CN120200401A - Stator assembly for electric motor, electric motor, electric drive assembly system and vehicle - Google Patents

Abstract

The present disclosure proposes a stator assembly (10) for an electric machine, comprising a stator core (100), the stator core (100) being configured as a hollow cylinder, a plurality of teeth (110) extending axially being provided on an inner circumferential wall of the stator core (100), conductor slots (120) being formed between adjacent teeth (110), a winding comprising a conductor (200) arranged in the conductor slots (120), an insulator (300) surrounding the conductor (200) within the conductor slots (120), an end insulating plate (400) provided with an end plate (410) extending radially along an outer end face (130) of an axial end of the stator core (100) and a plurality of nesting slots (420) extending axially from the end plate (410), each nesting slot (420) being inserted into a respective conductor slot (120) such that the conductor (200) extends through the respective nesting slot (420). The present disclosure also relates to an electric machine comprising the above stator assembly. The disclosure also relates to an electric drive assembly system and a vehicle.

Description

Stator assembly for an electric machine, electric drive assembly system and vehicle

Technical Field

The present disclosure relates to the field of electric machines, and more particularly to a stator assembly for an electric machine and an electric machine including such a stator assembly.

Background

A stator assembly for an electric machine includes a stator core and conductors disposed in recesses of the stator core for forming windings. The conductors of the windings typically protrude at both axial ends of the stator core, e.g. to form a chignon of the windings. The prior art generally uses insulating paper to achieve electrical insulation between the stator core and the winding conductors. In order to ensure that there is a sufficient creepage distance between the winding conductors beyond the axial ends of the stator core and the axial ends of the stator core to avoid electrical conduction between the conductors and the stator core to adversely affect the performance of the motor, it is necessary to provide insulating paper to a sufficient length beyond the respective axial ends of the stator core, which increases the length of the winding conductors protruding beyond the axial ends of the stator core and thus increases the axial dimension of the stator assembly, and inevitably over-sizing the overall size of the motor in which such a stator assembly is used. This is disadvantageous, on the one hand, for the integration of the motor in a confined space and, on the other hand, also increases the material costs of the winding conductors and the motor housing etc.

There remains a need for a stator assembly for an electric machine of a completely new design so that the above-mentioned technical problems can be solved.

Disclosure of Invention

To this end, the present disclosure proposes a stator assembly for an electric machine, comprising, according to one embodiment:

the stator core is configured into a hollow cylinder, a plurality of teeth extending axially are arranged on the peripheral wall of the stator core, and conductor grooves are formed between adjacent teeth;

A winding including a conductor disposed in the conductor slot;

An insulator surrounding the conductor within the conductor slot;

An end insulating plate provided with an end plate extending radially along an outer end face of an axial end of the stator core and a plurality of fit-on grooves extending axially from the end plate, each fit-on groove being inserted into a corresponding conductor groove such that the conductor extends through the corresponding fit-on groove.

Thus, in the present disclosure, the axially extending nesting slots of the end insulating plates inserted into the corresponding conductor slots extend the insulated creepage path around the corresponding winding conductors in such a way as to extend axially inwardly from the axial ends of the stator core, more particularly the insulated creepage path between the winding conductors located at the axial ends of the stator core and the stator core, so that it is unnecessary to use insulating paper around the winding conductors extending beyond the axial ends of the stator core, so that the length of the winding conductors extending beyond the axial ends of the stator core is not increased, and thus the axial dimension of the stator assembly is not increased, and the material of the winding conductors can be saved, increasing the cost effectiveness. In the case of a stator assembly for an electric machine, this also contributes to a more compact overall structure of the electric machine, to integration of the electric machine in a confined space, and at the same time to a reduction in the use of materials for the housing of the electric machine, etc., and thus to a reduction in costs. In addition, the end plates of the end insulating plates, which extend radially along the outer end face of the axial end of the stator core, then create a circumferential insulating creepage path between circumferentially adjacent nested slots, i.e. in the circumferential direction, an insulating creepage distance between adjacent winding conductors extending beyond the axial end of the stator core, ensuring electrical insulation between the winding conductors.

According to various embodiments of the present disclosure, the stator assembly proposed by the present disclosure may include one or more of the following further developments.

In some embodiments, each of the encasement slots is located between a respective insulator and the stator core in a respective conductor slot. This further ensures electrical insulation between the stator core and the winding conductors.

In some embodiments, the end insulating plate is annular, the end insulating plate being provided radially inside with a flange extending from the end plate. The provision of the flange may further increase the insulated creepage path between the winding conductor located at the axial end of the stator core and the stator core.

In some embodiments, the flange extends axially in a direction opposite to the direction of extension of the nesting groove. Due to the provision of the nesting groove, the flange does not have to extend too much in the axial direction. More specifically, the flange does not have to extend axially outward in a manner that would require an increase in the length of the winding conductor beyond the axial end of the stator core.

In some embodiments, the end insulating plate further comprises a plurality of spacer ribs extending outwardly from the end plate, each spacer rib being disposed at a junction between two adjacent nesting grooves. This provision of the spacer ribs can further increase the insulation creepage distance between adjacent winding conductors extending out of the axial ends of the stator core.

In some embodiments, the separator rib extends axially in a direction opposite to the direction of extension of the nesting groove. More specifically, the separator ribs do not have to extend axially outward in a manner that would require an increase in the length of the winding conductors beyond the axial ends of the stator core.

In some embodiments, the end insulating plate is a single piece made of plastic. Thereby, the end insulating plate can be made in a process and material saving, and thus cost saving, and the end insulating plate in one piece saves assembly process, further contributing to cost effectiveness.

In some embodiments, the nesting groove of the end insulating plate is elastically deformable. This facilitates the mounting of the sleeve grooves of the end insulating plates in place in the conductor grooves of the stator core and the retention of the end insulating plates on the stator core.

In some embodiments, the end plates of the end insulating plates cover at least a portion or all of the outer end face of the axial end of the stator core.

In some embodiments, one of the end insulating plates is provided at each axial end of the stator core.

In some embodiments, the notch cross-section of the conductor slot that receives the segment of the corresponding encasement slot is larger than the notch cross-section of the remainder of the conductor slot. This aspect facilitates the installation of the nesting slots of the end insulating plates in the corresponding conductor slots while still ensuring the slot filling rate of the conductor slots so as not to have any adverse effect on the performance of the stator assembly due to the arrangement of the end insulating plates.

According to another aspect of the present disclosure, the present disclosure also proposes an electric machine comprising a stator assembly according to any one of the above embodiments. And therefore the motor proposed by the present disclosure has the various advantages described above with respect to the stator assembly.

According to yet another aspect of the present disclosure, the present disclosure also proposes an electric drive assembly system comprising a stator component or an electric motor as described previously.

According to yet another aspect of the disclosure, the disclosure also proposes a vehicle comprising a stator assembly as described above, an electric machine or an electric drive train as described above.

Drawings

In order to more clearly illustrate the technical solutions of the embodiments of the present disclosure, the drawings that are needed in the embodiments will be briefly described below, it being understood that the following drawings only illustrate some embodiments of the present disclosure and therefore should not be considered as limiting the scope, and other related drawings may be obtained according to these drawings without inventive effort for a person of ordinary skill in the art. In the drawings:

FIG. 1 is a schematic perspective view of a stator assembly with a majority of winding wires removed according to an exemplary embodiment;

FIG. 2 is a schematic perspective view of an end insulator plate of a stator assembly according to one exemplary embodiment;

Fig. 3 is a perspective view of the end insulating plate of fig. 2 shown from another angle;

FIG. 4 is a schematic perspective view of the stator assembly of FIG. 1 shown from another angle;

FIG. 5 is a partial longitudinal cross-sectional view of a stator assembly according to an exemplary embodiment;

FIG. 6 is a partial longitudinal cross-sectional view of a stator assembly according to an exemplary embodiment shown from another angle;

fig. 7 shows in a partial enlarged cross-sectional view the extension of the nesting groove, flange and spacer bead of the end insulating plate according to an exemplary embodiment.

List of reference numerals

10 Stator assembly

100 Stator core

110 Teeth

120 Conductor slot

130 Outer end face

150. 160 Axial ends of stator core

170 Hollow part

200 Conductor

300 Insulator

400 End insulating plate

410 End plate

420 Suit groove

430 Flange

440 Separating rib

470 Hole

A first extension length

B second extension length

C third extension length

DETAILED DESCRIPTION OF EMBODIMENT (S) OF INVENTION

A stator assembly according to an embodiment of the present disclosure is described in detail below with reference to the accompanying drawings. For the purposes of making the objects, technical solutions and advantages of the present disclosure more apparent, the technical solutions in the embodiments of the present disclosure will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present disclosure, and it is apparent that the described embodiments are some embodiments of the present disclosure, but not all embodiments.

Accordingly, the following detailed description of the embodiments of the present disclosure, provided in connection with the accompanying drawings, is not intended to limit the scope of the disclosure, as claimed, but is merely representative of selected embodiments of the disclosure. All other embodiments, which can be made by one of ordinary skill in the art without inventive effort, based on the embodiments in this disclosure are intended to be within the scope of this disclosure.

The singular forms include the plural unless the context defines otherwise. Throughout the specification the terms "comprises," "comprising," "includes," "including," and the like are used herein to specify the presence of stated features, integers, steps, operations, elements, components, or groups thereof, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, or groups thereof.

In addition, even though terms including ordinal numbers such as "first", "second", etc. may be used to describe various components, the components are not limited by these terms, and these terms are used only to distinguish one element from other elements. For example, a first component may be referred to as a second component, and similarly, a second component may be referred to as a first component, without departing from the scope of the present disclosure.

In the description of the present invention, it should be understood that the directions or positional relationships indicated by the terms "upper", "lower", "left", "right", "inner", "outer", etc. are based on the directions or positional relationships shown in the drawings, or the directions or positional relationships conventionally put in place when the disclosed product is used, or the directions or positional relationships conventionally understood by those skilled in the art are merely for convenience of describing the present disclosure and simplifying the description, and do not indicate or imply that the apparatus or elements referred to must have a specific direction, be configured and operated in a specific direction, and therefore should not be construed as limiting the present disclosure.

As shown in fig. 1-6, a stator assembly 10 for an electric machine is presented in accordance with an aspect of the present disclosure. According to one embodiment, the stator assembly 10 includes a stator core 100, windings, an insulator 300, and an end insulating plate 400.

In one embodiment, as shown in fig. 1 and 4-6, the stator core 100 is configured as a hollow cylinder, and a plurality of teeth 110 extending axially are provided on the circumferential wall of the stator core 100, more specifically the teeth 110 are open on the inner circumferential wall, and conductor slots 120 are formed between adjacent teeth 110. For example, the hollow 170 of the stator core 100 may accommodate a rotor (not shown) for forming an electric machine. The winding may then comprise conductors 200 arranged in the conductor slots 120. In some embodiments, the stator core 100 of the stator assembly 10 may be formed of a stack of thin metal plates, and the stator core 100 may be provided on an inner circumferential wall thereof with slots 120 open to the inside, the slots 120 being defined in the circumferential direction by the stator teeth 110, the slots 120 for receiving windings forming respective phase windings. Windings pass axially through slots 120 and form a bun protruding at each axial end 150, 160 of stator core 100. The windings are obtained, for example, by continuous wires covered with enamel or by winding around the respective teeth 110 conductive elements in the form of pins connected to each other by welding. These windings form a multiphase winding, for example connected in the form of a star or triangle, the output of which is connected to an inverter (not shown), which may also be used as a rectifier bridge.

It should be noted that in the sense herein, "axial" refers to a direction along a central longitudinal axis X (schematically shown in dashed lines in fig. 1) of the stator assembly 10, more specifically an axis of rotation which may be along a rotor shaft of an electric machine comprising the stator assembly 100, "circumferential" refers to a direction encircling the axial direction, more specifically a direction encircling the central longitudinal axis X of the stator assembly 10, and "radial" refers to a direction orthogonal to the central longitudinal axis X of the stator assembly 100, more specifically a direction extending from the central longitudinal axis X of the stator assembly 100 towards the outside of the stator assembly 100 in a direction perpendicular to the central longitudinal axis X.

In some embodiments, as shown in fig. 5-6, the insulator 300 then surrounds the winding conductor 200 within the corresponding conductor slot 120 to ensure electrical insulation between the conductor 200 and the stator core 100. More specifically, the insulator 300 is insulating paper. For example, the insulating paper may be folded to match the shape of the inner circumference of the conductor groove 120 so as to be capable of being laid in the conductor groove 120 in a form-fitting manner.

In some embodiments, as shown in fig. 2-6, the end insulating plate 400 may be provided with an end plate 410 extending radially along the outer end face 130 of the axial end 150 of the stator core 100 and a plurality of encasement slots 420 extending axially from the end plate 410, each encasement slot 420 being inserted into a respective conductor slot 120 such that the conductors 200 received in the respective conductor slots 120 can also extend through the respective encasement slot 420 beyond the axial end 150 of the stator core 100, e.g., to form a chignon. In some embodiments, the end plates 410 of the end insulating plates 400 cover at least a portion of the outer end faces 130 of the respective axial ends 150 of the stator core 100. In other embodiments, the end plates 410 of the end insulating plates 400 cover all of the outer end faces 130 of the respective axial ends 150 of the stator core 100. More specifically, the end plates 410 of the end insulating plates 400 are disposed against the outer end faces 130 of the respective axial ends 150 of the stator core 100. More specifically, the encasement slots 420 may be disposed against the inner walls of the respective conductor slots 120.

Thus, in the present disclosure, the axially extending encasement slots 420 of the end insulating plates 400 inserted into the respective conductor slots 120 of the stator core 100 surround the respective winding conductors 200, elongating the insulated creepage path in an axially inward extending manner from the axial ends 150, 160 of the stator core 100, more specifically, elongating the insulated creepage path between the winding conductors 200 located at the axial ends 150, 160 of the stator core 100 and the stator core 100, thereby eliminating the need to use insulating paper around the winding conductors 200 extending beyond the axial ends 150, 160 of the stator core 100, thereby not increasing the length of the winding conductors 200 extending beyond the axial ends 150, 160 of the stator core 100, and thus not increasing the axial dimension of the stator assembly 10, and enabling saving of material of the winding conductors 200, increasing cost effectiveness. In the case where the stator assembly 10 is used in an electric machine, this also facilitates the formation of an electric machine having a more compact overall structure, facilitates the integration of the electric machine in a confined space, and also reduces the use of materials for the housing or the like of the electric machine, thereby reducing costs. Furthermore, the end plates 410 of the end insulating plates 400 extending radially along the outer end faces 130 of the axial ends 150, 160 of the stator core 100 create a circumferential insulating creepage path between circumferentially adjacent nesting grooves 420, i.e. an insulating creepage distance between adjacent winding conductors 200 extending beyond the axial ends 150, 160 of the stator core 100 in the circumferential direction, ensuring electrical insulation between the winding conductors 200.

More specifically, the end insulating plate 400 of the present disclosure may be provided at one or both of the two axial ends 150, 160 of the stator core 100.

In some embodiments, as shown in fig. 5-6, a nesting groove 420 of an end insulating plate 400 may be provided between the corresponding insulator 300 and the stator core 100. This further ensures electrical insulation between the stator core 100 and the winding conductor 200. In a more specific embodiment, it may be provided that the slot cross section of the conductor slot 120 of the stator core 100 receiving the section of the corresponding encasement slot 420 is larger than the slot cross section of the remaining part of the conductor slot 120. This aspect facilitates the installation of the nesting slots 420 of the end insulating plates 400 in place in the corresponding conductor slots 120 while still ensuring the slot fill rate of the conductor slots 120 so as not to have any adverse effect on the performance of the stator assembly 10 due to the placement of the end insulating plates 400. More specifically, in the case where the stator core 100 of the stator assembly 10 is provided with the end insulating plates 400 at both axial ends 150, 160, the conductor slots 120 of the stator core 100 are formed such that the slot cross-section near both axial ends is larger than that of the axial intermediate section, the end sections with large slot cross-sections being for receiving the encasement slots 420 and the optional insulator 300.

In some embodiments, the end insulating plate 400 may be configured such that its nesting groove 420 is elastically deformable. This facilitates the mounting of the nesting grooves 420 of the end insulating plate 400 in place in the conductor grooves 120 of the stator core 100 and the retention of the end insulating plate 400 on the stator core 100.

In some embodiments, as shown in fig. 2-4, the end insulating plate 400 is generally annular in shape. For example, the end insulating plate 400 may be provided with a central hole 470 aligned with the hollow 170 of the stator core 100, for example, to allow the rotor received in the hollow 170 of the stator core 100 to protrude. In some embodiments, as shown in fig. 2-6, the end insulator plate 400 is provided radially inward with a flange 430 extending from its end plate 410. This provision of the flange 430 may further increase the insulated creepage path between the winding conductors 200 located at the axial ends 150, 160 of the stator core 100 and the stator core 100. In an embodiment not shown, flange 430 may extend radially from a radially inner side of end insulator plate 400, such as the side defining its central aperture 440. In another particular embodiment, as shown, the flange 430 may extend axially in a direction opposite the direction of extension of the nesting groove 420. Due to the provision of the nesting groove 420, the flange 430 does not have to extend too much in the axial direction to achieve a sufficiently long insulated creepage path. More specifically, flange 430 need not extend axially outward in a manner that would require an increase in the length of winding conductor 200 beyond axial ends 150, 160 of stator core 100. It should be appreciated that flange 430 may extend in other directions as well, so long as it may increase the insulated creepage path without increasing the axial extension of conductor 200.

In a specific embodiment, as shown in fig. 7, the axial extension length of the nesting groove is referred to as a first extension length a, which should be not smaller than the minimum allowable creepage distance between the winding conductor 200 located at the axial end 150, 160 of the stator core 100 and the stator core 100, i.e., if smaller than the minimum allowable creepage distance, there is a risk that current creeps up the stator core 100 from the winding conductor 200 located at the axial end 150, 160 of the stator core 100. The extension length of the flange 430 of the end insulating plate 400, more specifically, the linear extension length from the connection with the end plate 410 of the end insulating plate 400 to the free edge of the flange 430 is referred to as a second extension length b, which is smaller than the first extension length a, more specifically, b=a/2 is set.

In some embodiments, as shown in fig. 3-6, the end insulating plate 400 may further include a plurality of spacer ribs 440 extending outwardly from the end plate 410 thereof, each spacer rib 440 being disposed at a junction between two adjacent nesting grooves 420. This provision of the separation rib 440 may further increase the insulated creepage path between the adjacent winding conductors 200 extending out of the axial ends 150, 160 of the stator core 100. In some embodiments, as shown, the spacer ribs 440 extend axially in a direction opposite the direction of extension of the nesting groove 420. More specifically, the separator ribs 440 do not have to extend axially outward in a manner that would require an increase in the length of the winding conductor 200 beyond the axial ends 150, 160 of the stator core 100 to achieve a sufficiently long insulated creepage path. In some embodiments, as shown, the spacer bars 440 are disposed to extend radially outwardly from the flange 430 of the end insulator plate 400 beyond the radial extent of the nesting groove 420 adjacent thereto. More specifically, in an embodiment not shown, the separation rib 440 may have a radial cross section of a triangle or trapezoid, i.e., it includes an inclined surface to further increase the creepage path. It should be appreciated that the spacer 440 may extend in other directions as long as it increases the insulated creepage path without increasing the axial extension of the conductor 200. In a specific embodiment, as shown in fig. 7, the length of extension of the spacer ribs 440 from their connection with the end plate 410 to their free edges, referred to as the third extension c, is smaller than the first extension a by a specific value, depending on the creepage distance between the circumferentially adjacent winding conductors 200 extending out of the axial ends 150, 160 of the stator core 100.

In some embodiments, as shown in fig. 2-4, the end insulating plate 400 is a single piece, i.e., is a unitary piece. More specifically, the end insulating plate 400 is made of plastic. Thus, the end insulating plate 400 may be manufactured in a process and material saving, and thus cost saving, and the end insulating plate 400 in one piece saves an assembly process, further contributing to cost effectiveness.

According to another aspect of the present disclosure, the present disclosure also proposes an electric machine comprising a stator assembly 10 according to any of the above embodiments. And thus the motor proposed by the present disclosure provides the various advantages described above with respect to the stator assembly 10.

According to another aspect of the present disclosure, the present disclosure also proposes an electric drive assembly system comprising the stator assembly or the motor described above.

According to another aspect of the present disclosure, the present disclosure also proposes a vehicle comprising a stator assembly, an electric machine or an electric drive train as described previously, and having the functions as described previously. The vehicle may be an electrified vehicle (ELECTRIFIED VEHICLE), such as a Battery electric vehicle (BEV, battery ELECTRIC VEHICLE), a Hybrid electric vehicle (HEV, hybrid ELECTRIC VEHICLE), a Plug-in Hybrid ELECTRIC VEHICLE, an extended range electric vehicle (Range extended EV), a Fuel cell vehicle (FCEV, fuel CELL ELECTRIC VEHICLE). The vehicle may also be a hydrogen-powered vehicle.

While the exemplary embodiments of the stator assembly according to the present invention have been described in detail with reference to the preferred embodiments, it will be understood by those skilled in the art that various changes and modifications may be made to the specific embodiments described above and various technical features and structures of the present invention may be combined without departing from the scope of the present invention.

The scope of the present disclosure is defined not by the above-described embodiments but by the appended claims and their equivalents.

Claims (14)

1. A stator assembly (10) for an electric machine, comprising:

a stator core (100), wherein the stator core (100) is configured as a hollow cylinder, a plurality of teeth (110) extending axially are arranged on the peripheral wall of the stator core (100), and conductor grooves (120) are formed between adjacent teeth (110);

A winding comprising a conductor (200) arranged in the conductor slot (120);

An insulator (300) surrounding the conductor (200) within the conductor slot (120);

An end insulating plate (400) provided with an end plate (410) extending radially along an outer end face (130) of an axial end of the stator core (100) and a plurality of fit-on grooves (420) extending axially from the end plate (410), each fit-on groove (420) being inserted into a corresponding conductor groove (120) such that the conductor (200) extends through the corresponding fit-on groove (420).

2. The stator assembly (10) of claim 1, wherein each of the nested slots (420) is located between a respective insulator (300) and the stator core (100) in a respective conductor slot (120).

3. The stator assembly (10) according to claim 1 or 2, wherein the end insulating plate (400) is annular, the end insulating plate (400) being provided radially inside with a flange (430) extending from the end plate (410).

4. A stator assembly (10) according to claim 3, wherein the flange (430) extends axially in a direction opposite to the direction of extension of the nesting groove (420).

5. The stator assembly (10) of claim 1 or 2, wherein the end insulator plate (400) further comprises a plurality of spacer ribs (440) extending outwardly from the end plate (410), each spacer rib (440) being disposed at a junction between two adjacent nesting slots (420).

6. The stator assembly (10) of claim 5, wherein the spacer ribs (440) extend axially in a direction opposite the direction of extension of the nesting groove (420).

7. The stator assembly (10) of claim 1 or 2, wherein the end insulating plate (400) is a single piece made of plastic.

8. The stator assembly (10) of claim 1 or 2, wherein the nesting grooves (420) of the end insulator plates (400) are elastically deformable.

9. The stator assembly (10) of claim 1 or 2, wherein the end plates (410) of the end insulating plates (400) cover at least a portion or all of the outer end faces (130) of the axial ends of the stator core (100).

10. The stator assembly (10) of claim 1 or 2, wherein one of the end insulating plates (400) is provided at each axial end of the stator core (100).

11. The stator assembly (10) of claim 1 or 2, wherein a slot cross-section of the conductor slot that receives a respective encasement slot is larger than a slot cross-section of the remainder of the conductor slot.

12. An electric machine comprising a stator assembly (10) according to any one of claims 1 to 11.

13. An electric drive assembly system comprising a stator assembly (10) according to any one of claims 1 to 11 or an electric machine according to claim 12.

14. A vehicle comprising a stator assembly (10) according to any one of claims 1 to 11 or an electric machine according to claim 12 or an electric drive train according to claim 13.