CN109586459B - Stator assembly and method of making the same - Google Patents

Abstract

The invention discloses a stator assembly and a preparation method thereof, which are suitable for a z-slot 2p-level m-phase motor, wherein the number of slots per pole and phase is q=z/m/(2p), the number of parallel branches is a, a≤q, the stator assembly includes: a cylindrical stator core; a stator winding, the stator winding includes a plurality of U-shaped conductor segments, and each U-shaped conductor segment includes a bent portion and a first conductor connected to the bent portion respectively. an inner slot portion and a second inner slot portion, the first inner slot portion passes through one of the slot layers in one of the stator slots, and the second inner slot portion passes through one of the slot layers in the other stator slot; the preparation The method includes: connecting one terminal lead wire of any phase with a different star point lead wire of the phase. According to the stator assembly and the preparation method of the present invention, the number of windings of the stator assembly can be adjusted, so that different vehicle requirements can be matched. The invention also discloses a plurality of stator assemblies with different numbers of paths obtained by the preparation method.

Description

Stator assembly and method of making the same

technical field

The present invention relates to the field of electric motors, and in particular, to a stator assembly suitable for a driving motor of a vehicle, a preparation method of the stator assembly, and a stator assembly obtained after processing by the preparation method.

Background technique

In the related art, in terms of the parallel branches of the windings of the drive motor used by the vehicle, one-way access and two-way access use different winding methods respectively, and the number of roads is not adjustable, making it difficult to match the needs of different vehicle high-efficiency areas.

SUMMARY OF THE INVENTION

The present invention aims to solve at least one of the technical problems existing in the prior art. To this end, the present invention proposes a method for preparing a stator assembly with a simple structure, on the basis of which, it can be processed to obtain stator assemblies with different numbers of paths.

The present invention also provides a stator assembly prepared by using the above preparation method.

A method for manufacturing a stator assembly according to the first aspect of the present invention is suitable for a z-slot 2p-level m-phase motor, where the number of slots per pole and phase is q=z/m/(2p), and the number of parallel branches is a, a≤q, the stator assembly includes: a cylindrical stator core, the stator core is provided with a plurality of stator slots spaced along the 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 includes a bent portion and a first in-slot portion and a second in-slot portion connected to the bent portion, respectively, the U-shaped conductor segment has The first in-slot portion passes through one of the slot layers in one of the stator slots, the second in-slot portion passes through one of the slot layers in the other stator slot, the first in-slot portion and the second After the inner part of the slot passes through the stator slot, its end extends beyond the stator core to form a welding end, on which the plurality of U-shaped conductor segments are located in the first slot of the adjacent layer The part is welded to the inner part of the second groove;

The preparation method includes: connecting one terminal lead wire of any phase with a different star point lead wire of the phase.

According to an embodiment of the present invention, on the welding end, the star point lead wire of each channel of any phase is located on the outermost layer in the radial direction, and the terminal lead wire of each channel of any phase is located at the outermost layer in the radial direction; On the welding end, the star point lead-out line and the terminal lead-out line of each channel of any phase differ by 3q stator slots in the circumferential direction, and the star point lead-out lines of multiple channels of any phase differ by 1 stator in the circumferential direction. Slots, the multi-channel terminal lead-out lines of any phase differ by 1 stator slot in the circumferential direction.

According to an embodiment of the present invention, one terminal lead-out line of any phase differs from the star point lead-out line of a different phase of the phase by 3q-1 stator slots in the circumferential direction.

According to an embodiment of the present invention, when q is an even number, the number of parallel branches of the stator assembly is a=2n or a=1, wherein n is a natural number from 1 to q/2;

Connect the terminal lead wire of the kth road in each phase to the star point lead wire of the k-1th road in the phase in turn, where k is a natural number from 2 to q, and connect the terminal lead wire of the first road in each phase with the wiring The terminals are connected; the star point lead wire of the qth road in each phase is connected with the neutral wire to form a stator assembly with a parallel branch number a=1;

The parallel branches in each phase are divided into n groups, the terminal lead-out line of one of the at least one group of the n groups is connected with the star point lead-out line of the other way in the group, and the star point lead-out line of one of the group is connected to the group. The neutral line is connected, and the terminal lead-out line of the other channel in the group is connected with the connection terminal to form a stator assembly with the number of parallel branches a=2n.

According to an embodiment of the present invention, when q is an odd number, the number of parallel branches of the stator assembly is a=1 or a=q,

Connect the terminal lead wire of the kth channel in each phase to the star point lead wire of the k-1th channel in the phase in turn, where k is a natural number from 2 to q; connect the terminal lead wire of the first channel in each phase with the wiring The terminals are connected with each other; the star point lead wire of the qth road in each phase is connected with the neutral wire to form a stator assembly with the number of parallel branches a=1;

When a = q, connect the star point lead wire of each phase and each channel to the neutral line; connect the terminal lead wire of each phase and each channel to the terminal to form a stator assembly with parallel branch number a = q.

According to an embodiment of the present invention, the number of stator slots of the stator assembly is 48, the number of poles is 8, the number of phases is 3 and includes U-phase, V-phase and W-phase, and the number of slots per pole and phase is q=2, the number of parallel branches is 2,

Wherein, there is a difference of 6 stator slots between the star point lead-out line and the terminal lead-out line of each channel of the U-phase;

The difference between the two paths of each phase is 1 stator slot in the circumferential direction;

The star point lead-out lines corresponding to U-phase, V-phase and W differ by 4 stator slots in the circumferential direction;

The terminal lead wires corresponding to U phase, V phase and W phase differ by 4 stator slots in the circumferential direction;

The preparation method includes: connecting the second terminal lead wire of any phase with the first star point lead wire of the phase to form a stator assembly with one parallel branch.

According to an embodiment of the present invention, the number of stator slots of the stator assembly is 72, the number of poles is 8, the number of phases is 3 and includes U-phase, V-phase and W-phase, and the number of slots per pole and phase is q=3, the number of parallel branches is 3,

Wherein, the difference between the star point lead-out line and the terminal lead-out line of each channel of the U-phase is 9 stator slots;

There is a stator slot difference in the circumferential direction between the three paths of the U-phase;

The difference between the three circuits of the V phase is 1 stator slot in the circumferential direction;

The difference between the three circuits of the W-phase is 1 stator slot in the circumferential direction;

The star point lead-out lines corresponding to U-phase, V-phase and W differ by 6 stator slots in the circumferential direction;

The terminal lead wires corresponding to U-phase, V-phase and W-phase differ by 6 stator slots in the circumferential direction;

The preparation method includes: connecting the second terminal lead wire of any phase with the first star point lead wire of the phase, and connecting the third terminal lead wire of any phase to the second star point of the phase The lead wires are connected to form a stator assembly with a parallel branch number of 1.

According to an embodiment of the present invention, the first in-slot portion and the second in-slot portion of the plurality of U-shaped conductor segments located in different layers are welded and connected on the welding end, so that the The winding direction of the windings is configured so that in each phase and each way:

S31. Lead out the terminal lead wires to the radially outermost groove layer of the initial groove;

S32, spanning y stator slots in the same layer along the first direction;

S33, spanning along the second direction, the number of layers of the slot layers varies by one layer every spanning y stator slots, wherein the number of layers varies from the outside to the inside along the radial direction until the radially innermost slot layer;

S34, spanning y stator slots in the same layer along the first direction;

S35, spanning along the first direction, the number of layers of the slot layers varies by one layer every spanning y stator slots, wherein the number of layers varies from the inside to the outside along the radial direction to the outermost slot layer in the radial direction;

S36, S32-S35 are repeated until the winding reaches the adjacent layer of the radially outermost groove layer of the termination groove, and then the star point lead-out line of the phase and the path is drawn out, wherein the termination groove is in the positive direction away from the initial Slot y stator slots;

Wherein, the first direction and the second direction are opposite directions along the circumference of the stator core.

According to an embodiment of the present invention, any cross-section of the U-shaped conductor segment perpendicular to its extending direction is a rectangular shape.

According to an embodiment of the present invention, in the extending direction of the U-shaped conductor segments, the cross-sectional areas of the U-shaped conductor segments are equal.

The stator assembly according to the second aspect of the present invention is produced using the method for producing a stator assembly according to the embodiment of the first aspect of the present invention.

Additional aspects and advantages of the present invention will be set forth, in part, from the following description, and in part will be apparent from the following description, or may be learned by practice of the invention.

Description of drawings

The above and/or additional aspects and advantages of the present invention will become apparent and readily understood from the following description of embodiments in conjunction with the accompanying drawings, wherein:

1 is a schematic diagram of a stator core in a stator assembly according to an embodiment of the present invention;

2 is a schematic diagram of a U-shaped conductor segment in a stator assembly according to an embodiment of the present invention;

FIG. 3 is a schematic view of the welded connection between the U-shaped conductor segments shown in FIG. 2;

4 is a schematic diagram of a stator assembly as an initial setting according to an embodiment of the first aspect of the present invention, in which 8 poles, 48 slots and 3 phases are used as an example;

FIG. 5 is a schematic diagram of the winding mode of the stator assembly in FIG. 4 , in which the U-phase 1 path is used as an example;

Fig. 6 is the final stator assembly of the stator assembly in Fig. 4 after processing to form a 2-way wiring;

FIG. 7 is a final stator assembly in which the stator assembly in FIG. 4 is processed to form a one-way wiring.

Reference number:

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,

Neutral line 3, hairpin end I, welding end II;

Three-phase: U-phase, V-phase, W-phase

U-phase 1-way terminal lead-out line U1A; U-phase 2-way terminal lead-out line U2A;

U-phase 1-way star point lead U1A; U-phase 2-way star point lead U2B;

V-phase 1-way terminal lead-out line V1A; V-phase 2-way terminal lead-out line V2A;

V-phase 1-way star point lead-out line V1A; V-phase 2-way star point lead-out line V2B;

W-phase 1-way terminal lead wire W1A; W-phase 2-way terminal lead wire W2A;

W-phase 1-way star point lead wire W1A; W-phase 2-way star point lead wire W2B

Detailed ways

The following describes in detail the embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein the same or similar reference numerals refer to the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary, only used to explain the present invention, and should not be construed as a limitation of the present invention.

In the description of the present invention, it should be understood that the orientation or positional relationship indicated by the terms "central", "axial", "radial", "circumferential", etc. is based on the orientation or positional relationship shown in the accompanying drawings, It is only for the convenience of describing the present invention and simplifying the description, not to indicate or imply that the indicated device or element must have a particular orientation, be constructed and operate in a particular orientation, and therefore should not be construed as a limitation of the present invention. In addition, the terms "first" and "second" are only used for descriptive purposes, and should not be understood as indicating or implying relative importance or implying the number of indicated technical features. Thus, a feature defined as "first", "second" may expressly or implicitly include one or more of that feature. In the description of the present invention, unless otherwise specified, "plurality" means two or more.

In the description of the present invention, it should be noted that the terms "installed", "connected" and "connected" should be understood in a broad sense, unless otherwise expressly specified and limited, for example, it may be a fixed connection or a detachable connection Connection, or integral connection; can be mechanical connection, can also be electrical connection; can be directly connected, can also be indirectly connected through an intermediate medium, can be internal communication between two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood in specific situations.

Hereinafter, a method for manufacturing a stator assembly according to an embodiment of the first aspect of the present invention will be described with reference to FIGS. 1 to 7 .

The manufacturing method of the stator assembly according to the embodiment of the present invention is suitable for a z-slot 2p-level m-phase motor, where the number of slots per pole and phase is q=z/m/(2p), and the number of parallel branches is a, a≤ q.

As shown in Figures 1-4, the stator assembly includes: a cylindrical stator core and a stator winding, wherein the stator core has a plurality of stator slots spaced along the circumferential direction of the stator core; the stator winding A plurality of U-shaped conductor segments are included, and each U-shaped conductor segment includes a bent portion, a first in-slot portion and a second in-slot portion, and the first and second in-slot portions are respectively connected to the bent portion.

The first in-slot portion of the U-shaped conductor segment passes through one of the slot layers in one of the stator slots, the second in-slot portion passes through one of the slot layers in the other stator slot, the first in-slot portion and the second slot After the inner part passes through the stator slot, its end extends beyond the stator core to form a welding end, on which the first inner slot part and the second inner slot part of the plurality of U-shaped conductor segments located in adjacent layers are welded and connected.

The preparation method includes: connecting one terminal lead wire of any phase with a different star point lead wire of the phase.

According to the preparation method of the stator assembly of the present invention, the number of windings of the stator assembly can be adjusted, and the adjustment method is simple and fast; and the vehicle requirements of different motor voltage levels can be matched, and the vehicle requirements of different high-efficiency areas can also be matched.

According to some embodiments of the present invention, on the welding end, the star point lead wire of each channel of any phase is located on the outermost layer in the radial direction, and the terminal lead wire of each channel of any phase is located at the outermost layer in the radial direction; On the welding end, the star point lead-out line and the terminal lead-out line of each channel of any phase differ by 3q stator slots in the circumferential direction, and the star point lead-out lines of multiple channels of any phase differ by 1 stator in the circumferential direction. Slots, the multi-channel terminal lead-out lines of any phase differ by 1 stator slot in the circumferential direction.

According to some embodiments of the present invention, one of the terminal lead-out lines of any phase differs by 3q-1 stator slots in the circumferential direction from the star-point lead-out lines of different paths of the phase.

According to some embodiments of the present invention, when q is an even number, the number of parallel branches of the stator assembly is a=2n or a=1, where n is a natural number from 1 to q/2;

Connect the terminal lead wire of the kth road in each phase to the star point lead wire of the k-1th road in the phase in turn, where k is a natural number from 2 to q, and connect the terminal lead wire of the first road in each phase with the wiring The terminals are connected; the star point lead wire of the qth road in each phase is connected with the neutral wire to form a stator assembly with a parallel branch number a=1;

The parallel branches in each phase are divided into n groups, the terminal lead-out line of one of the at least one group of the n groups is connected with the star point lead-out line of the other way in the group, and the star point lead-out line of one of the group is connected to the group. The neutral line is connected, and the terminal lead-out line of the other channel in the group is connected with the connection terminal to form a stator assembly with the number of parallel branches a=2n.

According to some embodiments of the present invention, when q is an odd number, the number of parallel branches of the stator assembly is a=1 or a=q,

Connect the terminal lead wire of the kth channel in each phase to the star point lead wire of the k-1th channel in the phase in turn, where k is a natural number from 2 to q; connect the terminal lead wire of the first channel in each phase with the wiring The terminals are connected with each other; the star point lead wire of the qth road in each phase is connected with the neutral wire to form a stator assembly with the number of parallel branches a=1;

When a = q, connect the star point lead wire of each phase and each channel to the neutral line; connect the terminal lead wire of each phase and each channel to the terminal to form a stator assembly with parallel branch number a = q.

In some specific embodiments of the present invention, the number of stator slots of the stator assembly is 48, the number of poles is 8, the number of phases is 3 and includes U-phase, V-phase and W-phase, and the number of slots per pole and phase is q=2, The number of parallel branches is 2.

Among them, the difference between the star point lead-out line and the terminal lead-out line of each U-phase channel is 6 stator slots; the difference between the two channels of each phase is 1 stator slot in the circumferential direction; the star point corresponding to U-phase, V-phase and W The point lead-out line differs by 4 stator slots in the circumferential direction; the terminal lead-out lines corresponding to U-phase, V-phase and W differ by 4 stator slots in the circumferential direction.

The preparation method includes: connecting the second terminal lead wire of any phase with the first star point lead wire of the phase to form a stator assembly with one parallel branch.

In some specific embodiments of the present invention, the number of stator slots of the stator assembly is 72, the number of poles is 8, the number of phases is 3 and includes U-phase, V-phase and W-phase, and the number of slots per pole and phase is q= 3. The number of parallel branches is 3.

Among them, the difference between the star point lead-out line and the terminal lead-out line of each channel of the U phase is 9 stator slots; the difference between the three channels of the U phase is 1 stator slot in the circumferential direction; the difference between the three channels of the V phase is 1 stator slot. There is a difference of 1 stator slot in the circumferential direction; the difference between the three-way of the W phase is 1 stator slot in the circumferential direction; the star point lead-out lines corresponding to the U phase, V phase and W have a difference of 6 stator slots in the circumferential direction; The terminal lead wires corresponding to U-phase, V-phase and W-phase differ by 6 stator slots in the circumferential direction.

The preparation method includes: connecting the second terminal lead wire of any phase with the first star point lead wire of the phase, and connecting the third terminal lead wire of any phase to the second star point of the phase The lead wires are connected to form a stator assembly with a parallel branch number of 1.

According to some embodiments of the present invention, the first in-slot portion and the second in-slot portion of the plurality of U-shaped conductor segments located at different layers are welded and connected on the soldered end, so that the The winding direction of the windings is configured so that in each phase and each way:

S31. Lead out the terminal lead wires to the radially outermost groove layer of the initial groove;

S32, spanning y stator slots in the same layer along the first direction;

S33, spanning along the second direction, the number of layers of the slot layers varies by one layer every spanning y stator slots, wherein the number of layers varies from the outside to the inside along the radial direction until the radially innermost slot layer;

S34, spanning y stator slots in the same layer along the first direction;

S35, spanning along the first direction, the number of layers of the slot layers varies by one layer every spanning y stator slots, wherein the number of layers varies from the inside to the outside along the radial direction to the outermost slot layer in the radial direction;

S36, S32-S35 are repeated until the winding reaches the adjacent layer of the radially outermost groove layer of the termination groove, and then the star point lead-out line of the phase and the path is drawn out, wherein the termination groove is in the positive direction away from the initial Slot y stator slots;

Wherein, the first direction and the second direction are opposite directions along the circumference of the stator core.

In some embodiments of the present invention, any cross-section perpendicular to the extending direction of the U-shaped conductor segment is a rectangular shape. Thereby, the tank full rate can be improved. Further, in the extending direction of the U-shaped conductor segments, the cross-sectional areas of the U-shaped conductor segments are equal.

The stator assembly according to the second aspect of the present invention is produced using the method for producing a stator assembly according to the embodiment of the first aspect of the present invention.

According to the stator assembly of the embodiment of the present invention, by using the above-mentioned preparation method for the stator assembly, the number of windings can be adjusted, so that it can match the needs of the whole vehicle with different motor voltage levels, and can also match the whole vehicle in different high-efficiency areas. need. In addition, since the number of circuits can be adjusted to be different, the voltage difference between adjacent layers in each stator slot is different, and the requirements for the layer insulation system are different, and different circuits can be selected according to actual risks and cost control. number plan.

Specific embodiments of the stator assembly and the manufacturing method according to the embodiments of the present invention are described below.

The stator assembly according to the first embodiment of the present invention is described according to FIG. 1-FIG. 4. The stator assembly can be used as an initial stator assembly and processed according to customer requirements to obtain final stator assemblies with different numbers of paths.

A stator assembly 100 according to an embodiment of the present invention includes: a stator core 1 and a stator winding 2 .

As shown in FIG. 1 , the stator core 1 has a plurality of stator slots 11 , and each stator slot 11 has a plurality of slot layers. The stator winding 2 includes a plurality of U-shaped conductor segments 20 . As shown in FIGS. 2 and 3 , 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 respectively connected to the bent portion 201 , the first in-slot portion 202 Passing through one of the slot layers in one of the stator slots 11, the second in-slot portion 203 passes through one of the slot layers in the other stator slot 11, and the first in-slot portion 202 and the second in-slot portion 203 pass through the stator The ends of the slots 11 extend beyond the stator core 1 .

Any cross section perpendicular to the extending direction of the U-shaped conductor segment 20 is a rectangular shape. Optionally, any cross section of the U-shaped conductor segment 20 is a rectangle, and the short side of the rectangle is perpendicular to the bottom wall of the stator slot 11 . Further, in the extending direction of the U-shaped conductor segments 20, the cross-sectional areas of the U-shaped conductor segments 20 are equal.

As shown in FIG. 4 , the end where the bent portion 201 of the plurality of U-shaped conductor segments 20 is located is the hairpin end I of the stator winding 2, and the end where the ends of the first in-slot portion 202 and the second in-slot portion 203 are located is called It is the welding end II of the stator winding 2. As shown in FIG. 3, the welding end 2 is composed of a first in-slot portion 202 of a plurality of U-shaped conductor segments 20 and a second in-slot portion of the adjacent U-shaped conductor segments 20. 203 is formed by welding in sequence.

Among them, on the welding end II, the star point lead-out line and the terminal lead-out line of each phase of any phase differ by 3q stator slots 11 in the circumferential direction, and the multiple channels of any phase differ by one stator slot 11 in the circumferential direction;

The corresponding star point lead-out lines between multiple phases differ by 2q stator slots 11 in the circumferential direction;

The corresponding terminal lead-out lines between multiple phases differ by 2q stator slots 11 in the circumferential direction,

Among them, the number of slots per pole and phase is q=z/m/(2p), the number of parallel branches is g, and g≤q;

Among them, z is the number of stator slots, m is the number of phases, and 2p is the number of poles.

The stator assembly 100 here is suitable for a z-slot 2p-level 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 number of pole pairs p can be It is 8-pole, 4-pole, etc., which can be set according to the specific application of the motor.

It should be noted here that "difference" refers to the difference between the numbers of two slots. For example, if the initial slot is 1, the seventh slot is the difference of 6 slots.

According to the stator assembly of the embodiment of the present invention, the distance between the terminal lead wire and the star point lead wire is the smallest, which can be used as the structure of the initial stator assembly, such as the structure setting at the factory, and the number of parallel winding branches can be adjusted according to customer requirements. make adjustments. In this way, on the basis of the stator assembly, if the user needs 1-way access, the stator assembly of the embodiment of the present invention can be processed to adjust it into a stator assembly with 1-way parallel branches, and then connected with the rotor, etc. The components are assembled to obtain a motor connected to one channel; correspondingly, when two channels are required to be connected, the stator assembly of the embodiment of the present invention is processed to adjust it into a stator assembly with two parallel branches.

According to the stator assembly of the embodiment of the present invention, the number of winding lines can be adjusted, so that it can match the needs of the whole vehicle of different motor voltage levels, and can also match the needs of the whole vehicle in different high-efficiency areas. In addition, since the number of circuits can be adjusted to be different, the voltage difference between adjacent layers in each stator slot is different, and the requirements for the layer insulation system are different, and different circuits can be selected according to actual risks and cost control. number plan.

According to an embodiment of the present invention, the above-mentioned winding coil structure can be wound by the following winding method:

S1. Provide a plurality of U-shaped conductor segments 20, each U-shaped conductor segment 20 includes a bent portion and a first in-slot portion 202 and a second in-slot portion 203 respectively connected to the bent portion, the first in-slot portion 202 The pitch between the second inner slot portion 203 is y stator slots 11, where y is an integer and y=z/2p, and any cross section of the U-shaped conductor segment 20 perpendicular to its extending direction is a rectangle shape;

S2. Pass the first in-slot portion 202 of the U-shaped conductor segment 20 through one of the slot layers in one of the stator slots 11, and the second in-slot portion 203 through one of the slot layers in the other stator slot 11, and the first After the first in-slot portion 202 and the second in-slot portion 203 pass through the stator slot 11, the ends thereof protrude beyond the stator core to form welding ends;

S3. Welding and connecting the first in-slot portion 202 and the second in-slot portion 203 of the plurality of U-shaped conductor segments 20 located in multiple layers on the welding end, so that the winding direction of the coil is configured to be in each phase and each path :

S31, lead out the terminal lead wire to the radially outermost slot layer of the initial slot, and the initial slot is the stator slot 11 inserted for the first time when the terminal lead wire is ready to be wound;

S32, spanning y stator slots 11 along the same layer in the opposite direction;

S33, spanning along the positive direction, the number of layers of each spanning y stator slots 11 is changed by one layer, wherein the number of layers varies from the outside to the inside along the radial direction to the innermost groove layer in the radial direction;

S34, spanning y stator slots 11 along the same layer in the opposite direction;

S35, spanning in the reverse direction, the number of layers of each spanning y stator slots 11 is changed by one layer, wherein the number of layers changes from the inside to the outside along the radial direction to the outermost groove layer in the radial direction;

S36. Repeat S32-S35 until the winding reaches the adjacent layer of the radially outermost slot layer of the termination slot, and then leads out the star point lead wire of the phase and the path, wherein the termination slot is y stators away from the initial slot in the positive direction Slot 11, wherein the term "terminating slot" here refers to the last stator slot that passes through after the coil is wound.

Among them, the forward direction is the rotation direction of the motor rotor, and the reverse direction is the reverse direction of the motor rotor rotation.

For the sake of clarity, in the following description, the stator assembly according to the embodiment of the present invention is used for the motor with 8 poles, 48 slots and 3 phases as an example, that is, the number of stator slots is z=48, and the number of phases m=3, wherein, The three phases include U phase, V phase and W phase; the number of poles is 2p=8 (that is, the number of pole pairs is 4), and each of the three phases includes two circuits.

As shown in FIG. 4 , in the stator winding 2 of the stator assembly 100 , the pitches between the first in-slot portion 202 and the second in-slot portion 203 of the U-shaped conductor segment 20 are both y stator slots, where y is an integer And y=z/2p. For an 8-pole 48-slot stator assembly 100, y=6. That is, the difference between the first in-slot portion 202 and the second in-slot portion 203 of each U-shaped conductor segment 20 is 6 stator slots.

In the following description, the present invention is described by taking 6 layers in each stator slot 11 as an example, and the 6-layer line includes layers a, b, c, d, e, and f arranged in sequence. Among them, the innermost layer in the radial direction of the stator core 1 is the a-layer, and the outermost layer is the f-layer.

In the stator assembly shown in Figure 4, the difference between the star point lead-out line and the terminal lead-out line of each U-phase channel is 6 stator slots 11, and the difference between the two channels of each phase is 1 stator slot 11 in the circumferential direction; U The star point lead-out lines corresponding to phase, V-phase and W differ by four stator slots 11 in the circumferential direction; the terminal lead-out lines corresponding to U-phase, V-phase and W differ by four stator slots 11 in the circumferential direction.

More specifically, as shown in FIG. 5 and FIG. 6 , the difference between the terminal lead wire U1A of U phase 1 channel and the terminal lead wire U2A of U phase 2 channel is 1 stator slot, and the terminal lead wire V1A of V phase 1 channel is different by 1 stator slot. There is a difference of 1 stator slot between the terminal lead wire V2A of the V phase 2 channels; the difference between the terminal lead wire W1A of the W phase 1 channel and the terminal lead wire W2A of the W phase 2 channel is 1 stator slot.

As shown in Figure 5 and Figure 6, there is a difference of 6 stator slots between the terminal lead wire U1A of U-phase 1 and the star point lead U1B of U-phase 1, and the terminal lead U2A of U-phase 2 and U-phase There is a difference of 6 stator slots between the 2-way star-point lead-out U2B; similarly, the two-way terminal lead-out line V1A and star-point lead-out line V1B, terminal lead-out line V2A and star-point lead-out line V2B in the V phase are also different. There are 6 stator slots; there is also a difference of 6 stator slots between the terminal lead wire W1A and the star point lead wire W1B, and the terminal lead wire W2A and the star point lead wire W2B of the two circuits in the W phase.

Further, the star point lead-out lines corresponding to U-phase, V-phase, and W differ by 4 stator slots in the circumferential direction. The star point lead-out line V1B of channel 1 and the star-point lead-out line W1B of phase W 1 channel are separated by 4 slots in the circumferential direction. For example, as shown in Figure 2, U1B is led out from the e-layer of the 07 slot, and V1B is led from the 03 slot e-layer. Lead out, W1B is led out from the 47-slot e-layer. Similarly, U2B, V2B and W2B of the second path are drawn from the 08-slot e-layer, the 04-slot e-layer and the 48-slot e-layer respectively, and the difference between them is 4 stator slots in turn.

Correspondingly, the terminal lead wires corresponding to U-phase, V-phase, and W differ by four stator slots 11 in the circumferential direction. Specifically, taking the first channel as an example, the terminal lead wire U1A of the U phase 1 channel, the terminal lead wire V1A of the V phase channel 1, and the terminal lead wire W1A of the W phase 1 channel are separated by 4 slots in the circumferential direction, for example As shown in Figure 2, U1A is introduced from the 01 slot f layer, V1A is introduced from the 45 slot f layer, and W1A is introduced from the 41 slot f layer. Similarly, U2A, V2A and W2A of the second channel are respectively introduced from the 02-slot f-layer, the 46-slot f-layer and the 42-slot f-layer, with a difference of 4 stator slots in turn.

The above-mentioned winding coil structure can be wound by the following winding methods, as shown in Figure 5 and Figure 6, taking the first circuit of phase A as an example, the winding wire is as follows:

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

The winding line of the second path of the A-phase is 1 stator slot different from the first path of the A-phase in the circumferential direction,

The star point lead-out lines corresponding to A phase, B phase and C differ by 4 stator slots in the circumferential direction;

The terminal lead-out lines corresponding to A-phase, B-phase and C-phase differ by 4 stator slots in the circumferential direction.

Of course, when the number of stator slots, poles and phases are different, the winding structure of each phase and each channel is also different.

For example, when the number of stator slots is 72, the number of poles is 8, and the number of phases is 3 and includes U-phase, V-phase and W-phase, each phase includes three circuits (not shown in the figure), wherein the star point of each circuit of U-phase is The difference between the lead wire and the terminal lead wire is 9 stator slots 11, the difference between the three-way of the U-phase is 1 stator slot 11 in the circumferential direction; the difference between the three-way of the V-phase is 1 stator in the circumferential direction. Slot 11, the three-way of W phase differs by 1 stator slot 11 in the circumferential direction, and the star point lead-out lines corresponding to U phase, V phase and W differ by 6 stator slots in the circumferential direction 11, U phase, V The terminal lead wires corresponding to the phases and W differ by 6 stator slots 11 in the circumferential direction.

It is worth noting that, in some preferred embodiments, on the welding end II of the stator winding, the star point lead wire of each channel of any phase is located at the outermost layer in the radial direction, and the terminal lead wire of each channel of any phase is located at the outermost layer in the radial direction. The secondary outer layer in the radial direction is convenient for the lead-in of the terminal lead-in and the lead-out of the star-point lead-out, and the structure of the entire stator winding is simple.

The manufacturing method of the stator assembly 100 according to the embodiment of the present invention will be described below, which is used to process the stator assembly 100 of the above-mentioned embodiment according to user requirements to obtain stator assemblies with different numbers of paths. The stator assembly 100 is suitable for a z-slot 2p-level m-phase motor, the number of slots per pole per phase is q=z/m/(2p), the number of parallel branches is g, and g≤q.

The preparation method according to the embodiment of the present invention comprises:

S1. Select the number of paths g, g is a natural number greater than or equal to 1

When q is odd, g has 2 choices: q way and 1 way;

When q is an even number, g has q/2+1 choices, q, q/2, q/4, ..., 1;

S2. When selecting the number of channels g=q, bend the star point lead wires of each channel in the m-phase outwards and connect them through the neutral wire 3; the terminal lead-out wires of each channel in the m-phase are welded and fixed with the external control connected to the interface. Alternatively, the material in the neutral conductor 3 here may be the same as the material of the U-shaped conductor segment 20.

S3. When the number of channels g=1 is selected, the terminal lead wire of the kth channel in each phase is stretched and bent outward, and then the star point lead wire of the k-1th channel in the corresponding phase is welded and fixed in turn, where k is A natural number from 2 to q; the terminal lead wires of the first channel in each phase are welded and fixed, and then connected to the external controller interface; the star point lead wires of the other channels except the first channel in each phase are bent outward and pass through Neutral 3 connection.

At this time, in order to describe clearly, take 4-way U-phase winding as an example. If you want to change it into one, you can do it in the following way: The lead wire of the U-phase 4-way is stretched and bent, and the U-phase 3-way is connected. The star point lead-out line is connected, the U-phase 3-way lead-out line is stretched and bent and connected to the U-phase 2-way star point lead-out line, and the U-phase 2-way lead-out line is stretched and bent with the U-phase 1-way star point lead-out line. Connect the point lead wire, the lead wire of U phase 1 channel is welded and fixed and connected to the external controller; in addition, the star point lead wire of U phase 4 channel is connected through the first neutral wire 3; the star point lead wire of U phase 3 channel is connected Connect through the second neutral line 3 ;

When S4 and q are even numbers, the q-way in each phase is divided into q/2 groups, and the terminal lead-out wire of one of the at least one group of the q/2 group is stretched and bent and welded with the star-point lead-out wire of the other way. One of the star point lead wires is bent outward and connected through the neutral wire 3, and the other terminal lead wire is welded and fixed and connected to the external controller interface.

In order to describe clearly, the U-phase in the 4-way is still taken as an example. If you want to change it into two-way, you can do it in the following way: The 4-way in the U-phase is divided into two groups, and the first and second channels are the first and second. One group, No. 3 and No. 4 are the second group, in which the lead wire of No. 2 is welded and fixed with the star point lead wire of No. 1, and the star point lead wire of No. 2 is connected to the neutral wire 3. The first road is connected to the external controller. And the lead wire of No. 4 is welded and fixed with the star point lead wire of No. 3, the star point lead wire of No. 4 is connected to the neutral wire 3, and the No. 3 is connected to the external controller. Thus, 2 paths are finally formed.

According to the preparation method of the stator assembly according to the embodiment of the present invention, the number of windings of the stator assembly can be adjusted, and the adjustment method is simple and fast; and the vehicle requirements of different motor voltage levels can be matched, and the vehicle requirements of different high-efficiency areas can also be matched. . In addition, since the number of circuits can be adjusted to be different, the voltage difference between adjacent layers in each stator slot is different, and the requirements for the layer insulation system are different, and different circuits can be selected according to actual risks and cost control. number plan.

In one of the embodiments of the present invention, in step S2 and step S3, the connection method through the neutral wire 3 is welding.

In other embodiments, in the above-mentioned steps S2 and S3, the angle of the outward bending of the star point lead wire and the terminal lead wire is 60-150 degrees, and optionally, the angle of the outward bending may be approximately 90 degrees , which can facilitate welding, simple and convenient.

When describing the preparation method of the stator assembly of the embodiment of the present invention, for the convenience of description, the stator assembly according to the embodiment of the present invention is used for the motor with 8 poles, 48 slots and 3 phases as an example, that is, the number of stator slots is z=48, The number of phases m=3, wherein, the three phases include U phase, V phase and W phase; the number of poles is 2p=8 (that is, the number of pole pairs is 4), and each of the three phases includes two circuits, as shown in Figure 4- shown in Figure 5.

As shown in FIG. 4 , in the stator winding 2 of the stator assembly 100 , the pitches between the first in-slot portion 202 and the second in-slot portion 203 of the U-shaped conductor segment 20 are both y stator slots, where y is an integer And y=z/2p. For an 8-pole 48-slot stator assembly 100, y=6. That is, the difference between the first in-slot portion 202 and the second in-slot portion 203 of each U-shaped conductor segment 20 is 6 stator slots.

For a stator assembly suitable for an 8-pole 48-slot 3-phase motor, based on the initial stator assembly 100, a two-way solution or a one-way solution can be selected.

When the user chooses the two-way solution, bend the first star point lead wires U1B, V1B, W1B, and the second star point lead wires U2B, V2B, W2B of the U, V, W three-phase outwards respectively, And connect them by welding the center line 3, as shown in Figure 7, and finally connect the U, V, W three-phase first terminal lead wires U1A, V1A, W1A, and the second terminal lead wires U2A, V2A, W2A by welding After the terminals are welded and fixed, they are connected to the external controller interface.

When the user chooses a one-way solution, after the U2A, V2A, W2A terminal leads of the U, V, W three-phase are stretched and bent, and the U, V, W three-phase first star point lead-out lines are stretched and bent. U1B, V1B and W1B are respectively welded and fixed, and the second star point lead wires U2B, V2B and W2B are respectively bent outward and connected by welding through the center line 3 . Finally, connect U1A, V1A, W1A of the first terminal lead-out wires of U, V, W three-phase through welding terminals and then connect to the external controller interface.

The following describes the stator assembly 200 according to the third embodiment of the present invention, which is obtained by the processing method of step S2 in the above-mentioned preparation method, wherein the same components as those in the stator assembly 100 of the embodiment have the same reference numerals.

The stator assembly 200 according to an embodiment of the present invention is suitable for use in a z-slot 2p-level m-phase motor, where the number of slots per pole and phase is q=z/m/(2p), the number of parallel branches is g, and g≤ q. 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, and each stator slot 11 has a plurality of slot layers.

The stator winding 2 includes a plurality of U-shaped conductor segments 20, and 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 connected to the bent portion 201, respectively. The first slot The inner portion 202 passes through one of the slot layers in one of the stator slots 11 , the second inner slot portion 203 passes through one of the slot layers in the other stator slot 11 , the first inner slot portion 202 and the second inner slot portion 203 After passing through the stator slot 11 , its end protrudes beyond the stator core 1 .

Any cross section perpendicular to the extending direction of the U-shaped conductor segment 20 is a rectangular shape. Optionally, any cross section of the U-shaped conductor segment 20 is a rectangle, and the short side of the rectangle is perpendicular to the bottom wall of the stator slot 11 . Further, in the extending direction of the U-shaped conductor segments 20, the cross-sectional areas of the U-shaped conductor segments 20 are equal.

As shown in FIG. 4 , the end where the bent portion 201 of the plurality of U-shaped conductor segments 20 is located is the hairpin end I of the stator winding 2, and the end where the ends of the first in-slot portion 202 and the second in-slot portion 203 are located is called It is the welding end II of the stator winding 2. As shown in FIG. 3, the welding end 2 is composed of a first in-slot portion 202 of a plurality of U-shaped conductor segments 20 and a second in-slot portion of the adjacent U-shaped conductor segments 20. 203 is formed by welding in sequence.

Among them, on the welding end II, the star point lead-out line and the terminal lead-out line of each phase of any phase differ by 3q stator slots 11 in the circumferential direction, and the multiple channels of any phase differ by one stator slot 11 in the circumferential direction;

The corresponding star point lead-out lines between multiple phases differ by 2q stator slots 11 in the circumferential direction;

The corresponding terminal lead-out lines between multiple phases differ in space by 2q stator slots 11;

The star point leads of each channel in the m-phase are bent outward and connected through the neutral line 3; the terminal leads of each channel in the m-phase are welded and fixed and connected to the external controller interface. Optionally, the material of the neutral wire 3 is the same as the material of the U-shaped conductor segment 20 . Further optionally, the neutral wire 3 is formed in an arc shape and is concentric with the stator core 1, thereby facilitating welding and having a good connection effect. Of course, the cross-section of the neutral wire 3 can also be formed into a rectangle, and a cross-section equal to the cross-sectional area of the U-shaped conductor section 20 can also be used.

As shown in Figure 6, when the stator assembly is suitable for a motor with 8 poles, 48 slots and 3 phases, that is, the number of stator slots is 48, the number of poles is 8, and the number of phases is 3, including U-phase, V-phase and W-phase. After step S2, a stator assembly 200 with 8 poles, 48 slots, 3 phases and 2 circuits is formed. Based on the stator assembly 100 of the first aspect, the stator assembly 200 bends the two star point lead wires of the U-phase, V-phase and W-phase outwards, and connects them by welding through the neutral wire 3; After the two-way terminal lead wires corresponding to V phase and W are welded and fixed, they are connected to the external controller interface. Optionally, the two-way terminal lead wires corresponding to U-phase, V-phase and W are welded and fixed by welding terminal II.

The following describes the stator assembly 300 according to the fourth embodiment of the present invention, which is obtained by the processing method of step S3 in the above-mentioned preparation method, wherein the same components as those in the stator assembly 100 of the first aspect embodiment use the same reference numerals.

The stator assembly 300 according to an embodiment of the present invention is suitable for a z-slot 2p-level m-phase motor, where the number of slots per pole and phase is q=z/m/(2p), the number of parallel branches is g, and g≤ q. 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, and each stator slot 11 has a plurality of slot layers.

The stator winding 2 includes a plurality of U-shaped conductor segments 20, and 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 connected to the bent portion 201, respectively. The first slot The inner portion 202 passes through one of the slot layers in one of the stator slots 11 , the second inner slot portion 203 passes through one of the slot layers in the other stator slot 11 , the first inner slot portion 202 and the second inner slot portion 203 After passing through the stator slot 11 , its end protrudes beyond the stator core 1 .

Any cross section perpendicular to the extending direction of the U-shaped conductor segment 20 is a rectangular shape. Optionally, any cross section of the U-shaped conductor segment 20 is a rectangle, and the short side of the rectangle is perpendicular to the bottom wall of the stator slot 11 . Further, in the extending direction of the U-shaped conductor segments 20, the cross-sectional areas of the U-shaped conductor segments 20 are equal.

As shown in FIG. 4 , the end where the bent portion 201 of the plurality of U-shaped conductor segments 20 is located is the hairpin end I of the stator winding 2, and the end where the ends of the first in-slot portion 202 and the second in-slot portion 203 are located is called It is the welding end II of the stator winding 2. As shown in FIG. 3, the welding end 2 is composed of a first in-slot portion 202 of a plurality of U-shaped conductor segments 20 and a second in-slot portion of the adjacent U-shaped conductor segments 20. 203 is formed by welding in sequence.

On the welding end II, the star point lead-out line and the terminal lead-out line of each channel of any phase differ by 3q stator slots 11 in the circumferential direction, and the multiple channels of any phase differ by one stator slot 11 in the circumferential direction;

The corresponding star point lead-out lines between multiple phases differ by 2q stator slots 11 in the circumferential direction;

The corresponding terminal lead-out lines between multiple phases differ in space by 2q stator slots 11;

Among them, the terminal lead wire of the kth channel in each phase is welded and fixed with the star point lead wire of the k-1th channel in the corresponding phase in turn, where k is a natural number from 2 to q; the terminal lead wire of the first channel in each phase is welded and fixed After fixing, it is connected to the external controller interface; the star-point lead-out lines of other channels in each phase except the first channel are connected through the neutral line 3.

In some embodiments, the terminal lead wire of the kth channel in each phase is first bent outward, and then welded and fixed to the star point lead wire of the k-1th channel in the corresponding phase in turn.

In some optional examples, the star point lead-out wires of the other paths in each phase except the first path are bent outwards and then connected through the neutral line 3 .

Optionally, the material of the neutral wire 3 is the same as the material of the U-shaped conductor segment 20 . Further optionally, the neutral wire 3 is formed in an arc shape and is concentric with the stator core 1, thereby facilitating welding and having a good connection effect. Of course, the cross-section of the neutral wire 3 can also be formed into a rectangle, and a cross-section equal to the cross-sectional area of the U-shaped conductor segment 20 can also be used.

As shown in Figure 7, when the stator assembly is suitable for a motor with 8 poles, 48 slots and 3 phases, that is, the number of stator slots is 48, the number of poles is 8, and the number of phases is 3, including U-phase, V-phase and W-phase. is 2, at this time, after step S3, a stator assembly 300 with 8 poles, 48 slots, 3 phases and 1 channel is formed. The stator assembly 200 is based on the stator assembly 100 of the first aspect. After the second terminal lead wires of the U-phase, V-phase and W-phase are elongated and bent, they are connected to the U-phase, V-phase and W-phase respectively. The first star point lead-out line is welded and fixed, and the second star point lead-out line of U-phase, V-phase and W-phase is bent outward and connected through neutral wire 3 welding; U-phase, V-phase and W-phase corresponding After the lead wire of the first terminal is welded and fixed, it is connected to the interface of the external controller. Optionally, the lead wires of the two terminals corresponding to the U-phase, the V-phase and the W are fixed by welding through the welding terminal II.

Of course, in another example of the present invention, it is assumed that the number of parallel branches of the stator assembly 100 is 4. If the number of parallel branches of the stator assembly 100 is to be changed to one, the following methods can be used: Connect with the star point lead wire of U-phase 3 channels, the lead wire of U-phase 3 channels is stretched and bent and connected to the star point lead wire of U-phase 2 channels, and the lead wire of U-phase 2 channels is stretched and bent to connect with U-phase 2 channels. The star point lead wire of phase 1 is connected, and the lead wire of U phase 1 channel is connected to the external controller after being welded and fixed; in addition, the star point lead wire of U phase 4 channel is connected through the first neutral line 3; U phase 3 channel The star point lead-out line of U-phase 2 is connected through the second neutral line 3; the star point lead-out line of U-phase 2 is connected through the third neutral line 3.

The following describes the stator assembly 400 according to the fifth embodiment of the present invention, which is obtained by the processing method of step S4 in the above-mentioned preparation method, wherein the same components as those in the stator assembly 100 of the first aspect embodiment use the same reference numerals.

The stator assembly 400 according to an embodiment of the present invention is suitable for use in a z-slot 2p-level m-phase motor, where the number of slots per pole and phase is q=z/m/(2p), the number of parallel branches is g, and g≤ q. 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, and each stator slot 11 has a plurality of slot layers.

The stator winding 2 includes a plurality of U-shaped conductor segments 20, and 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 connected to the bent portion 201, respectively. The first slot The inner portion 202 passes through one of the slot layers in one of the stator slots 11 , the second inner slot portion 203 passes through one of the slot layers in the other stator slot 11 , the first inner slot portion 202 and the second inner slot portion 203 After passing through the stator slot 11 , its end protrudes beyond the stator core 1 .

As shown in FIG. 4 , the end where the bent portion 201 of the plurality of U-shaped conductor segments 20 is located is the hairpin end I of the stator winding 2, and the end where the ends of the first in-slot portion 202 and the second in-slot portion 203 are located is called It is the welding end II of the stator winding 2. As shown in FIG. 3, the welding end 2 is composed of a first in-slot portion 202 of a plurality of U-shaped conductor segments 20 and a second in-slot portion of the adjacent U-shaped conductor segments 20. 203 is formed by welding in sequence.

On the welding end II: the star point lead-out line and the terminal lead-out line of each channel of any phase differ by 3q stator slots 11 in the circumferential direction, and the multiple channels of any phase differ by 1 stator slot 11 in the circumferential direction;

The corresponding star point lead-out lines between multiple phases differ by 2q stator slots 11 in the circumferential direction;

The corresponding terminal lead-out lines between multiple phases differ in space by 2q stator slots 11;

Among them, q is an even number, and the q channels in each phase are divided into q/2 groups. In at least one group of q/2 groups, the terminal lead wire of one channel is welded and fixed with the star point lead wire of the other channel, and the star point lead wire of one channel is welded and fixed. The line is connected through the neutral line 3, and the terminal lead-out line of the other channel is welded and fixed and connected to the external controller interface.

In some embodiments, the terminal lead-out wire of one channel is first stretched and bent, and then welded and fixed with the star point lead-out wire of the other channel. In other examples, the star point lead-out line of one of them is bent outwards and then connected through the neutral line 3 .

Optionally, the material of the neutral wire 3 is the same as the material of the U-shaped conductor segment 20 . Further optionally, the neutral wire 3 is formed in an arc shape and is concentric with the stator core 1, thereby facilitating welding and having a good connection effect. Of course, the cross-section of the neutral wire 3 can also be formed into a rectangle, and a cross-section equal to the cross-sectional area of the U-shaped conductor segment 20 can also be used.

When the stator assembly is suitable for 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 number of channels is 4 including U-phase, V-phase and W-phase. At this time, step S4 in the preparation method in the above-mentioned second aspect embodiment is adopted, and the 4 channels in each phase are divided into two groups, the first group includes the first channel and the second channel, and the second group includes the third channel and the second channel. Four circuits, in which the terminal lead wire in the second circuit is stretched and bent and welded to the star point lead wire of the first circuit, and the star point lead wire of the second circuit is bent outward and connected through the neutral line 3. The terminal lead wire of one channel is welded and fixed and connected to the external controller interface; the terminal lead wire of the fourth channel is stretched and bent, and then welded and fixed to the star point lead wire of the third channel, and the star point lead wire of the fourth channel is connected to the external controller interface. It is bent outside and connected through the neutral wire 3, and the terminal lead wire of the third channel is welded and fixed and connected to the external controller interface (not shown in the figure).

To sum up, according to the stator assembly 100 according to the embodiment of the present invention, the stator assemblies 200 and 300 according to the third, fourth and fifth embodiments of the present invention can be obtained through different steps in the manufacturing method of the stator assembly according to the embodiment of the present invention. , 400. That is to say, through the stator assembly and the preparation method thereof in the embodiment of the present invention, the number of paths of the stator assembly can be adjusted, and the adjustment method is simple and fast; moreover, it can match the needs of the whole vehicle with different motor voltage levels, and can also match the different high-efficiency vehicle demand in the area. In addition, since the number of circuits can be adjusted to be different, the voltage difference between adjacent layers in each stator slot is different, and the requirements for the layer insulation system are different, and different circuits can be selected according to actual risks and cost control. number plan.

In the description of this specification, reference to the terms "one embodiment," "some embodiments," "exemplary embodiment," "example," "specific example," or "some examples", etc., is meant to incorporate the embodiments A particular feature, structure, material, or characteristic described by an example or example is included in at least one embodiment or example of the present invention. In this specification, schematic representations of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the particular features, structures, materials or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.

Although embodiments of the present invention have been shown and described, it will be understood by those of ordinary skill in the art that various changes, modifications, substitutions and alterations can be made in these embodiments without departing from the principles and spirit of the invention, The scope of the invention is defined by the claims and their equivalents.

Claims (9)

1. The preparation method of a stator assembly is suitable for a z-slot 2 p-level m-phase motor, the number of slots of each phase of each pole is q ═ z/m/(2p), the number of parallel branches is a, and a is less than or equal to q, and the stator assembly is characterized by comprising the following steps of:

a cylindrical stator core having a plurality of stator slots arranged at intervals in a circumferential direction of the stator core;

a stator winding including a plurality of U-shaped conductor segments, each of the U-shaped conductor segments including a bend and first and second in-slot portions connected to the bend, respectively, the first in-slot portion of the U-shaped conductor segment passing through one of the slot layers in one of the stator slots and the second in-slot portion passing through one of the slot layers in the other stator slot, the first and second in-slot portions passing through the stator slots with ends thereof protruding beyond the stator core to form a weld terminal on which the first and second in-slot portions of the plurality of U-shaped conductor segments located in adjacent layers are welded;

the preparation method comprises the following steps: connecting one path of terminal outgoing line of any phase with different path star point outgoing lines of the phase;

when q is an even number, the number of parallel branches of the stator assembly is a-2 n or a-1, wherein n is a natural number from 1 to q/2;

sequentially connecting the terminal outgoing line of the kth path in each phase with the star point outgoing line of the kth-1 path in the phase, wherein k is a natural number of 2-q, and connecting the terminal outgoing line of the 1 st path in each phase with a connecting terminal; the star point outgoing line of the q-th path in each phase is connected with a neutral line to form a stator assembly with the number a of parallel branches equal to 1;

dividing parallel branches in each phase into n groups, wherein a terminal outgoing line of one path in at least one group of the n groups is connected with a star point outgoing line of the other path in the group, the star point outgoing line of one path in the group is connected with a neutral line, and the terminal outgoing line of the other path in the group is connected with a wiring terminal to form a stator assembly with the number of the parallel branches a being 2 n;

when q is an odd number, the number of the parallel branches of the stator component is a-1 or a-q,

sequentially connecting the terminal outgoing line of the kth path in each phase with the star point outgoing line of the kth-1 path in the phase, wherein k is a natural number from 2 to q; connecting a terminal outgoing line of the 1 st path in each phase with a connecting terminal; the star point outgoing line of the q-th path in each phase is connected with a neutral line to form a stator assembly with the number a of parallel branches equal to 1;

when a is q, connecting the star point outgoing line of each path of each phase with a neutral line; and the terminal lead wire of each path of each phase is connected with the wiring terminal to form a stator assembly with the number a of parallel branches equal to q.

2. The method for manufacturing a stator assembly according to claim 1, wherein a star point lead-out wire of each path of any phase is positioned on a radially last outer layer on the welding end, and a terminal lead-out wire of each path of any phase is positioned on a radially outermost layer;

on the welding end, the star point outgoing line and the terminal outgoing line of each path of any phase are different by 3q stator slots in the circumferential direction, the multi-path star point outgoing line of any phase is different by 1 stator slot in the circumferential direction, and the multi-path terminal outgoing line of any phase is different by 1 stator slot in the circumferential direction.

3. The method for manufacturing a stator assembly according to claim 1, wherein one of the terminal outgoing lines of any phase is circumferentially different from a different one of the star point outgoing lines of the phase by 3q-1 stator slots.

4. The method of claim 1, wherein the stator assembly has a stator slot number of 48, a pole number of 8, a phase number of 3 including a U phase, a V phase, and a W phase, a slot number of 2 per pole and phase, a parallel branch number of 2,

the difference between a star point outgoing line and a terminal outgoing line of each U phase is 6 stator slots;

the two paths of each phase are circumferentially different by 1 stator slot;

the star point outgoing lines corresponding to the U phase, the V phase and the W phase are different by 4 stator slots in the circumferential direction;

the terminal outgoing lines corresponding to the U phase, the V phase and the W phase are different by 4 stator slots in the circumferential direction;

the preparation method comprises the following steps: and connecting the second terminal outgoing line of any phase with the first star point outgoing line of the phase to form the stator assembly with the number of parallel branches being 1.

5. The method of claim 1, wherein the stator assembly has a stator slot number of 72, a pole number of 8, a phase number of 3 including a U phase, a V phase, and a W phase, a slot number of 3 per pole per phase, a parallel branch number of 3,

the phase difference between the star point outgoing line and the terminal outgoing line of each U phase is 9 stator slots;

every two of the three U-phase paths are circumferentially different by 1 stator slot;

every two of the three paths of the V phase are circumferentially different by 1 stator slot;

every two of the three W-phase paths are circumferentially different by 1 stator slot;

the star point outgoing lines corresponding to the U phase, the V phase and the W phase are different by 6 stator slots in the circumferential direction;

the terminal outgoing lines corresponding to the U phase, the V phase and the W phase are different by 6 stator slots in the circumferential direction;

the preparation method comprises the following steps: and connecting the second terminal outgoing line of any phase with the first star point outgoing line of the phase, and connecting the third terminal outgoing line of any phase with the second star point outgoing line of the phase to form the stator assembly with the number of parallel branches being 1.

6. The method of manufacturing a stator assembly according to claim 1, wherein the first in-slot portions and the second in-slot portions of the plurality of U-shaped conductor segments located at different layers are weld-connected on the weld ends such that a winding direction of the winding is configured to, in each phase per pass:

s31, leading out the terminal lead wire to the radial outermost groove layer of the initial groove;

s32, crossing y stator slots on the same layer along the first direction;

s33, spanning along the second direction, wherein the number of the groove layers changes by one layer when y stator grooves are spanned, and the number of the layer changes from outside to inside along the radial direction to the radially innermost groove layer;

s34, crossing y stator slots on the same layer along the first direction;

s35, spanning along the first direction, wherein the number of layers of the groove layers changes by one layer every time y stator grooves are spanned, and the number of layers changes from inside to outside along the radial direction to the radially outermost groove layer;

s36, repeating S32-S35 until the winding reaches the adjacent layer of the radial outermost slot layer of the termination slot and then the star point lead-out wire of the path of the phase is led out, wherein the termination slot is y stator slots away from the initial slot in the forward direction;

wherein the first direction and the second direction are opposite directions along the circumference of the stator core.

7. The method of manufacturing a stator assembly according to any of the claims 1-6, characterized in that any cross section of the U-shaped conductor segments perpendicular to their direction of extension is rectangular in shape.

8. The method of manufacturing a stator assembly according to claim 7, characterized in that the cross-sectional areas of the U-shaped conductor segments in the extending direction of the U-shaped conductor segments are equal.

9. A stator assembly characterized by being prepared using the preparation method as claimed in any one of claims 1 to 8.

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