阅读说明：本技术 一种采用连续波绕工艺的定子制作方法、定子及扁线电机 (Stator manufacturing method adopting continuous wave winding process, stator and flat wire motor ) 是由 丁晨 庄于方 肖泓扬 王鹏 于 2020-12-25 设计创作，主要内容包括：本发明涉及扁线电机技术领域,特别涉及一种采用连续波绕工艺的定子制作方法、定子及扁线电机,其中,一种采用连续波绕工艺的定子制作方法,包括将扁线导体原材料加工成型为U型,从定子本体内部的径向方向上嵌入若干层扁线导体至定子槽和齿部凹槽；将已嵌入扁线导体的定子本体放至加热炉中加热,使位于齿部凹槽的扁线导体膨胀；取出加热后的定子本体,在齿部凹槽中扣入齿部卡扣。避免了现有技术中扁线电机定子绕组去漆皮、扭头点焊及涂敷等多道工序,解决了因去漆皮、扭头点焊导致的漆皮不易去除干净,激光去漆皮设备成本过高,焊接存在气泡,绝缘涂敷不完全等问题,进而降低了生产成本,提高了定子槽槽满率和扁线电机使用的可靠性。(The invention relates to the technical field of flat wire motors, in particular to a stator manufacturing method adopting a continuous wave winding process, a stator and a flat wire motor, wherein the stator manufacturing method adopting the continuous wave winding process comprises the steps of processing and forming a flat wire conductor raw material into a U shape, and embedding a plurality of layers of flat wire conductors to a stator slot and a tooth part groove in the radial direction in a stator body; putting the stator body embedded with the flat wire conductor into a heating furnace for heating, so that the flat wire conductor positioned in the groove of the tooth part expands; and taking out the heated stator body, and buckling a tooth part buckle in the tooth part groove. The problems that in the prior art, a flat wire motor stator winding is subjected to paint coat removal, head twisting spot welding, coating and the like are solved, the problems that the paint coat is not easy to remove and is completely caused by the paint coat removal and the head twisting spot welding, the laser paint coat removing equipment cost is too high, bubbles exist in welding, the insulating coating is incomplete and the like are solved, the production cost is reduced, and the stator slot fullness rate and the use reliability of a flat wire motor are improved.)

1. A stator manufacturing method adopting a continuous wave winding process is characterized by comprising the following steps:

s1: processing and molding a flat wire conductor raw material into a U-shaped flat wire conductor, and embedding a plurality of layers of flat wire conductors (110) to a stator slot (120) and a tooth part groove (130) from the radial direction in a stator body (100);

s2: heating the stator body (100) in which the flat wire conductor (110) is embedded in a heating furnace to expand the flat wire conductor (110) located in the tooth groove (130);

s3: and taking out the heated stator body (100), and buckling tooth buckles (140) in the tooth grooves (130).

2. The method of claim 1, wherein the stator is manufactured by a continuous wave winding process, comprising the steps of: the flat wire conductor (110) is a flat copper wire.

3. A method of manufacturing a stator according to claim 2, wherein the method comprises: the flat wire conductors (110) embedded in the stator slots (120) are integrally formed, the flat wire conductors (110) in each stator slot (120) comprise n layers, and one or n layers of the flat wire conductors (110) are end conductors.

4. A method of manufacturing a stator according to claim 3, wherein the method comprises: the stator body (100) comprises z stator slots (120), the flat wire conductors (110) in different stator slots (120) form a branch, and each branch is connected with a controller direct current bus through the end conductor.

5. The method of claim 1, wherein the stator is manufactured by a continuous wave winding process, comprising the steps of: the heating temperature of the stator body (100) embedded in the flat wire conductor (110) in the heating furnace is 180-220 ℃, and the heating time is 30s-5 min.

6. The method of claim 1, wherein the stator is manufactured by a continuous wave winding process, comprising the steps of: the tooth part grooves (130) are located between every two stator grooves (120) and are arranged close to the top end of the rotor side, and tooth part buckles (140) are provided with tooth part protrusions matched with the tooth part grooves (130).

7. The method of claim 6, wherein the stator is manufactured by a continuous wave winding process, comprising the steps of: the tooth part buckles (140) are made of soft magnetic materials.

8. The method of claim 7, wherein the stator is manufactured by a continuous wave winding process, comprising the steps of: the tooth part buckle (140) is divided into b sections in the axial direction of the stator body (100), and b is larger than or equal to 1.

9. A stator, characterized by: made by a method of manufacturing a stator according to any of the preceding claims 1-8 using a continuous wave winding process.

10. A flat wire motor is characterized in that: comprising a stator and a rotor, the stator being a stator as claimed in claim 9.

Technical Field

The invention relates to the technical field of flat wire motors, in particular to a stator manufacturing method adopting a continuous wave winding process, a stator and a flat wire motor.

Background

The difference between the flat wire motor and the round wire motor lies in the forming mode of copper wires, the flat wires are beneficial to the improvement of the full rate of the motor slots, the full rate of the slots of the round wire motor is about 40 percent generally, and the full rate of the slots of the flat wire motor can reach more than 60 percent. The improvement of the full rate of the groove means that more copper wires can be filled under the premise that the space is not changed, stronger magnetic field intensity is generated, and power density is improved.

With the development of new energy automobile driving motor technology, the demand for a flat wire motor is more and more strong, and the flat wire motor is becoming an air port developed in the field of new energy driving motors due to the advantages of high power density, low cost, good temperature performance and the like. However, the connection device at the end part of the stator of the flat wire motor is difficult to manufacture and poor in precision, so that the use of the flat wire motor on a new energy automobile in a large scale is restricted.

However, in the prior art, the flat copper wire needs to be cut and segmented after being straightened, and then the flat copper wire is subjected to paint removal, and the flat copper wire needs to be inserted into a groove from the axial direction due to the fact that a tooth part is a semi-closed groove, then a head is twisted, the head is twisted and spot welded, and the operation of insulation coating is performed, for example, a manufacturing process of a flat motor stator winding is disclosed in Chinese patent application (with the publication number of CN109120124A), and in the process of paint removal, the paint is not easy to be removed completely, the cost of laser paint removal equipment is too high, bubbles exist in welding, the insulation coating is incomplete, and the like.

Disclosure of Invention

In order to solve the defect of high manufacturing cost of the flat wire motor in the prior art, the invention provides the stator manufacturing method adopting the continuous wave winding process, the stator and the flat wire motor, which can reduce the manufacturing cost of the flat wire motor and simultaneously improve the slot fullness rate of the flat wire motor and the use reliability of the flat wire motor.

The invention provides a stator manufacturing method adopting a continuous wave winding process, which comprises the following steps:

s1: processing and molding a flat wire conductor raw material into a U-shaped flat wire conductor, and embedding a plurality of layers of flat wire conductors to the stator slot and the tooth part groove from the radial direction in the stator body;

s2: placing the stator body embedded with the flat wire conductor into a heating furnace for heating, so that the flat wire conductor positioned in the tooth part groove is expanded;

s3: and taking out the heated stator body, and buckling a tooth part buckle in the tooth part groove.

Further, the flat wire conductor is a flat copper wire.

Further, the flat wire conductors embedded in the stator slots are integrally formed, the flat wire conductor in each stator slot comprises n layers, and one or n layers of the flat wire conductors are end conductors.

Furthermore, the stator body comprises z stator slots, the flat wire conductors in different stator slots form a branch, and each branch is connected with a controller direct current bus through the end conductor.

Further, the heating temperature of the stator body embedded into the flat wire conductor in the heating furnace is 180-220 ℃, and the heating time is 30s-5 min.

Furthermore, tooth part grooves are located between every two stator grooves and are close to the top end of the rotor side, and tooth part buckles are provided with tooth part bulges matched with the tooth part grooves.

Further, the tooth part buckles are made of soft magnetic materials.

Furthermore, the tooth part is buckled on the stator body in the axial direction and is divided into b sections, and b is larger than or equal to 1.

The invention also provides a stator which is manufactured by adopting the stator manufacturing method adopting the continuous wave winding process.

The invention also provides a flat wire motor which comprises a stator and a rotor, wherein the stator adopts any one of the stators.

Compared with the prior art, the stator manufacturing method, the stator and the flat wire motor adopting the continuous wave winding process, provided by the invention, have the advantages that the plurality of layers of flat wire conductors are embedded into the stator slot and the tooth part groove from the radial direction in the stator body, the flat wire conductors in the stator slot are subjected to continuous wave winding and integrated compression molding, then the stator body is placed into the heating furnace for heating, and finally the tooth part buckle is arranged at the inner opening of the tooth part groove, so that the multiple procedures of removing the paint coat, twisting head spot welding, coating and the like of the stator winding of the flat wire motor in the prior art are avoided, the problems of difficult removal of the paint coat, over-high equipment cost of laser paint coat removing, bubble existing in welding, incomplete insulation coating and the like caused by the paint coat removing and twisting head spot welding are solved, the production cost is further reduced, and the full rate of the stator slot and the use reliability of.

Drawings

In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings needed to be used in the description of the embodiments or the prior art will be briefly introduced below, and it is obvious that the drawings in the following description are some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to these drawings without creative efforts.

FIG. 1 is a flow chart of a method of manufacturing a stator according to the present invention;

FIG. 2 is a first schematic structural diagram of a stator according to the present invention;

FIG. 3 is a schematic structural diagram of a stator according to the present invention;

FIG. 4 is a side view of a stator provided by the present invention;

fig. 5 is a schematic view of the stator winding unwinding provided by the present invention.

Reference numerals:

100 stator body 110 flat wire conductor 120 stator slot

130 tooth groove 140 tooth snap

Detailed Description

In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are some, but not all, embodiments of the present invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.

In the description of the present invention, it should be noted that the terms "center", "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate orientations or positional relationships based on those shown in the drawings, and are only for convenience of description and simplicity of description, but do not indicate or imply that the referred device or element must have a specific orientation, be constructed and operated in a specific orientation, and thus, should not be construed as limiting the present invention. Furthermore, the technical features designed in the different embodiments of the present invention described below may be combined with each other as long as they do not conflict with each other.

Fig. 1 is a flowchart of a stator manufacturing method provided by the present invention, and as shown in fig. 1, the stator manufacturing method using a continuous wave winding process provided by the present invention includes the following steps:

s1: processing and molding the flat wire conductor raw material into a U shape, and embedding a plurality of layers of flat wire conductors 110 from the inner radial direction of the stator body 100 to the stator slots 120 and the tooth part grooves 130;

s2: heating the stator body 100 in which the flat wire conductor 110 is embedded in a heating furnace to expand the flat wire conductor 110 in the tooth groove 130;

s3: the heated stator body 100 is taken out, and a tooth snap 140 is snapped into the tooth groove 130.

In the specific implementation, the flat wire conductor raw material is generally supplied by a roll as a unit, namely, the flat wire conductor raw material with the length of about one hundred meters is wound into a roll when supplied, when a traditional flat wire motor stator is manufactured, the flat wire conductor raw material needs to be straightened, cut into sections, then remove paint coats, form a U-shaped wire, and then insert the U-shaped wire into a stator slot, and because the tooth slot is a semi-closed slot, the U-shaped wire conductor raw material needs to be inserted into the tooth slot from the axis in the stator body, and then the operation such as twisting head spot welding insulation coating is performed; in the traditional wave winding stator manufacturing and paint skin removing process, the paint skin is not easy to remove completely, the laser paint skin removing equipment is too high in cost, air bubbles exist in welding, and the insulating coating is incomplete.

In this embodiment, the flat wire conductor is a flat copper wire, as shown in fig. 1, the flat wire conductor is firstly straightened and then directly formed into a U-shaped flat wire conductor, a plurality of layers of flat wire conductors 110 are embedded into the stator slots 120 and the tooth grooves 130 from the radial direction inside the stator body 100, and then the stator body 100 embedded with the flat wire conductors 110 is placed into a heating furnace for heating, wherein the heating temperature is 180-.

Because the expansion coefficient of copper is higher than that of the stator body, in the present embodiment, the stator body, i.e., the stator core, the flat wire conductor 110 located in the stator slot 120 is relatively fixed and does not fall off, and the flat wire conductor 110 located in the tooth portion groove 130 expands and becomes larger, and finally, after the heated stator body 100 is taken out, the tooth portion buckle 140 is buckled into the tooth portion groove 130, so that the stator manufacturing is completed; by adopting the stator manufacturing method of the continuous wave winding process, the problems that the paint coat is not easy to remove completely, the cost of laser paint coat removing equipment is too high, bubbles exist in welding, the insulating coating is incomplete and the like in the traditional stator manufacturing process are solved.

Specifically, as shown in fig. 2 to 5, in this embodiment, the stator body 100 includes z stator slots 120, and the flat wire conductor 110 embedded in the stator slots 120 is formed by continuous wave winding and integral pressing, which not only improves the slot filling rate of the flat wire conductor in the flat wire motor, but also eliminates the operations of twist spot welding, coating and the like in the conventional stator manufacturing method, and does not have any welding spot, thereby avoiding the problem of bubbles existing in welding;

the flat wire conductors 110 in each stator slot 120 include n layers of flat wire conductors, where one or n layers of flat wire conductors 110 are end conductors; in this embodiment, taking n-4 and z-36 as an example, the first-layer flat wire conductor 110 located in the slots of the stator slots 120 is an end conductor, the flat wire conductors 110 located in different stator slots 120 form a branches, a is greater than or equal to 1, and each branch is connected to the controller dc bus through the end conductor.

As shown in fig. 2 to 5, in the present embodiment, the tooth groove 130 is located between two stator grooves 120 and is disposed near the top end of the rotor side, a tooth protrusion adapted to the tooth groove 130 is disposed on the tooth buckle 140, the tolerance fit between the tooth buckle 140 and the tooth groove 130 is less than or equal to 50 μm, the tooth buckle 140 is made of a soft magnetic material, and the tooth buckle 140 can be divided into b sections in the axial direction of the stator body 100, where b is greater than or equal to 1; after the heated stator body 100 is taken out, the flat wire conductor 110 located in the tooth groove 130 expands and becomes large, and the tooth snap 140 is snapped into the tooth groove 130.

Compared with the prior art, the stator manufacturing method adopting the continuous wave winding process, provided by the invention, has the advantages that the plurality of layers of flat wire conductors are embedded into the stator slot and the tooth part groove from the radial direction in the stator body, the flat wire conductors in the stator slot are subjected to continuous wave winding and are integrally pressed and molded, then the stator body is placed into the heating furnace for heating, and finally the tooth part buckle is arranged at the inner opening of the tooth part groove, so that the multiple processes of removing the paint coat, twisting head spot welding, coating and the like of the flat wire motor stator winding in the prior art are avoided, the problems that the paint coat is not easy to remove and is completely removed due to the removal of the paint coat and the twisting head spot welding, the cost of laser paint coat removing equipment is overhigh, the welding has bubbles, the insulating coating is incomplete and the like are solved, the production cost is further reduced, and the full.

The invention also provides a stator which is manufactured by adopting the stator manufacturing method adopting the continuous wave winding process.

The invention also provides a flat wire motor which comprises a stator and a rotor, wherein the stator adopts any one of the stators.

Compared with the prior art, the stator manufacturing method, the stator and the flat wire motor adopting the continuous wave winding process, provided by the invention, have the advantages that the plurality of layers of flat wire conductors are embedded into the stator slot and the tooth part groove from the radial direction in the stator body, the flat wire conductors in the stator slot are subjected to continuous wave winding and integrated compression molding, then the stator body is placed into the heating furnace for heating, and finally the tooth part buckle is arranged at the inner opening of the tooth part groove, so that the multiple procedures of removing the paint coat, twisting head spot welding, coating and the like of the stator winding of the flat wire motor in the prior art are avoided, the problems of difficult removal of the paint coat, over-high equipment cost of laser paint coat removing, bubble existing in welding, incomplete insulation coating and the like caused by the paint coat removing and twisting head spot welding are solved, the production cost is further reduced, and the full rate of the stator slot and the use reliability of.

Although terms such as stator body, flat wire conductors, stator slots, tooth grooves and tooth snaps are used more often herein, the possibility of using other terms is not excluded. These terms are used merely to more conveniently describe and explain the nature of the present invention; they are to be construed as being without limitation to any additional limitations that may be imposed by the spirit of the present invention.

Finally, it should be noted that: the above embodiments are only used to illustrate the technical solution of the present invention, and not to limit the same; while the invention has been described in detail and with reference to the foregoing embodiments, it will be understood by those skilled in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some or all of the technical features may be equivalently replaced; and the modifications or the substitutions do not make the essence of the corresponding technical solutions depart from the scope of the technical solutions of the embodiments of the present invention.