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Specification of Stator Assembly for Pure Electric Vehicles
1. Introduction
The stator assembly is a crucial component in the electric drive system of pure electric vehicles. It plays a vital role in converting electrical energy from the battery into mechanical energy to drive the vehicle, working in close cooperation with the rotor.
2. Structure and Components
2.1 Stator Core
- Composition: The stator core is composed of laminated steel sheets, typically made of high - quality silicon steel. These thin sheets are stacked together precisely. For example, in many modern electric vehicle motors, the thickness of each lamination is in the range of 0.2 - 0.5 mm.
- Function: The core provides a low - reluctance path for the magnetic flux. The lamination design effectively reduces energy losses caused by eddy currents. When an alternating current passes through the windings around the core, a magnetic field is generated, and the core guides this magnetic field to interact with the rotor.
2.2 Windings
- Material: Usually, high - conductivity copper wires are used for windings. In some cases where weight reduction is a priority, aluminum wires may also be considered. The wires are insulated to prevent short - circuits.
- Winding Configuration: There are different winding methods, such as concentrated windings and distributed windings. Concentrated windings are often used when high torque density is required. They are wound around fewer teeth of the stator core, which can increase the magnetic field strength in a specific area. Distributed windings, on the other hand, are spread more evenly around the core, resulting in a more sinusoidal magnetic field distribution, which is beneficial for reducing torque ripple and improving motor efficiency at high speeds.
2.3 Insulation Materials
- Type: Insulation materials are used to separate the windings from the stator core and from each other. Common insulation materials include polyester - based films, epoxy resins, and mica - based composites. These materials have excellent electrical insulation properties, high thermal resistance, and good mechanical strength.
- Function: They prevent electrical short - circuits between the windings and the core, protecting the integrity of the electrical circuit. Additionally, they can withstand high temperatures generated during the operation of the motor, ensuring reliable performance over a long period.
2.4 End Rings and Connectors
- End Rings: End rings are located at both ends of the stator core. They are used to hold the windings in place and provide mechanical support. In some designs, the end rings also contribute to the magnetic circuit by guiding the magnetic flux.
- Connectors: Connectors are used to connect the windings to the power supply or the motor controller. These connectors are designed to handle high - current and high - voltage electrical connections, ensuring stable power transfer.
3. Working Principle
When an alternating current is supplied to the windings of the stator assembly by the motor controller, a rotating magnetic field is generated. The frequency of the alternating current determines the speed of the rotating magnetic field. According to Faraday's law of electromagnetic induction, this rotating magnetic field interacts with the magnetic field of the rotor (which can be a permanent magnet or an electromagnet in some motor designs). The interaction between the two magnetic fields creates a torque that causes the rotor to rotate. In a pure electric vehicle, the rotation of the rotor is then transmitted to the wheels through a transmission system, enabling the vehicle to move.
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