”、“相连”、“连接”应做广义理解，例如，可以是固定连接，也可以是可拆卸连接，或一体地连接；可以是机械连接，也可以是电连接；可以是直接相连，也可以通过中间媒介间接相连，可以是两个元件内部的连通。对于本领域的普通技术人员而言，可以具体情况理解上述术语在本公开中的具体含义。
下面根据图1-图7描述根据本公开第一方面实施例的定子组件的制备方法。
本公开实施例的定子组件的制备方法，适用于z槽2p级m相的电机中，其每极每相槽数为q＝z/m/(2p)，并联支路数为a，a≤q。
如图1-图4所示，所述定子组件包括：圆筒形的定子铁芯和定子绕组，其中，定子铁芯上具有沿定子铁芯的圆周方向间隔排列的多个定子槽；每个定子槽11中具有多个槽层，具体地说，定子绕组插入到定子槽11后，定子槽内具有定子绕组形成的多个层，在本发明的一些实施例中，槽层包括依次排列的a、b、c、d、e、f各层，在每个定子槽11中，在定子铁芯1的径向方向上位于最内层的为a层，位于最外层的为f层。定子绕组包括多个U形导体段，每个U形导体段包括折弯部、第一槽内部分和第二槽内部分，第一槽内部分和第二槽内部分分别连接至折弯部。
U形导体段的第一槽内部分穿过其中一个定子槽中的其中一个槽层，第二槽内部分穿过另一个定子槽中的其中一个槽层，第一槽内部分和第二槽内部分穿过定子槽后其端部超出定子铁芯以形成焊接端，在焊接端上多个U形导体段的位于相邻层的第一槽内部分和第二槽内部分焊接连接。
所述制备方法包括：将任一相的其中一路引出线与该相的不同路星点线连接。
根据本公开的定子组件的制备方法，可以实现定子组件的绕线路数可调，且调节方式简易快捷；而且可以匹配不同电机电压等级的整车需求，也可以匹配不同高效区的整车需求。
根据本公开的一些实施例，在所述焊接端上，任一相每一路的星点线位于径向上次外层，且任一相每一路的引出线位于径向上的最外层；在所述焊接端上，任一相每一路的星点线和引出线在周向上相差3q个定子槽，任一相的多路的星点线在周向上两两相差1个定子槽，任一相的多路的引出线在周向上两两相差1个定子槽。
根据本公开的一些实施例，任一相的其中一路引出线与该相的不同路星点线在周向上相差3q-1个定子槽。
根据本公开的一些实施例，当q为偶数时，定子组件的并联支路数为a＝2n或a＝1,其中n为1～q/2的自然数；
将每相中第k路的引出线依次与其该相中第k-1路的星点线连接，其中k为2～q的自然数，将每相中第1路的引出线与接线端子相连接；每相中第q路的星点线与中性线连接，形成并联支路数a＝1的定子组件；
将每相中并联支路划分为n组，所述n组的至少一组中其中一路的引出线与该组中另一路的星点线连接，该组其中一路的星点线与中性线连接，该组中另一路的引出线与接线端子相连接，形成并联支路数a＝2n的定子组件。
根据本公开的一些实施例，当q为奇数时，定子组件的并联支路数为a＝1或者a＝q，
将每相中第k路的引出线依次与其该相中第k-1路的星点线连接，其中k为2～q的自然数；将每相中第1路的引出线与接线端子相连接；每相中第q路的星点线与中性线连接,形成并联支路数a＝1的定子组件；
当a＝q时，将每相每路的星点线与中性线连接；每相每路的引出线与接线端子相连接,形成并联支路数a＝q的定子组件。
在本公开的一些具体实施例中，定子组件的定子槽数为48，极数为8，相数为3且包括U相、V相和W相，每极每相槽数为q＝2，并联支路数为2。
其中，U相每一路的星点线和引出线之间相差6个定子槽；各相的两路之间在周向上相差1个定子槽；U相、V相、W中相邻相相对应的星点线在周向上相差4个定子槽；U相、V相、W相中相邻相对应的引出线在周向上相差4个定子槽。
所述制备方法包括：将任一相的第二路引出线与该相的第一路星点线连接，形成并联支路数为1的定子组件。
在本公开的一些具体实施例中，所述定子组件的定子槽数为72，极数为8，相数为3且包括U相、V相和W相，每极每相槽数为q＝3，并联支路数为3。
其中，U相每一路的星点线和引出线之间相差9个定子槽；U相的三路之间两两在周向上相差1个定子槽；V相的三路之间两两在周向上相差1个定子槽；W相的三路之间两两在周向上相差1个定子槽；U相、V相、W相中相邻相对应的星点线在周向上相差6个定子槽；U相、V相、W相中相邻相对应的引出线在周向上相差6个定子槽。
所述制备方法包括：将任一相的第二路引出线与该相的第一路星点线连接，将任一相的第三路引出线与该相的第二路星点线连接，形成并联支路数为1的定子组件。
根据本公开的一些实施例，在所述焊接端上将所述多个U形导体段的位于不同层的所述第一槽内部分和所述第二槽内部分焊接连接，以使所述绕组的缠绕方向被构造成在 每相每路中：
S31、将引出线引出至初始槽的径向最外槽层；
S32、沿第一方向同层跨越y个定子槽；
S33、从跨越y个定子槽后的径向次外槽层起，沿第二方向跨越，每跨越y个定子槽所述槽层的层数变化一层，其中所述层数沿径向从外到内变化直至径向次内槽层；
S34、从跨越y个定子槽后的径向最内槽层起，沿第一方向同层跨越y个定子槽；
S35、从跨越y个定子槽后的径向次内槽层起，沿第一方向跨越，每跨越y个定子槽所述槽层的层数变化一层，其中层数沿径向从内到外变化直至径向次外槽层；
S36、从跨越y个定子槽后的径向最外槽层起，沿第一方向同层跨越y个定子槽；
S37、重复S33-S36，直至绕线到达终止槽的径向最外槽层的相邻层、而后引出该相该路的星点线，其中所述终止槽在在正向上距离所述初始槽y个定子槽；
其中，所述第一方向和第二方向为沿定子铁芯圆周上的相反方向。
在本公开的一些实施例中，所述U形导体段的垂直于其延伸方向的横截面为矩形形状。由此，可以提高槽满率。在所述U形导体段的延伸方向上，所述U形导体段的横截面面积相等。
根据本公开第二方面的定子组件，使用根据本公开上述第一方面实施例的定子组件的制备方法进行制备。
根据本公开实施例的定子组件，通过采用上述定子组件的制备方法进行制备，可以实现其绕线路数可调，从而可以匹配不同电机电压等级的整车需求，也可以匹配不同高效区的整车需求。另外，由于路数可以调节为不同，从而使得在每个定子槽内的相邻层之间的电压差不同，对层件绝缘系统要求不同，进而可根据实际风险及成本控制来选择不同的路数方案。
下面描述根据本公开实施例的定子组件及制备方法的具体实施例。
根据图1-图4描述根据本公开实施例一的定子组件，该定子组件可以作为初始定子组件，并根据客户需求去对其进行加工以得到不同路数的最终形式的最终定子组件。
根据本公开一个实施例的一种定子组件100，包括：定子铁芯1和定子绕组2。
如图1所示，定子铁芯1上具有多个定子槽11，每个定子槽11中具有多个槽层，定子绕组2包括多个U形导体段20。如图2和图3所示，每个U形导体段20包括折弯部201和分别连接至折弯部201的第一槽内部分202和第二槽内部分203，第一槽内部 分202穿过其中一个定子槽11中的其中一个槽层，第二槽内部分203穿过另一个定子槽11中的其中一个槽层，第一槽内部分202和第二槽内部分203穿过定子槽11后其端部超出定子铁芯1。
U形导体段20的垂直于其延伸方向的横截面为矩形形状。可选地，U形导体段20的横截面为长方形形状，长方形的短边垂直于定子槽11底壁。在U形导体段20的延伸方向上，U形导体段20的横截面面积相等。
如图4所示，多个U形导体段20中的折弯部201所在一端为定子绕组2的发卡端I、且第一槽内部分202和第二槽内部分203的端部所在一端称为定子绕组2的焊接端II，如图3所示，焊接端2是由多个U形导体段20的第一槽内部分202和与其相邻的U形导体段20的第二槽内部分203依次焊接形成。
其中在焊接端II上，任一相每一路的星点线和引出线在周向上相差3q个定子槽11，任一相的多路在周向上两两相差1个定子槽11；
多相之间对应的星点线在周向上相差2q个定子槽11；
多相之间对应的引出线在周向上相差2q定子槽11，
其中，每极每相槽数为q＝z/m/(2p)，并联支路数为g，g≤q；
其中，z为定子槽数，m为相数，2p为极数。
这里的定子组件100适用于z槽2p级m相的电机中，这里的槽数z可以为24、48、72等，相数m可以是三相、两相或单相，极对数p可以是8极、4极等，可以根据具体适用的电机进行设定。
在这里需要说明的是，“相差”指的是两个槽数之间的差数，例如初始槽是1，则相差6个槽后为第7槽。
根据本公开实施例的定子组件，引出线和星点线之间的距离最小，可作为初始定子组件的结构，例如为出厂时的结构设置，可以针对客户需求分别对绕组并联支路数量进行调整。这样，在该定子组件的基础上，如用户需要1路接入时，可对本公开实施例的定子组件进行加工以将其调整成为并联支路数为1路的定子组件，然后再与转子等部件进行装配得到一路接入的电机；相应地，如需2路接入时，对本公开实施例的定子组件进行加工以将其调整成为并联支路数为2路的定子组件。
根据本公开实施例的定子组件，其绕线路数可调，从而可以匹配不同电机电压等级的整车需求，也可以匹配不同高效区的整车需求。另外，由于路数可以调节为不同，从而使得在每个定子槽内的相邻层之间的电压差不同，对层件绝缘系统要求不同，进而可根据实际风险及成本控制来选择不同的路数方案。
根据本公开的一个实施例，上述绕线线圈结构可以通过如下绕线方法进行绕制：
S1、提供多个U形导体段20，每个U形导体段20包括折弯部和分别连接至折弯部的第一槽内部分202和第二槽内部分203，第一槽内部分202和第二槽内部分203之间的节距均为y个定子槽11，其中y为整数且y＝z/2p；
S2、将U形导体段20的第一槽内部分202穿过其中一个定子槽11中的其中一个槽层，第二槽内部分203穿过另一个定子槽11中的其中一个槽层，第一槽内部分202和第二槽内部分203穿过定子槽11后其端部超出定子铁芯以形成焊接端；
S3、在焊接端上将多个U形导体段20的位于多层的第一槽内部分202和第二槽内部分203焊接连接，以使线圈的缠绕方向被构造成在每相每路中：
S31、将引出线引出至初始槽的径向最外槽层，所述初始槽即为引出线开始准备绕制时首次插入的定子槽11；
S32、沿第一方向同层跨越y个定子槽11；
S33、从跨越y个定子槽11后的径向次外槽层起，沿第二方向跨越，每跨越y个定子槽所述槽层的层数变化一层，其中层数沿径向从外到内变化直至径向次内槽层；
S34、从跨越y个定子槽后的径向最内槽层起，沿第一方向同层跨越y个定子槽11；
S35、从跨越y个定子槽后的径向次内槽层起，沿第一方向跨越，每跨越y个定子槽所述槽层的层数变化一层，其中层数沿径向从内到外变化直至径向次外槽层；
S36、从跨越y个定子槽后的径向最外槽层起，沿第一方向同层跨越y个定子槽；
S37、重复S33-S36，直至绕线到达终止槽的径向最外槽层的相邻层、而后引出该相该路的星点线，其中所述终止槽在在正向上距离所述初始槽y个定子槽；其中，这里的术语“终止槽”指的是线圈绕制完毕之后路过的最后一个定子槽。
其中，所述第一方向和第二方向为沿定子铁芯圆周上的相反方向。
为了描述清楚，在下面的说明中均以根据本公开实施例的定子组件用于8极48槽3相的电机为例进行说明，即定子槽数z＝48，相数m＝3，其中，三相包括U相、V相和W相；极数2p＝8(即极对数为4)，且三相中的每相均包括两路。
如图4所示，定子组件100的定子绕组2中，U形导体段20的第一槽内部分202和第二槽内部分203之间的节距均为y个定子槽，其中y为整数且y＝z/2p。对于8极48槽的定子组件100来说，y＝6。也就是说，每个U形导体段20的第一槽内部分202和第二槽内部分203之间相差6个定子槽。
在下面的描述中，以每个定子槽11中以6层为例对本公开进行说明，6层线包括依 次排列的a、b、c、d、e、f各层，在每个定子槽11中，在定子铁芯1的径向方向上位于最内层的为a层，位于最外层的为f层。
如图4所示的定子组件中，U相每一路的星点线和引出线之间相差6个定子槽11，各相的两路之间在周向上相差1个定子槽11；U相、V相、W中相邻相相对应的星点线在周向上相差4个定子槽11；U相、V相、W相中相邻相对应的引出线在周向上相差4个定子槽11。
更具体地，如图5和图6中所示，U相1路的引出线U1A和U相2路的引出线U2A之间相差1个定子槽，V相1路的引出线V1A和V相2路的引出线V2A之间相差1个定子槽；W相1路的引出线W1A和W相2路的引出线W2A之间相差1个定子槽。
如图5和图6中所示，U相1路的引出线U1A和U相1路的星点线U1B之间相差6个定子槽，U相2路的引出线U2A和U相2路的星点线U2B之间相差6个定子槽；同样地，V相中两路的引出线V1A和星点线V1B、引出线V2A和星点线V2B之间也相差6个定子槽；W相中两路的引出线W1A和星点线W1B、引出线W2A和星点线W2B之间也相差6个定子槽。
U相、V相、W相中相邻相对应的星点线在周向上相差4个定子槽，具体而言，以第一路为例，U相1路的星点线U1B、V相1路的星点线V1B、和W相1路的星点线W1B在周向上依次相差4个槽，例如图2中所示，U1B从07槽e层引出，V1B从03槽e层引出，W1B从47槽e层引出。类似地，第二路的U2B、V2B和W2B分别从08槽e层、04槽e层和48槽e层引出，它们之间依次相差4个定子槽。
相应地，U相、V相、W相中相邻相对应的引出线在周向上相差4个定子槽11。具体而言，以第一路为例，U相1路的引出线U1A、V相1路的引出线V1A、W相1路的引出线W1A在周向上依次相差4个槽，例如图2中所示，U1A自01槽f层引入，V1A从45槽f层引入，而W1A自41槽f层引入。类似地，第二路的U2A、V2A和W2A分别自02槽f层、46槽f层和42槽f层引入，它们之间依次相差4个定子槽。
而上述绕线线圈结构可以通过如下绕线方法进行绕制，如图5和图6所示，以A相第一路为例，其绕线路线如下：
1f→43f→1e→7d→13c→19b→25a→19a→13b→7c→1d→43e→37f→31f→37e→43d→1c→7b→13a→7a→1b→43c→37d→31e→25f→19f→25e→31d→37c→43b→1a→43a→37b→31c→25d→19e→13f→7f→13e→19d→25c→31b→37a→31a→25b→19c→13d→7e
其中A相第二路的绕线线路在周向上与所述A相第一路相差1个定子槽，
A相、B相、C相中相邻相对应的星点线在周向上相差4个定子槽；
A相、B相、C相中相邻相对应的引出线在周向上相差4个定子槽。
当然，当定子槽数、极数和相数不同时，每相每路的绕线结构也是不同的。
例如，当定子槽数为72，极数为8，相数为3且包括U相、V相和W相，每相包括三路(图未示出)，其中，U相每一路的星点线和引出线之间相差9个定子槽11，U相的三路之间两两在周向上相差1个定子槽11；V相的三路之间两两在周向上相差1个定子槽11，W相的三路之间两两在周向上相差1个定子槽11，U相、V相、W相对应的星点线在周向上相差6个定子槽11，U相、V相、W相对应的引出线在周向上相差6个定子槽11。
值得注意的是，在一些实施例中，在定子绕组的焊接端II上，任一相每一路的星点线位于径向上最外层，且任一相每一路的引出线位于径向上的次外层，这样便于引出线的引入、星点线的引出，而且整个定子绕组结构简单。
下面将描述根据本公开实施例的定子组件100的制备方法，用于将上述实施例的定子组件100根据用户需求进行加工，以得到不同路数的定子组件。定子组件100适用于z槽2p级m相的电机中，每极每相槽数为q＝z/m/(2p)，并联支路数为g，g≤q。
根据本公开实施例的制备方法包括：
S1、选择路数g，g为大于等于1的自然数
其中q为奇数时，g具有2个选择：q路和1路；
q为偶数时，g有q/2+1个选择，q，q/2，q/4，……，1；
S2、选择路数g＝q时，将m相中每路的星点线均向外折弯，并通过中性线3连接；m相中每路的引出线焊接固定后与外部控制器接口相连。可选地，这里的中性线3中的材料可以与U形导体段20的材料一致。
S3、选择路数g＝1时，将每相中第k路的引出线拉长向外折弯后，依次与其对应相中第k-1路的星点线焊接固定，其中k为2～q的自然数；将每相中第1路的引出线焊接固定后与外部控制器接口相连；每相中除了第1路之外的其他路的星点线向外折弯并通过中性线3连接。
此时，为了描述清楚，以4路的U相绕线为例，如要将其变为一路，可通过以下方式进行：U相第4路的引出线拉长折弯后与U相3路的星点线连接，U相3路的引出线 拉长折弯后与U相2路的星点线连接，U相2路的引出线拉长折弯后与U相1路的星点线连接，U相1路的引出线焊接固定后与外部控制器相连；另外，U相4路的星点线通过第一中性线3连接；U相3路的星点线通过第二中性线3连接；U相2路的星点线通过第三中性线3连接。
S4、q为偶数时，每相中q路分为q/2组，q/2组的至少一组中其中一路的引出线拉长折弯后与另一路的星点线焊接固定，其中一路的星点线向外折弯并通过中性线3连接，另一路的引出线焊接固定后与外部控制器接口相连。
为了描述清楚，仍以4路中的U相为例，如要将其变为二路，可通过以下方式进行：U相中的4路分为2组，第1路和第2路为第一组，第3路和第4路为第二组，其中，第2路的引出线与第1路的星点线焊接固定，第2路的星点线与中性线3连接，第1路与外控制器相连。而第4路的引出线与第3路的星点线焊接固定，第4路的星点线与中性线3连接，第3路与外控制器相连。由此，最后形成了2路。
根据本公开实施例的定子组件的制备方法，使得定子组件的绕线路数可调，且调节方式简易快捷；而且可以匹配不同电机电压等级的整车需求，也可以匹配不同高效区的整车需求。另外，由于路数可以调节为不同，从而使得在每个定子槽内的相邻层之间的电压差不同，对层件绝缘系统要求不同，进而可根据实际风险及成本控制来选择不同的路数方案。
在本公开的其中一个实施例，步骤S2和步骤S3中，通过中性线3连接的连接方式为焊接。
在另一些实施例中，上述步骤S2和S3中，星点线和引出线向外折弯的角度为60-150度，可选地，该向外折弯的角度可以为大体90度，这样可以便于焊接，简单方便。
在描述本公开实施例的定子组件的制备方法时，为了描述方便，以根据本公开实施例的定子组件用于8极48槽3相的电机为例进行说明，即定子槽数z＝48，相数m＝3，其中，三相包括U相、V相和W相；极数2p＝8(即极对数为4)，且三相中的每相均包括两路，如图4-图5所示。
如图4所示，定子组件100的定子绕组2中，U形导体段20的第一槽内部分202和第二槽内部分203之间的节距均为y个定子槽，其中y为整数且y＝z/2p。对于8极48槽的定子组件100来说，y＝6。也就是说，每个U形导体段20的第一槽内部分202和第二槽内部分203之间相差6个定子槽。
针对适用于8极48槽3相的电机的定子组件，在其初始定子组件100的基础上，可选择两路方案或一路方案。
当用户选择为两路方案时，将U、V、W三相的第一路星点线U1B、V1B、W1B、以及第二路星点线U2B、V2B、W2B分别向外折弯，并通过中心线3焊接相连，如图7所示，最后将U、V、W三相的第一路引出线U1A、V1A、W1A、以及第二路引出线U2A、V2A、W2A通过焊接端子焊接固定后与外部控制器接口相连。
当用户选择为一路方案时，将U、V、W三相的第二路引出线U2A、V2A、W2A拉长折弯后，与U、V、W三相的第一路星点线U1B、V1B、W1B分别焊接固定，且第二路星点线U2B、V2B、W2B分别向外折弯，通过中心线3焊接相连。最后，将U、V、W三相的第一路引出线U1A、V1A、W1A通过焊接端子焊接固定后与外部控制器接口相连。
下面描述根据本公开实施例三的定子组件200，由上述制备方法中步骤S2的加工手段得到，其中与实施例的定子组件100中相同的部件采用相同的标号。
根据本公开一个实施例的定子组件200，适用于z槽2p级m相的电机中，其每极每相槽数为q＝z/m/(2p)，并联支路数为g，g≤q。所述定子组件包括定子铁芯1和定子绕组2。如图2所示，定子铁芯1上具有多个定子槽11，每个定子槽11中具有多个槽层。
定子绕组2包括多个U形导体段20，每个U形导体段20包括折弯部201和分别连接至折弯部201的第一槽内部分202和第二槽内部分203，第一槽内部分202穿过其中一个定子槽11中的其中一个槽层，第二槽内部分203穿过另一个定子槽11中的其中一个槽层，第一槽内部分202和第二槽内部分203穿过定子槽11后其端部超出定子铁芯1。
U形导体段20的垂直于其延伸方向的横截面为矩形形状。可选地，U形导体段20的横截面为长方形形状，长方形的短边垂直于定子槽11底壁。在U形导体段20的延伸方向上，U形导体段20的横截面面积相等。
如图4所示，多个U形导体段20中的折弯部201所在一端为定子绕组2的发卡端I、且第一槽内部分202和第二槽内部分203的端部所在一端称为定子绕组2的焊接端II，如图3所示，焊接端2是由多个U形导体段20的第一槽内部分202和与其相邻的U形导体段20的第二槽内部分203依次焊接形成。
其中在焊接端II上，任一相每一路的星点线和引出线在周向上相差3q个定子槽11，任一相的多路在周向上两两相差1个定子槽11；
多相之间对应的星点线在周向上相差2q个定子槽11；
多相之间对应的引出线在空间上相差2q定子槽11；
其中m相中每路的星点线均向外折弯，并通过中性线3连接；m相中每路的引出线焊接固定后与外部控制器接口相连。可选地，中性线3的材料与U形导体段20的材料一致。可选地，中性线3形成为弧形形状且与定子铁芯1同心，由此便于焊接且连接效果好。当然，中性线3的横截面也可以形成为矩形，也可以采用与U形导体段20的横截面面积相等的横截面。
如图6所示，当定子组件适用于8极48槽3相的电机时，即定子槽数为48，极数为8，相数为3且包括U相、V相和W相，此时经过步骤S2之后形成8极48槽3相2路的定子组件200。该定子组件200在第一方面实施例的定子组件100的基础上，将U相、V相和W相的两路星点线往外折弯，通过中性线3焊接相连；将U相、V相、W相对应的两路引出线焊接固定后，与外部控制器接口相连。可选地，U相、V相、W相对应的两路引出线通过焊接端II子焊接固定。
下面描述根据本公开实施例四的定子组件300，由上述制备方法中步骤S3的加工手段得到，其中与第一方面实施例的定子组件100中相同的部件采用相同的标号。
根据本公开一个实施例的定子组件300，适用于z槽2p级m相的电机中，其每极每相槽数为q＝z/m/(2p)，并联支路数为g，g≤q。所述定子组件包括定子铁芯1和定子绕组2。如图2所示，定子铁芯1上具有多个定子槽11，每个定子槽11中具有多个槽层。
定子绕组2包括多个U形导体段20，每个U形导体段20包括折弯部201和分别连接至折弯部201的第一槽内部分202和第二槽内部分203，第一槽内部分202穿过其中一个定子槽11中的其中一个槽层，第二槽内部分203穿过另一个定子槽11中的其中一个槽层，第一槽内部分202和第二槽内部分203穿过定子槽11后其端部超出定子铁芯1。
U形导体段20的垂直于其延伸方向的横截面为矩形形状。可选地，U形导体段20的横截面为长方形形状，长方形的短边垂直于定子槽11底壁。在U形导体段20的延伸方向上，U形导体段20的横截面面积相等。
如图4所示，多个U形导体段20中的折弯部201所在一端为定子绕组2的发卡端I、且第一槽内部分202和第二槽内部分203的端部所在一端称为定子绕组2的焊接端II，如图3所示，焊接端2是由多个U形导体段20的第一槽内部分202和与其相邻的U形导体段20的第二槽内部分203依次焊接形成。
在焊接端II上，任一相每一路的星点线和引出线在周向上相差3q个定子槽11，任 一相的多路在周向上两两相差1个定子槽11；
多相之间对应的星点线在周向上相差2q个定子槽11；
多相之间对应的引出线在空间上相差2q定子槽11；
其中，每相中第k路的引出线依次与其对应相中第k-1路的星点线焊接固定，其中k为2～q的自然数；每相中第1路的引出线焊接固定后与外部控制器接口相连；每相中除了第1路之外的其他路的星点线通过中性线3连接。
在一些实施例中，每相中第k路的引出线先向外折弯后，再依次与其对应相中第k-1路的星点线焊接固定。
在一些可选示例中，每相中除了第1路之外的其他路的星点线先向外折弯后再通过中性线3连接。
可选地，中性线3的材料与U形导体段20的材料一致。可选地，中性线3形成为弧形形状且与定子铁芯1同心，由此便于焊接且连接效果好。当然，中性线3的横截面也可以形成为矩形，也可以采用与U形导体段20的横截面面积相等的横截面。
如图7所示，当定子组件适用于8极48槽3相的电机时，即定子槽数为48，极数为8，相数为3且包括U相、V相和W相，路数为2，此时经过步骤S3之后形成8极48槽3相1路的定子组件300。该定子组件200在第一方面实施例的定子组件100的基础上，将U相、V相和W相的第二路引出线拉长折弯后，分别与U相、V相和W相的第一路星点线焊接固定，U相、V相和W相的第二路星点线向外折弯，通过中性线3焊接相连；U相、V相和W相对应的第一路引出线焊接固定后，与外部控制器接口相连。可选地，U相、V相、W相对应的两路引出线通过焊接端II子焊接固定。
当然，在本公开的另一个示例中，假设定子组件100的并联支路数为4，如要将其变为一路，可通过以下方式进行：U相第4路的引出线拉长折弯后与U相3路的星点线连接，U相3路的引出线拉长折弯后与U相2路的星点线连接，U相2路的引出线拉长折弯后与U相1路的星点线连接，U相1路的引出线焊接固定后与外部控制器相连；另外，U相4路的星点线通过第一中性线3连接；U相3路的星点线通过第二中性线3连接；U相2路的星点线通过第三中性线3连接。
下面描述根据本公开实施例五的定子组件400，由上述制备方法中步骤S4的加工手段得到，其中与第一方面实施例的定子组件100中相同的部件采用相同的标号。
根据本公开一个实施例的定子组件400，适用于z槽2p级m相的电机中，其每极每相槽数为q＝z/m/(2p)，并联支路数为g，g≤q。所述定子组件包括定子铁芯1和定子 绕组2。如图2所示，定子铁芯1上具有多个定子槽11，每个定子槽11中具有多个槽层。
定子绕组2包括多个U形导体段20，每个U形导体段20包括折弯部201和分别连接至折弯部201的第一槽内部分202和第二槽内部分203，第一槽内部分202穿过其中一个定子槽11中的其中一个槽层，第二槽内部分203穿过另一个定子槽11中的其中一个槽层，第一槽内部分202和第二槽内部分203穿过定子槽11后其端部超出定子铁芯1。
如图4所示，多个U形导体段20中的折弯部201所在一端为定子绕组2的发卡端I、且第一槽内部分202和第二槽内部分203的端部所在一端称为定子绕组2的焊接端II，如图3所示，焊接端2是由多个U形导体段20的第一槽内部分202和与其相邻的U形导体段20的第二槽内部分203依次焊接形成。
在焊接端II上：任一相每一路的星点线和引出线在周向上相差3q个定子槽11，任一相的多路在周向上两两相差1个定子槽11；
多相之间对应的星点线在周向上相差2q个定子槽11；
多相之间对应的引出线在空间上相差2q定子槽11；
其中，q为偶数，每相中q路分为q/2组，q/2组的至少一组中其中一路的引出线与另一路的星点线焊接固定，其中一路的星点线通过中性线3连接，另一路的引出线焊接固定后与外部控制器接口相连。
在一些实施例中，其中一路的引出线先拉长折弯后再与另一路的星点线焊接固定。在另一些示例中，其中一路的星点线先向外折弯后再通过中性线3连接。
可选地，中性线3的材料与U形导体段20的材料一致。可选地，中性线3形成为弧形形状且与定子铁芯1同心，由此便于焊接且连接效果好。当然，中性线3的横截面也可以形成为矩形，也可以采用与U形导体段20的横截面面积相等的横截面。
当定子组件适用于6极72槽3相的电机时，即定子槽数为72，极数为6，相数为3且包括U相、V相和W相，路数为4。此时采用上述第二方面实施例中的制备方法中的步骤S4，将各相中的4路分成两组，第一组包括第一路和第二路，第二组包括第三路和第四路，其中第二路中的引出线拉长折弯后与第一路的星点线焊接固定，第二路的星点线向外折弯并通过中性线3连接，第一路的引出线焊接固定后与外部控制器接口相连；第四路中的引出线拉长折弯后与第三路的星点线焊接固定，第四路的星点线向外折弯并通过中性线3连接，第三路的引出线焊接固定后与外部控制器接口相连(图未示出)。
综上所述，根据本公开实施例的定子组件100，经过根据本公开实施例的定子组件的制备方法中的不同步骤，可以得到本公开实施例三、四、五中的定子组件200、300、400。也就是说，通过本公开实施例中的定子组件及其制备方法，实现了定子组件的路数可调，调节方式简易快捷；而且可以匹配不同电机电压等级的整车需求，也可以匹配不同高效区的整车需求。另外，由于路数可以调节为不同，从而使得在每个定子槽内的相邻层之间的电压差不同，对层件绝缘系统要求不同，进而可根据实际风险及成本控制来选择不同的路数方案。
在本说明书的描述中，参考术语“一个实施例”、“一些实施例”、“示意性实施例”、“示例”、“具体示例”、或“一些示例”等的描述意指结合该实施例或示例描述的具体特征、结构、材料或者特点包含于本公开的至少一个实施例或示例中。在本说明书中，对上述术语的示意性表述不一定指的是相同的实施例或示例。而且，描述的具体特征、结构、材料或者特点可以在任何的一个或多个实施例或示例中以合适的方式结合。
尽管已经示出和描述了本公开的实施例，本领域的普通技术人员可以理解：在不脱离本公开的原理和宗旨的情况下可以对这些实施例进行多种变化、修改、替换和变型，本公开的范围由权利要求及其等同物限定。

Claims (11)

  1. 一种定子组件的制备方法，适用于z槽2p级m相的电机中，其每极每相槽数为q＝z/m/(2p)，并联支路数为a，a≤q，其特征在于，
    所述定子组件包括：
    圆筒形的定子铁芯，所述定子铁芯上具有沿所述定子铁芯的圆周方向间隔排列的多个定子槽；
    定子绕组，所述定子绕组包括多个U形导体段，每个所述U形导体段包括折弯部和分别连接至所述折弯部的第一槽内部分和第二槽内部分，所述U形导体段的第一槽内部分穿过其中一个定子槽中的其中一个槽层，所述第二槽内部分穿过另一个定子槽中的其中一个槽层，所述第一槽内部分和所述第二槽内部分穿过所述定子槽后其端部超出所述定子铁芯以形成焊接端，在所述焊接端上所述多个U形导体段的位于相邻层的所述第一槽内部分和所述第二槽内部分焊接连接，在所述焊接端上，任一相每一路的星点线位于径向上次外层，且任一相每一路的引出线位于径向上的最外层；
    所述制备方法包括：
    将任一相的其中一路引出线与该相的不同路星点线连接。
  2. 根据权利要求1所述的定子组件的制备方法，其特征在于，
    在所述焊接端上，任一相每一路的星点线和引出线在周向上相差3q个定子槽，任一相的多路的星点线在周向上两两相差1个定子槽，任一相的多路的引出线在周向上两两相差1个定子槽。
  3. 根据权利要求1或2所述的定子组件的制备方法，其特征在于，任一相的其中一路引出线与该相的不同路星点线在周向上相差3q-1个定子槽。
  4. 根据权利要求1-3中任一项所述的定子组件的制备方法，其特征在于，
    当q为偶数时，定子组件的并联支路数为a＝2n或a＝1,其中n为1～q/2的自然数；
    将每相中第k路的引出线依次与其该相中第k-1路的星点线连接，其中k为2～q的自然数，将每相中第1路的引出线与接线端子相连接；每相中第q路的星点线与中性线连接，形成并联支路数a＝1的定子组件；
    将每相中并联支路划分为n组，所述n组的至少一组中其中一路的引出线与该组中另一路的星点线连接，该组其中一路的星点线与中性线连接，该组中另一路的引出线与接线端子相连接，形成并联支路数a＝2n的定子组件。
  5. 根据权利要求1-4中任一项所述的定子组件的制备方法，其特征在于，
    当q为奇数时，定子组件的并联支路数为a＝1或者a＝q，
    将每相中第k路的引出线依次与其该相中第k-1路的星点线连接，其中k为2～q的自然数；将每相中第1路的引出线与接线端子相连接；每相中第q路的星点线与中性线连接,形成并联支路数a＝1的定子组件；
    当a＝q时，将每相每路的星点线与中性线连接；每相每路的引出线与接线端子相连接,形成并联支路数a＝q的定子组件。
  6. 根据权利要求1-5中任一项所述的定子组件的制备方法，其特征在于，所述定子组件的定子槽数为48，极数为8，相数为3且包括U相、V相和W相，每极每相槽数为q＝2，并联支路数为2，
    其中，所述U相每一路的星点线和引出线之间相差6个定子槽；
    各相的两路之间在周向上相差1个定子槽；
    U相、V相、W相中相邻相对应的星点线在周向上相差4个定子槽；
    U相、V相、W相中相邻相对应的引出线在周向上相差4个定子槽；
    所述制备方法包括：将任一相的第二路引出线与该相的第一路星点线连接，形成并联支路数为1的定子组件。
  7. 根据权利要求1-5中任一项所述的定子组件的制备方法，其特征在于，所述定子组件的定子槽数为72，极数为8，相数为3且包括U相、V相和W相，每极每相槽数为q＝3，并联支路数为3，
    其中，所述U相每一路的星点线和引出线之间相差9个定子槽；
    U相的三路之间两两在周向上相差1个定子槽；
    V相的三路之间两两在周向上相差1个定子槽；
    W相的三路之间两两在周向上相差1个定子槽；
    U相、V相、W相中相邻相对应的星点线在周向上相差6个定子槽；
    U相、V相、W相中相邻相对应的引出线在周向上相差6个定子槽；
    所述制备方法包括：将任一相的第二路引出线与该相的第一路星点线连接，将任一相的第三路引出线与该相的第二路星点线连接，形成并联支路数为1的定子组件。
  8. 根据权利要求1-7中任一项所述的定子组件的制备方法，其特征在于，在所述焊接端上将所述多个U形导体段的位于不同层的所述第一槽内部分和所述第二槽内部分焊接连接，以使所述绕组的缠绕方向被构造成在每相每路中：
    S31、将引出线引出至初始槽的径向最外槽层；
    S32、沿第一方向同层跨越y个定子槽；
    S33、从跨越y个定子槽后的径向次外槽层起，沿第二方向跨越，每跨越y个定子槽所述槽层的层数变化一层，其中所述层数沿径向从外到内变化直至径向次内槽层；
    S34、从跨越y个定子槽后的径向最内槽层起，沿第一方向同层跨越y个定子槽；
    S35、从跨越y个定子槽后的径向次内槽层起，沿第一方向跨越，每跨越y个定子槽所述槽层的层数变化一层，其中层数沿径向从内到外变化直至径向次外槽层；
    S36、从跨越y个定子槽后的径向最外槽层起，沿第一方向同层跨越y个定子槽；
    S37、重复S33-S36，直至绕线到达终止槽的径向最外槽层的相邻层、而后引出该相该路的星点线，其中所述终止槽在在正向上距离所述初始槽y个定子槽；
    其中，所述第一方向和第二方向为沿定子铁芯圆周上的相反方向。
  9. 根据权利要求1-8中任一项所述的定子组件的制备方法，其特征在于，所述U形导体段的垂直于其延伸方向的横截面均为矩形形状。
  10. 根据权利要求9所述的定子组件的制备方法，其特征在于，在所述U形导体段的延伸方向上，所述U形导体段的横截面面积相等。
  11. 一种定子组件，其特征在于，使用如权利要求1至10中任一项的制备方法进行制备。
PCT/CN2018/108641 2017-09-29 2018-09-29 定子组件及其制备方法 Ceased WO2019062915A1 (zh)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
CN201710912471.3 2017-09-29
CN201710912471.3A CN109586459B (zh) 2017-09-29 2017-09-29 定子组件及其制备方法

Publications (1)

Publication Number Publication Date
WO2019062915A1 true WO2019062915A1 (zh) 2019-04-04

Family

ID=65900607

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/CN2018/108641 Ceased WO2019062915A1 (zh) 2017-09-29 2018-09-29 定子组件及其制备方法

Country Status (2)

Country Link
CN (1) CN109586459B (zh)
WO (1) WO2019062915A1 (zh)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN112332564A (zh) * 2020-11-06 2021-02-05 天津市松正电动汽车技术股份有限公司 一种电机定子及电机
WO2021105593A1 (fr) * 2019-11-26 2021-06-03 Nidec Psa Emotors Stator de machine électrique tournante avec bobinage asymétrique
CN116865479A (zh) * 2023-02-28 2023-10-10 北京海纳川汽车部件股份有限公司 电机定子和电机

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2021093835A (ja) * 2019-12-10 2021-06-17 本田技研工業株式会社 回転電機
US12176775B2 (en) 2019-12-31 2024-12-24 Saic Motor Corporation Limited Stator winding structure and motor comprising same
CN113595346B (zh) * 2020-04-30 2023-03-14 比亚迪股份有限公司 定子组件的绕组绕线方法、定子组件以及电机
CN114629272B (zh) * 2020-12-11 2023-12-12 比亚迪股份有限公司 定子组件及具有其的电机
CN113162280B (zh) * 2021-04-14 2023-06-30 浙江龙芯电驱动科技有限公司 防松动型定子组件及电机

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN103339834A (zh) * 2011-12-02 2013-10-02 Lg电子株式会社 电力装置的定子、具有定子的电机及具有电机的电动车
CN204761241U (zh) * 2015-07-01 2015-11-11 袁正彪 一种带有多段抽头绕组的电机
CN106787290A (zh) * 2017-01-21 2017-05-31 浙江方正电机股份有限公司 一种三相电机定子结构及电机

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP6446932B2 (ja) * 2014-09-16 2019-01-09 スズキ株式会社 回転電機
CN105958765B (zh) * 2016-05-28 2018-03-30 中车永济电机有限公司 一种适应双电压制式的可调整并联支路数交流异步电动机

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN103339834A (zh) * 2011-12-02 2013-10-02 Lg电子株式会社 电力装置的定子、具有定子的电机及具有电机的电动车
CN204761241U (zh) * 2015-07-01 2015-11-11 袁正彪 一种带有多段抽头绕组的电机
CN106787290A (zh) * 2017-01-21 2017-05-31 浙江方正电机股份有限公司 一种三相电机定子结构及电机

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2021105593A1 (fr) * 2019-11-26 2021-06-03 Nidec Psa Emotors Stator de machine électrique tournante avec bobinage asymétrique
US12316180B2 (en) 2019-11-26 2025-05-27 Nidec Psa Emotors Rotary electric machine stator with asymmetric winding
CN112332564A (zh) * 2020-11-06 2021-02-05 天津市松正电动汽车技术股份有限公司 一种电机定子及电机
CN116865479A (zh) * 2023-02-28 2023-10-10 北京海纳川汽车部件股份有限公司 电机定子和电机

Also Published As

Publication number Publication date
CN109586459A (zh) 2019-04-05
CN109586459B (zh) 2020-11-20

Similar Documents

Publication Publication Date Title
CN109586456B (zh) 电机、定子组件及其线圈绕线方法
WO2019062915A1 (zh) 定子组件及其制备方法
CN109586430B (zh) 定子组件和电机
CN109586444B (zh) 定子组件及具有其的电机
WO2019062914A1 (zh) 定子组件和具有其的电机和车辆
JP2021526789A (ja) 平角線連続波巻き千鳥巻線及びその巻線を有する固定子
EP2388895A2 (en) Electric motor
CN109586462B (zh) 定子组件及具有其的电机
US9641036B2 (en) Rotary electric machine
WO2019062905A1 (zh) 定子组件和具有其的电机和车辆
CN111884382A (zh) 一种电机定子绕组、定子及电机
CN111181264B (zh) 一种电机定子及电机
CN115037068B (zh) 扁线定子及电机
CN116094222B (zh) 一种三相三支路连续波绕绕组及电机
WO2019062897A1 (zh) 定子组件和具有其的电机和车辆
WO2019062921A1 (zh) 定子组件和具有其的电机和车辆
CN111146891A (zh) 一种电机定子
KR20230034943A (ko) 전기 기계용 스테이터 및 전기 기계
WO2019062903A1 (zh) 定子组件和具有其的电机和车辆
WO2019062906A1 (zh) 定子组件和具有其的电机和车辆
CN109586457B (zh) 定子组件和具有其的电机和车辆
WO2019062909A1 (zh) 定子组件和具有其的电机和车辆
CN115733281B (zh) 一种定子组件
CN109586452B (zh) 定子组件和具有其的电机和车辆
CN111478484A (zh) 一种电机定子及电机

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 18861614

Country of ref document: EP

Kind code of ref document: A1

NENP Non-entry into the national phase

Ref country code: DE

122 Ep: pct application non-entry in european phase

Ref document number: 18861614

Country of ref document: EP

Kind code of ref document: A1