Super-flat wire common winding motor and design method

Abstract

The invention discloses a super-flat wire common-winding motor and a design method, and belongs to the technical field of motor design and manufacturing. The invention discloses an equal-pole common-winding axial magnetic flux motor and a design method, the equal-pole common-winding axial magnetic flux motor comprises a motor winding, a stator, a rotor, a casing and the like, and is characterized in that the number of magnetic poles of the stator and the number of magnetic poles of the rotor are equal, all the magnetic poles of the stator or the rotor on the same disc are excited through the same annular coil winding, and the winding can be a conventional round wire, a flat wire or a super-flat wire; alternatively, two or more concentric circle winding units, such as an outer ring winding unit and an inner ring winding unit, can be arranged on the same disc, radially adjacent iron cores can be shared or can also be independently arranged, meanwhile, the radial size of the shared iron core can be wider in consideration of the magnetic saturation problem, or the radial size of the shared iron core can be smaller in consideration of the magnetic saturation problem. The radial sizes of the iron core and the winding in the small-diameter area can be larger; the working principle can be a reluctance type, a switch reluctance type, a permanent magnet synchronous type, a direct-current motor type or an alternating-current motor type; the direct current motor can be a commutator or a plane commutator; or a brushless control scheme; the alternating current motor can be square wave, sine wave or other waveform; the phase difference of the three-phase alternating current can be 120 degrees; or two-phase or four-phase alternating current or other phase difference current with the phase difference of 90 degrees.

Description

Technical Field

[0001] This invention belongs to the field of motor design and manufacturing technology. Background Technology

[0002] With the rapid development of the new energy vehicle industry, especially the pure electric vehicle industry, higher requirements are placed on the high-speed performance and high power density of electric motors. As the motor speed increases, higher requirements are placed on the performance of motors and related components. More stringent requirements are placed on the high-speed performance NVH of motor rotors, high-speed bearings, and gears, which increases costs. At the same time, safety and failure rate issues arise. Furthermore, the cross-slot problem based on distributed windings also increases the number of end windings and complicates the process. Summary of the Invention

[0003] Based on the following prior applications:

[0004] 202211030428.1 Dual-rotor motor current dynamic and static physical ports

[0005] 202211098410.5 Design and manufacturing method of constant reluctance rotary transformer and core

[0006] 202211409893.6 Current-carrying dynamic and static port electrical conduction devices and design methods

[0007] 202211411199.8 High Power Density Dual-Disc Permanent Magnet Synchronous Motor and Design Method 202211496278.3 Disk-Type High Power Density Motor and Design Method 202211717339.4 Three-wire four-phase wave equal-pole common winding motor and its design method 202310043018.9 Three-wire four-phase wave permanent magnet synchronous motor and electromagnetic differential vector dual drive system 202310050918.6 High-Density Pole-Pair Number Three-Wire Four-Phase Wave Permanent Magnet Synchronous Motor and Design Method 202310053689.3 High-power-density motors with ultra-flat wires and their design methods 202311781742.8 High-power-density motors with non-differential disc-type equal-pole common windings and their design methods 202311781804.5 Non-differential disc type equal pole common winding permanent magnet synchronous motor and its design method 202410741743.8 Ultra-flat wire axial flux motor and its design method

[0008] This invention further improves upon the aforementioned prior applications and existing motors, particularly based on the prior application "202410741743.8 Ultra-flat wire axial flux motor and design method," proposing an ultra-flat wire equal-pole common winding motor and design method applicable to radial flux and axial flux motors. This paper focuses on radial flux motors, using a radial bidirectional flux configuration as an example. It can also be a counter-rotating dual-rotor configuration where the stator windings also participate in reverse rotation, which can significantly increase the motor's power density in a proportional relationship.

[0009] A common-pole motor with ultra-flat wire and its design method, including motor windings, stator, rotor, and housing, is characterized by: the number of magnetic poles of the stator and rotor on each disc being equal or an integer multiple; all stator or rotor magnetic poles on the same disc (in the same phase) being energized through the same ring coil winding (generally a one-disc-one-phase structure, i.e., the same disc is the same phase winding; to increase power, each phase can also be composed of multiple discs). This winding can be conventional round wire, flat wire, or ultra-flat wire (for the structure, process, and principle of ultra-flat wire, please refer to relevant prior applications); or, there can be one or two or more concentric circular winding units on the same disc, such as: outer winding unit, inner winding unit, whose radially (or axially, for axial flux configuration) adjacent iron cores can be shared, or can be arranged independently; at the same time, considering the magnetic saturation problem, the radial dimension of the shared iron core can be wider, or the iron core and winding in the small-diameter region can have a larger radial dimension.

[0010] Generally speaking: the component in the winding area is the stator, which can be a common-winding configuration with equal poles; the rotor side can be a permanent magnet rotor, an electrically excited rotor (an electrically excited rotor can also use a common-winding configuration with equal poles), or an induction rotor; alternatively, the stator on the winding side can also participate in rotation, achieving a counter-rotating dual-rotor configuration, reducing the absolute rotor speed or increasing the relative speed between the stator and rotor, thereby increasing power density; Note: When the winding side is designed as a rotatable winding structure, the power supply principle of its windings can adopt various schemes such as rolling brushes and induction brushes. For details, please refer to relevant prior applications, such as: 202211030428.1; 202211098410.5; 202211409 893.6 Equal-Pole Common Winding Configuration Concept Explanation: The excitation current of all magnetic poles originates from the same winding, as shown in the figure. Advantages: The winding has a concentric disk structure, which can be formed by concentrically winding ultra-flat wire. The winding process can control its preload to ensure a high and reasonable preload density between layers, improving slot fill factor, thermal conductivity, and safety, reducing electromagnetic noise, optimizing dynamic balance, and all windings are effective windings with no end windings. The winding utilization rate is close to 100%, and it realizes arbitrary free design of the number of magnetic poles. Regardless of the number of magnetic poles, they all correspond to the same set of windings. This advantage completely surpasses the traditional centralized winding and distributed winding, and the process is greatly simplified. Note: Generally, the poles are equal, meaning the stator and rotor have the same number of poles. This can also be an integer multiple or a fractional multiple (fractional pole relationships can also be used to eliminate cogging torque). Because the staggered and complementary magnetic poles of different phases in a disk-type motor cleverly eliminate cogging torque, the stator and rotor can have an equal pole relationship to optimize harmonics, and the back EMF is essentially a sine wave. Since a spatial configuration of different phases on different disks is achieved, the magnetic circuits of different phases no longer intersect (although adjacent phases can share magnetic poles). Furthermore, it avoids the problem of long and thick yokes in traditional motors with fewer pole pairs. The magnetic circuits in this configuration can all be closed-loop with the shortest possible length, greatly reducing iron losses and the yoke, thus reducing weight and increasing power density and efficiency. For bidirectional flux types, a yoke-less structure can be achieved; see the attached diagram.

[0011] Alternatively, another important feature is that the winding wiring can be a concentric circle or serpentine route around the motor shaft, which makes the winding very compact, without iron core yoke, without end winding, and all windings participate in excitation, resulting in high power density, high efficiency, and simple processing and assembly wiring processes.

[0012] Note: For external rotor motors, it is recommended that the external rotor output power via a hole structure. This is because the structural relationship between the external rotor and the inner stator is equivalent to a hole-shaft relationship, while the conventional structural relationship between the inner rotor and the outer stator is a shaft-hole relationship. That is, the inner rotor is the shaft and the outer stator is the hole. Therefore, it is more suitable for the inner rotor to output power via a shaft, but it is more reasonable for the outer rotor to output power via a hole structure. Specific structural solutions can include a hollow shaft structure, with output power via a flange or gear / sprocket transmission relationship; or a planetary gear structure to output power flow.

[0013] Alternatively: The above scheme is also applicable to axial flux motors, see attached figure; it is also divided into centralized winding and distributed winding schemes; all of them can be improved into ultra-flat wire winding structure by adopting the above scheme.

[0014] Its single-layer copper strip can be composed of several parallel copper strips with the smallest possible gaps, or it can be made using micro-hole drilling.

[0015] The circumferential ultra-flat wire adopts an assembly scheme from the tooth groove gap, which can fill the remaining gap by inserting a rectangular flat wire or a round wire at the end.

[0016] Its working principle can be reluctance, synchronous reluctance, switched reluctance, permanent magnet synchronous, or asynchronous induction type; it can be a DC motor or an AC motor; the DC motor can be a brushless control scheme, a brushed commutator, or a planar commutator scheme; the AC motor can be a permanent magnet synchronous or induction asynchronous scheme, and its control waveform can be a square wave, a sine wave, or other waveforms; it can be a three-phase AC with a phase difference of 120 degrees; or a two-phase or four-phase AC with a phase difference of 90 degrees or other phase difference currents.

[0017] Switched reluctance motors typically consist of three or more discs, with each disc having a phase difference that is arranged at equal intervals to obtain a uniform, continuous, and stable torque output. They can have a large number of poles to ensure a more stable torque output, such as 30 or other numbers.

[0018] Permanent magnet synchronous motors generally consist of two or more disks (e.g., a three-wire four-phase wave equal-pole common winding motor type). The phase difference of each disk is arranged in equal intervals to obtain a uniform, continuous and stable torque output. The number of poles can be large to ensure a more stable torque output, such as 30 or other numbers.

[0019] Alternatively, it can be composed of a single disk, which uses independent inner and outer ring windings and iron core magnetic circuit units to achieve continuous and stable torque output through phase complementary alternating operation.

[0020] Its magnetic circuit is a spatial magnetic circuit. The concentric circular magnetic circuit in the winding area is composed of concentric circular iron cores wound together. In order to eliminate eddy currents, the concentric circular iron cores are radially cut off. The magnetic circuit in the non-winding area is generally arranged radially and axially. The radial iron cores can be glued together or tightly attached by mechanical means, or grooves or baffles can be opened between the iron core and the iron core frame to enhance safety.

[0021] The magnetic circuit area is made of a core material with very high magnetic permeability, such as stacked silicon steel sheets with very thin thickness; the rest of the core skeleton support frame is made of magnetically resistive materials with very low magnetic permeability (materials shown at the commercial vehicle exhibition), such as: aluminum, aluminum alloy, magnesium-aluminum alloy, titanium alloy, carbon fiber, ceramics, mica and other high temperature resistant, high magnetic resistance, high resistance and high strength composite materials and other metal or non-metal materials.

[0022] This core layout can be either a fan-shaped core arranged radially or a rectangular core arranged radially.

[0023] Its characteristic is that it can be a dual-rotor configuration, with concentric inner and outer iron cores forming a dual-rotor structure.

[0024] Its principle applies to most types of motors, including DC motors, AC motors such as permanent magnet motors and switched reluctance motors, as well as induction motors and hysteresis motors.

[0025] The input current waveform of the motor can be: when the motor is transformed into an engine, the induced current waveform generated by driving the motor windings with stable torque at a constant speed can guide the design of its control current waveform.

[0026] In other words, if the control current waveform of any motor is the same as the current waveform generated when the motor is driven to rotate with constant torque and constant angular velocity as a generator, then the output torque of the motor as a motor must be constant. This method can be called the "energy reverse measurement simulation method" and can be used as a guide for optimizing the control current waveform of a motor. It is applicable to any type of motor.

[0027] Alternatively, its characteristics are: there is only one or a group of windings in the same phase of the motor, different magnetic pole anisotropy is obtained through the magnetic circuit design of salient pole and concave pole, and torque is obtained through spatial misalignment and displacement with permanent magnet rotor or induction rotor or the principle of minimum magnetic reluctance. Generally speaking, the stator and rotor magnetic poles are of equal pole and common winding structure, or the stator and rotor magnetic poles are of non-equal pole or integer multiple or fractional multiple differential misalignment relationship.

[0028] The winding wiring is simple, requiring only concentric circle winding, making it suitable for ultra-flat wires. It has good dynamic balance, making it easy to manufacture dual-rotor motors. It has no end windings, good thermal conductivity, axial magnetic flux, radial magnetic flux, and no magnetic yoke. The magnetic circuit is simple, the back electromotive force is sinusoidal, and there is no cogging torque.

[0029] Note: The difference between a commutator and a phase commutator is that a switched reluctance motor uses a phase commutator to switch the current on and off of different phase windings, while a DC motor uses a commutator to switch the direction of the winding current. Therefore, a commutator requires switching between positive and negative electrodes and requires two circuits, while a phase commutator only needs one circuit to switch the current on and off of different phases; see the attached diagram for details, or refer to the prior application.

[0030] Basic principle: The same phase iron core is uniformly embedded by using an integrated winding, and the specific magnetic circuit required is formed by relying on the convex and concave relationship of the iron core. A claw pole scheme can also be adopted. If a claw pole scheme is adopted, the corresponding permanent magnet structure will be further simplified.

[0031] Alternatively, it can be designed as a shared magnetic circuit. For example, the middle iron core can also be shared, that is, the concentric ring iron cores of adjacent windings can be merged and shared as shown in the figure.

[0032] It can also be an inductive method, where electromagnetic excitation replaces permanent magnets;

[0033] Advantages: It achieves a separate design of winding and magnetic poles, and can obtain any number of magnetic poles using the same integral winding. For switched reluctance motors, the number of pole pairs can be designed to be very close, reducing torque ripple.

[0034] This approach can be used for ultra-low-speed motors, such as wind turbines, as well as low-speed, high-torque motors and generators. It allows for the design of any number of magnetic poles or optimal efficiency and power parameters within a limited space.

[0035] Endless windings improve winding utilization and heat dissipation performance; Attached Figure Description

[0036] The accompanying drawings of this application show that the motor types are roughly divided into: A, B, C, D, and E types; for ease of description, they are named as follows: Class A, B, C, D, and E motors, and are shown in the accompanying drawings in order:

[0037] Figure 1-2 : Structural diagram of Type A "Equal-pole common winding bidirectional axial flux-switched reluctance ultra-flat wire motor"

[0038] Figure 3-5 Structural diagram of Type B "Equal-pole common winding bidirectional axial flux permanent magnet synchronous counter-rotating dual rotor ultra-flat wire motor"

[0039] Figure 6-7 Structural diagram of the C-type "Dragon-shaped bidirectional axial flux permanent magnet synchronous ultra-flat wire motor"

[0040] Figure 8-16, 16.1: Structural diagram of type D and E "equal pole common winding bidirectional radial flux permanent magnet synchronous counter-rotating dual rotor ultra-flat wire motor", where: the difference between type D and E motors is the difference between 8 and 16 poles; for simplicity, this case describes its structure and working principle using a two-phase or "three-wire four-phase wave" as an example. In the diagram, M and N represent two-phase windings and the specific names of corresponding parts; it can also be a three-phase motor, please refer to the specific implementation plan below.

[0041] Figure 17 for Figure 3 , Figure 5 The assembly drawing shows a counter-rotating dual-rotor model where the winding current is introduced through a rolling brush assembly.

[0042] Figure 18 , 19 for Figure 6 The final assembly drawing of the aircraft model, in which Figure 18 This application involves a two-phase AC motor, which is an AC model. Figure 19 The image shows a permanent magnet DC motor that uses a commutator.

[0043] Figure 20 for Figure 1 Aircraft assembly drawing ( Figure 20 Four angle views are shown. Figure 1 The model can use a dedicated switched reluctance controller or a commutator, such as... Figure 20 (A commutator is used as shown).

[0044] Figure 21 , 22 for Figure 8 The overall assembly drawing and half-sectional view of the aircraft model are attached, along with detailed plan and sectional assembly drawings. Figure 16 .

[0045] Figure 23 , 24 Exploded view of the commutator assembly

[0046] Figure 25 , 26 Exploded view of the commutator assembly

[0047] Figure 27 , 28 Exploded view of a three-phase rolling brush assembly

[0048] Figures 29-33 Explanation diagram of the space helical winding scheme

[0049] Note: Some types of this application (mainly referring to types A, B, and C) are further and fully disclosed and described in the prior application "202410741743.8 Ultra-flat wire axial flux motor and design method". For ease of reading, some of the text, figures, and part number markings are adopted from the prior application. You can also refer to the relevant text and figures of the prior application 202410741743.8.

[0050] Note: Types A, B, and C all involve the problem of multiple sets of windings arranged concentrically. This application only discloses the spatial structure layout and does not analyze the electromagnetic field relationship. This scheme can make the spatial structure more compact and make full use of the internal space of the motor. However, considering the magnetic flux density distribution, the spatial and radial dimensions of each phase will be discussed later. For types A, B, and C, please refer to the relevant text and figures in the prior application 202410741743.8. Alternatively, the two, three, or more magnetic circuits arranged concentrically can be axially shifted and separated to form two, three, or more phases of axially parallel windings and closed magnetic circuits. Please refer to the disc-type configuration and description in the prior application; and this application. Figure 8 The structure shown depicts windings 24 and 25 as two separate, axially arranged disks (phases). This illustration represents a radial bidirectional flux two-phase motor type (which could be a three-wire four-phase wave motor, see relevant prior applications), with a 90-degree phase difference between the currents in the two windings; alternatively, it could be a three-disc, three-phase winding, receiving a conventional sinusoidal three-phase AC input. (Note: This embodiment uses ultra-flat wire windings, see attached...) Figure 8 The windings 24 and 25 shown in the example are ultra-flat wire windings made of three rows of ultra-flat wires per layer. See Appendix. Figure 8 Enlarged view of the part and attached Figure 14 , 15 and appendix Figure 16 As shown, or it could be formed by coiling one or more columns of ultra-flat wire per layer, see appendix. Figure 10 , 11 As shown in Figures 1, 12, and 13; Note: To ensure clarity, the attached figures are enlarged as much as possible, so multiple figures such as... Figure 10-16 Some components have been omitted; please refer to the appendix for the specific locations of the components. Figure 16 (See also previous applications for related information).

[0051] Figure 1 , Figure 2 This is an axial flux bidirectional flux-switched reluctance motor, officially named "Equal-pole common winding bidirectional axial flux-switched reluctance ultra-flat wire motor". See also the prior application 202410741743.8 (attached). Figure 9-14 and explanation;

[0052] The switched reluctance rotor disks 26 and 45 are connected by an outer spline to output torque. They are made of high reluctance and high strength material. Their windows are assembled one-to-one with the iron cores of each phase. Note: Except for the iron cores, the remaining areas are made of high reluctance and high strength material. A cooling channel can be set in the middle gap. Alternatively, if the magnetic poles of adjacent different phases are designed to be of the same polarity, there is no need to worry about magnetic short circuits. This middle channel space can be reduced. Or, since the different phases of the switched reluctance do not work at the same time, and the working mechanism of the switched reluctance is based on the principle of minimum reluctance, which is not closely related to the polarity of the magnetic poles, a certain amount of space isolation should still be provided to prevent magnetic short circuits.

[0053] As shown in the figure, this is a 30-pole case, divided into 3-phase windings to achieve torque phase connection. The phase difference between each phase is 1 / 3 to obtain continuous torque connection. In order to obtain continuous power flow, the phase differences of different phases can also have a certain degree of overlap to obtain a certain degree of overlap of torque between different phases. Considering the working principle of switched reluctance, adjacent iron cores of different phases are not shared. The iron cores are: 3 sets x 2 = 6 sets of iron cores. Each set of iron cores is made of multiple layers of silicon steel laminations concentrically wound. Alternatively, they can be shared, which can reduce two sets of iron cores. Alternatively, it can be a counter-rotating double rotor structure in which the windings also participate in the rotation.

[0054] Figure 3 , 4 5: "Equal-pole common winding bidirectional axial flux permanent magnet synchronous counter-rotating dual rotor ultra-flat wire motor", as shown in the embodiment in the figure. Figure 3 It is a 12-pole two-phase system. Figure 5 , Figure 17 for Figure 3 Aircraft assembly drawing ( Figure 5 (This is a sectional view) Figure 4 For a 24-pole motor, the following explanation uses a two-phase motor as an example (a three-phase motor can also be used). It uses four sets of concentric circular iron cores, with one phase winding between every two sets. Generally, the middle iron cores cannot be shared because the permanent magnets cannot be shared; the two phase permanent magnets need to be staggered. Note: This embodiment is a two-phase structure with a 90-degree phase difference; see the prior application "Related Description of Three-Wire Four-Phase Wave Motor". Considering the limited space in three-phase motors, this application will not elaborate further. Generally, three-phase motors are implemented with a split-disc structure, as described below (e.g., ...). Figure 8 (equal configuration) and related applications; if changed to a claw pole structure, the middle iron core can be shared.

[0055] See also the earlier application 202410741743.8 (attached). Figure 1-8 and explanation;

[0056] in: Figure 4The winding excitation magnetic field passes through the iron core where the winding is located and is guided by a one-to-one corresponding fan-shaped claw-pole iron core arranged with salient poles on both sides and axially attached, forming a large area of ​​air gap magnetic flux cross section, which then interacts magnetically with the rotor permanent magnet, resulting in a large air gap area; for example Figure 4 The structural description corresponding to part numbers 2, 3, 4, 5, 6; 16, 17, 18, 19, 20.

[0057] Alternatively, the salient poles of the winding core directly interact magnetically with the permanent magnet rotor, resulting in a smaller air gap area and more concentrated magnetic flux density. This reduces the amount of permanent magnets used and eliminates the need for claw-pole cores and claw-pole core frame disks, simplifying the structure. Figure 3 As shown in the diagram, the two sides of the annular iron cores 9, 10, 11, and 12 are all convex and concave pole shapes, forming a bidirectional magnetic flux iron core convex pole (the embodiment shown in this figure is a bidirectional magnetic flux iron core without a magnetic yoke), which corresponds to the permanent magnet rotors on both sides respectively.

[0058] Note: Generally speaking, the inner and outer ring core salient poles of the same phase winding need to be staggered; however, for the type of core without claw poles, they can be aligned, but it is necessary to ensure that the inner and outer ring permanent magnets of the corresponding rotor permanent magnets need to be further layered, each further divided into narrower inner and outer ring permanent magnets (see the part numbers 21.1, 21.2, 22.1, and 22.2 in Figure 53 of the prior application 202410741743.8), and it is necessary to ensure that the magnetic poles correspond one-to-one and have opposite polarities.

[0059] Figure 6 , 7 The "Dragon-shaped Axial Flux Permanent Magnet Synchronous Counter-rotating Dual-Rotor Ultra-Flat Wire Motor," as its name suggests, has a dragon-shaped winding structure. Its advantages include 100% utilization of the ultra-flat wire windings, no end windings, and a counter-rotating dual-rotor structure; as shown in the figure: Figure 6 It is a 20-pole motor. Figure 7 It is a 22-pole motor, but the basic structure and principle are the same. The difference lies in the number of poles and the shape of the windings. Figure 6 It is trapezoidal or rectangular. Figure 7 The windings are arc-shaped or petal-shaped, with an overall dragon-like orientation, hence the name: Dragon-shaped winding motor; alternatively, it can be a motor with two or more dragon-shaped windings, or a three-dimensional 3D double-dragon or multi-dragon motor. It can be powered by two-phase, three-phase, or multi-phase AC current supplying different phases of the dragon-shaped windings, and can be spatially staggered; the windings can be made of flat wire or ultra-flat wire, such as... Figure 6 The 60 part number corresponds to 6 columns of ultra-flat wire per layer (see relevant application for a description of ultra-flat wire), or it can be a combination of flat wire and round wire, which can obtain more diverse winding configurations.

[0060] The attached diagram shows a scheme where the winding core interacts directly with the rotor permanent magnet, or a scheme where the magnetic flux cross-section is expanded by deforming magnetic poles; or a scheme where the winding core and the external core are integrated into a single design, optimizing the magnetic circuit, reducing magnetic leakage, and maximizing the introduction of the winding excitation magnetic field into the effective magnetic circuit. This structure is also safer, provides more effective axial positioning of the winding and itself, and helps to improve high-speed performance and reduce the air gap.

[0061] Figure 17 for Figure 3 , Figure 5 The assembly drawing shows a counter-rotating dual-rotor model where the winding current is introduced through a rolling brush assembly.

[0062] Figure 18 , 19 for Figure 6 The final assembly drawing of the aircraft model, in which Figure 18 This application involves a two-phase AC motor, which is an AC model. Figure 19 The image shows a permanent magnet DC motor that uses a commutator.

[0063] Figure 20 for Figure 1 Aircraft assembly drawing ( Figure 20 Four angle views are shown. Figure 1 The model can use a dedicated switched reluctance controller or a commutator, such as... Figure 20 (A commutator is used as shown).

[0064] Figure 21 , 22 for Figure 8 The overall assembly drawing and half-sectional view of the aircraft model are attached, along with detailed plan and sectional assembly drawings. Figure 16 .

[0065] The difference between a commutator and a phase commutator: Generally speaking, a phase commutator is used in DC switched reluctance motors (AC phase commutators can also be used in non-critical specific situations) to switch the on and off states of different phase currents as needed; a commutator is used in permanent magnet DC motors to change the direction of winding current as needed.

[0066] Figure 23 , 24 Exploded view of the commutator assembly

[0067] Figure 25 , 26 This is an exploded view of a commutator assembly, typically used in switched reluctance motors.

[0068] Note: The commutator and phase commutator components described in 23, 24, 25, and 26 above all include a rolling brush assembly with conductive rolling elements, which can enable the windings to not participate in rotation. As long as the corresponding rotating parts of the commutator or phase commutator are fixedly connected to the rotor to collect the phase relationship between the rotor and stator, the commutation or phase commutation function can be realized in a timely manner. This is also an advantage of this application (traditional DC motors using commutators basically require the windings to participate in rotation, that is: the permanent magnet is the stator, and the windings and commutator are the rotor).

[0069] As shown in the attached diagram, the commutator or phase commutator structure can achieve efficient and lossless electrical connection through the rolling brush structure, and realize the function of a brushed motor with non-rotating windings (generally speaking, the windings of a brushed motor rotate, but the solution in this paper realizes a brushed motor with non-rotating windings). It can also be a brushless motor solution, which uses an angle sensor to collect the rotor angle and then controls the power semiconductor switching circuit to realize the commutation or phase commutation of the winding current.

[0070] Figure 27 , 28 This is an exploded view of a three-phase rolling brush assembly. Current can be transmitted without sliding friction through the rolling conductor 119. The diagram shows a three-phase rolling brush assembly capable of transmitting three-phase current simultaneously. (See attached image.) Figure 27 , 28 and appendix Figure 16.1 Assembly drawing.

[0071] in:

[0072] 1. Left-side permanent magnet rotor disc (output torque via external spline connection; alternatively, an induction external rotor)

[0073] 2. Left-side claw-pole core skeleton disk (made of high-resistivity and high-strength material, its windows are assembled one-to-one with the claw-pole core, and its central inner hole is connected to the winding shaft by splines or cylindrical keys to form concentric positioning and transmit torque)

[0074] 3. The claw-type iron core corresponding to the left salient pole of the outer ring iron core of the outer ring group (made of stacked thin silicon steel sheets).

[0075] 4. The claw-type iron core (made of stacked thin silicon steel sheets) corresponding to the left salient pole of the inner ring iron core corresponding to the outer ring group.

[0076] 5. The claw-type iron core (made of stacked thin silicon steel sheets) corresponding to the left salient pole of the outer ring iron core of the inner ring group.

[0077] 6. The claw-type iron core (made of stacked thin silicon steel sheets) corresponding to the left salient pole of the inner ring iron core of the inner ring group.

[0078] 7. Left salient pole positioning plate of the toroidal iron core (made of high magnetic resistance and high strength material, its window is assembled to correspond to the left salient pole).

[0079] 8. Winding Shaft (In this embodiment, a bidirectional flux winding rotor is used, meaning the winding also participates in the rotation, forming a counter-rotating dual-rotor configuration with the permanent magnet rotors on both sides. This means both the winding rotor and the permanent magnet rotor can rotate in opposite directions to output torque, effectively doubling the magnetic field speed. Furthermore, the bidirectional flux configuration doubles the air gap area, resulting in a 4-fold increase in power density overall. Note: This shaft is hollow in the center for weight reduction and wire transmission. If the winding participates in the rotation, it is electrically connected to the outside via a rolling brush or other means; see relevant prior applications for details.)

[0080] 9. The outer ring core corresponding to the outer ring assembly (made of thin silicon steel sheets wound and stacked, with salient poles on both sides; to reduce eddy currents, narrow slits are cut radially into the wound core to isolate eddy current circulation;)

[0081] 10. The inner ring core corresponding to the outer ring assembly (made of thin silicon steel sheets wound and stacked, with salient poles on both sides, whose salient poles are offset and complementary to the salient poles corresponding to part number 9; to reduce eddy currents, a narrow slit is cut radially into the wound core to isolate the eddy current circulation; Note: This ring core can be shared with the ring core of part number 11, but the radial dimension of the core can be appropriately widened for reasonable magnetic flux density distribution).

[0082] 11. The outer ring core corresponding to the inner ring group (made of thin silicon steel sheets wound and stacked, with salient poles on both sides; to reduce eddy currents, a narrow slit is cut radially into the wound core to isolate the eddy current circulation; Note: This ring core can be shared with the ring core marked 10, but the radial dimension of the core can be appropriately widened for reasonable magnetic flux density distribution).

[0083] 12. The inner ring core corresponding to the inner ring assembly (made of thin silicon steel sheets wound and stacked, with salient poles on both sides, whose salient poles are offset and complementary to the salient poles corresponding to part number 11; in order to reduce eddy currents, a narrow gap is cut radially into the wound core to isolate the eddy current circulation).

[0084] 13. Inner winding group (In this embodiment, it is an ultra-flat wire winding, as shown in the figure. The example shown in the figure is an ultra-flat wire winding formed by winding 6 columns of ultra-flat wire in each layer. See the prior application for details.)

[0085] 14. Outer winding assembly (In this embodiment, it is an ultra-flat wire winding assembly, as shown in the figure. The example shown in the figure is an ultra-flat wire winding assembly formed by winding 6 columns of ultra-flat wire per layer. See the prior application for details.)

[0086] 15. Right-side salient pole positioning plate of the toroidal core (made of high-resistivity, high-strength material, with its window corresponding to the right-side salient pole).

[0087] 16. Right-side claw-pole core skeleton disk (made of high-resistivity and high-strength material, its windows are assembled one-to-one with the claw-pole core, and its central inner hole is connected to the winding shaft by splines or cylindrical keys to form concentric positioning and transmit torque)

[0088] 17. The claw-type iron core corresponding to the right salient pole of the outer ring iron core of the outer ring group (made of stacked thin silicon steel sheets).

[0089] 18. The claw-type iron core (made of stacked thin silicon steel sheets) corresponding to the right salient pole of the inner ring iron core corresponding to the outer ring group.

[0090] 19. The claw-type iron core (made of stacked thin silicon steel sheets) corresponding to the right salient pole of the outer ring iron core corresponding to the inner ring group.

[0091] 20. The claw-type iron core corresponding to the right salient pole of the inner ring iron core of the inner ring group (made of stacked thin silicon steel sheets).

[0092] 21. The outer ring magnetic circuit corresponds to the outer ring permanent magnet (composed of concentrically arranged fan-shaped permanent magnets with alternating N and S polarities; in this embodiment, it has 24 poles and 12 pole pairs).

[0093] 22. The inner ring magnetic circuit corresponds to the inner ring permanent magnet (composed of concentrically arranged fan-shaped permanent magnets with alternating N and S polarities; in this embodiment, it has 24 poles and 12 pole pairs).

[0094] 23. Right-side permanent magnet rotor disk (output torque is connected via an outer spline; it can also be an induction outer rotor).

[0095] Note: This application implements a two-phase motor (it can also be a three-wire four-phase wave motor, see earlier applications). The phase difference between the inner and outer winding currents is 90 degrees. Therefore, the magnetic pole arrangement of the inner ring permanent magnet 22 and the outer ring permanent magnet 21 is a staggered, centered, and complementary relationship, that is, satisfying the magnetic force relationship with a 90-degree phase difference. If it is a three-phase motor, then there are three sets of windings corresponding to three sets of permanent magnets, and their phase difference and magnetic pole arrangement relationship must satisfy a 120-degree relationship.

[0096] 24, 25: Windings 24 and 25 are two different phase windings arranged separately in an axially split (phase) configuration. This illustration represents a radial bidirectional flux two-phase motor type (it could be a three-wire four-phase wave motor, see relevant prior applications), with a 90-degree phase difference between the currents in the two-phase windings. It could also be a three-disc, three-phase winding, with a conventional sinusoidal three-phase AC input.

[0097] 26, 45 Switched reluctance rotor disk (output torque is connected via an external spline, made of high reluctance and high strength material, with its windows corresponding to the cores of each phase).

[0098] Iron cores on rotor discs of different phases: 27, 28, 29, 42, 43, 44

[0099] 30 and 40 winding core salient pole positioning disks (made of high resistance and high strength material, with windows that are assembled one-to-one with the salient poles of the winding core).

[0100] 31, 32, 33, Three-phase winding (In this embodiment, it is an ultra-flat wire winding, as shown in the figure. The example shown in the figure is an ultra-flat wire winding made of 6 columns of ultra-flat wire per layer. See the prior application for details.)

[0101] The toroidal cores with salient poles on both sides corresponding to each of the windings in phases 34, 35, 36, 37, 38, and 39.

[0102] 41. Shaft

[0103] 46. ​​Windings, core, and winding side shaft assembly

[0104] 47. Switched reluctance iron core rotor side hub (connecting the two rotor discs via splines to form an integrated output torque)

[0105] 48, 59, Dragon-shaped winding motors with rotor discs on both sides

[0106] 49. Rotor shaft (connected to 48 and 59 via a key)

[0107] 50, 51 Two-phase dragon-shaped winding (This embodiment is a two-phase motor, but it can also be a three-phase winding type)

[0108] 52-55: Bidirectional flux non-magnetic yoke iron core (forming a close interlocking relationship with the dragon-shaped winding).

[0109] 56. Winding side hub

[0110] 57, 58 permanent magnet

[0111] 60. Six columns of ultra-flat wire per layer (Refer to relevant ultra-flat wire patent applications. Note: Part numbers 60, 61, and 62 are specific part numbers and are general-purpose ultra-flat wire part numbers. They do not conflict with part numbers 76 and 77. It can be understood that the 76 and 77 dragon-shaped windings use six columns of ultra-flat wire. Other arbitrary number of columns can also be selected according to space and process to reduce the skin effect.)

[0112] 61. Conductor portion of ultra-flat wire

[0113] 62. Insulation substrate of ultra-flat wire

[0114] 63 and 64 combine to form the permanent magnet frame of the rotor. Permanent magnets are embedded in the four concentric windows on 64 to form a permanent magnet rotor. This model has bidirectional magnetic flux, so there is also a permanent magnet rotor on the other side (the permanent magnet is hidden in this illustration for clarity of the structure); or it can be an induction rotor.

[0115] 65. Motor stator or winding rotor frame disc sleeve (with) Figure 3 The embodiment is a counter-rotating dual-rotor electric motor configuration in which the windings participate in rotation, so it is a winding rotor skeleton disc sleeve.

[0116] 66. Torque output disc fixedly connected to the motor winding rotor frame

[0117] 67. Brake disc, fixedly connected to 66. When 67 brakes, the motor winding rotor transforms into the stator. At this moment, if the motor frequency remains unchanged, rotor components such as 63 and 64 will rotate at twice the speed.

[0118] 68. The rolling brush assembly is an important component that provides current to the windings in a rotatable winding rotor.

[0119] 69. Bearing; 70. Switched reluctance rotor disk external limit protection disk, combined with switched reluctance rotor disk 26, to provide installation positioning constraints for each phase core.

[0120] 71. Motor stator winding frame base

[0121] 72 and 78 together form the permanent magnet frame of the rotor. Permanent magnets are embedded in the two concentric windows on 72 to form a permanent magnet rotor. This model has bidirectional magnetic flux, so there is also a permanent magnet rotor on the other side (the permanent magnet is hidden in this illustration for clarity of the structure); or it can be an induction rotor.

[0122] 73. Winding core salient pole positioning plate (made of high resistance and high strength material, with its windows corresponding one-to-one with the salient poles of the winding core).

[0123] 74 and 75 correspond to the inner and outer ring dragon-shaped winding cores, respectively.

[0124] 76 and 77 correspond to the inner and outer ring serpentine windings, respectively (this embodiment is a two-phase motor, but it can also be a three-phase winding type).

[0125] 79. Commutator assembly (for brushed DC motors; not required for AC motors)

[0126] 80. Radial bidirectional flux winding rotor power output shaft (hollow in the middle to accommodate wires and concentrically assembled with the rolling brush assembly to achieve rotor current transmission).

[0127] 81. Winding bobbin protection disc

[0128] 82. Winding inner frame

[0129] 83. Inner skeleton isolation arc block

[0130] 84. Winding outer frame

[0131] 85. Exoskeleton isolation arc block

[0132] 86. M-phase left-side permanent magnet inner rotor (the illustration shows a two-phase or "three-wire four-phase wave" motor, see prior application; for ease of description, M and N are used to represent specific names for two-phase motors; it can also be a three-phase motor)

[0133] 87. The left-side core of the M-phase winding 24 (in this embodiment, it has a radial bidirectional magnetic flux configuration; both the inner and outer circumferences of the core are salient pole structures, available in 8-pole and 16-pole versions, see attached). Figure 10 It has 8 poles, with... Figure 11 (16 poles)

[0134] 88. Right side core of M-phase winding 24

[0135] 89. Isolation disc (can be removed; corresponding to claw pole structure, the intermediate iron cores of phases M and N can be shared, that is: 88 and 90 can be merged, and the rotor can also be merged, such as merging 86 and 111; merging 112 and 113; see prior applications; such as: magnetic circuit optimization design scheme 4.3 for high power density motor with equal pole common winding, magnetic circuit optimization design scheme 4.19 for permanent magnet synchronous motor)

[0136] 90. Left side core of N-phase winding 25

[0137] 91. Right side core of N-phase winding 25

[0138] 92, 93 Inter-rotor isolation discs

[0139] 94. Winding inner and outer frame closing plate

[0140] 95. Safeguard ring

[0141] 96. External rotor protection disc

[0142] 97. M-phase left-side permanent magnet external rotor

[0143] 98. Isolation tray

[0144] 99. M-phase right-side permanent magnet external rotor

[0145] 100, N-phase left-side permanent magnet external rotor

[0146] 101. N-phase right-side permanent magnet external rotor

[0147] 102. External rotor power closing output plate (fixed to 103)

[0148] 103. Power output shaft of internal and external permanent magnet rotor (or induction rotor)

[0149] 104, 105, 106, 107, 108, 109, and 110 correspond to the corresponding components of a 16-pole motor. Their composition and function are the same as those of an 8-pole motor, and will not be described again.

[0150] 111. M-phase right-side permanent magnet inner rotor

[0151] 112. N-phase left-side permanent magnet inner rotor

[0152] 113. N-phase right-side permanent magnet inner rotor

[0153] 114 and 115 motor brackets and bases (for bench testing models; the actual product has an integrated housing).

[0154] 116. Rolling brush non-rotating disk limit block

[0155] The following part number markings are for attachments Figure 27 , 28 16.1 Correspondence Explanation:

[0156] 117 and 126 are insulator rotating disks fixedly connected to shaft 80 and rotating together. The right side of 117 is in close contact with the conductive flat disk 118 (a conductive material disk such as a copper or silver disk), and the left and right sides of 126 are in close contact with conductive flat disks 125 and 127, respectively. 122 and 130 are insulator non-rotating disks concentric with shaft 80 but not fixedly connected. They are positioned by their outer circumferential protrusions and limiting blocks 116, and are in a stationary, non-rotating state. The left side of 130 is in close contact with conductive flat disk 129, and the left and right sides of 122 are in close contact with conductive flat disks 121 and 125, respectively. The conductive flat disks 118 and 121, 123 and 125, and 127 and 129 are respectively fitted with freely rotatable rolling element isolation and positioning cages 120, 124, and 128, along with a number of corresponding conductive rolling elements 119. These conductive rolling elements 119 are the core components of the rolling brush and can be made of conductive materials such as copper, silver, aluminum, and graphite. Their shapes can be cylindrical, conical, spherical, drum-shaped, etc. Through the above assembly and operational relationships, the power supply function to the rotating winding is achieved.

[0157] The core component of the rolling brush—the conductive rolling element 119—is shown in the attached diagram. In counter-rotating motors, when the inner and outer rotors rotate at equal speeds in opposite directions, the rolling element only rotates on its own axis and does not revolve around the central axis, keeping its needle roller cage stationary, which helps extend its lifespan. For single-rotor motors or dual-rotor motors with a large difference in speed between the inner and outer rotors, and for types where the rolling element's revolution speed is high and its cage speed is fast, the needle roller structure of the rolling brush can be replaced with a tapered bearing or ball bearing structure. Detailed Implementation Plan

[0158] The following section focuses on types D and E (see above for related descriptions and part number information):

[0159] The above-mentioned types A, B, and C are introduced with axial flux configuration. The following text introduces the structure and working principle of types D and E with radial flux configuration as examples. However, they all have common winding characteristics and winding and magnetic pole separation structural characteristics. Types D and E are detailed below and are also the focus of this application.

[0160] Types D and E "Equal-pole common winding bidirectional radial flux permanent magnet synchronous counter-rotating dual rotor ultra-flat wire motor", see appendix. Figure 8-16 (Appendix) Figure 21 , 22 In this application, the D and E classes disclosed in the embodiments are analyzed using 8-pole and 16-pole motors as examples, respectively (where: Figure 8 , 9 10 and 12 are 8 poles; Figure 11 , 13 (16 poles); The motor has synchronously rotating permanent magnet rotors in the area near the shaft center and the area near the outer ring of the housing. The windings are located in the middle area and it is a counter-rotating dual rotor structure. Therefore, the power density can be increased by 4 times compared to a conventional motor (5.4 times in this case model, the outer rotor can provide 2.7 times the power of the inner rotor, and the counter-rotating dual rotor is multiplied by 2 = 2.7 x 2 = 5.4 times). It can also be a motor with permanent magnets designed only inside or outside, or a single inner rotor or single outer rotor unidirectional flux motor with no rotating windings (equivalent to a conventional motor), or a radial bidirectional flux motor with inner and outer dual permanent magnet rotors (or induction rotors) with no rotating windings. The winding power supply system of the counter-rotating dual rotor motor disclosed in this application adopts a rolling brush structure, as shown in the figure. It can obtain excellent conductivity and long life. This structure can also be used in synchronous motors where electrical excitation replaces permanent magnets.

[0161] Alternatively, you can attach Figure 16 The radial bidirectional magnetic flux structure of the model shown is changed to radial unidirectional magnetic flux, that is: remove one of the salient poles inside or outside the iron core in the corresponding area of ​​the winding, and add a corresponding magnetic yoke on the removed side to form a closed magnetic circuit, and remove the corresponding outer rotor or inner rotor to become a pure inner rotor or outer rotor motor. Alternatively, the winding iron core can be fixed to become a common radial magnetic flux motor. See also the prior application and attached drawings (Magnetic circuit optimization design scheme 4.3 for high power density motor with equal pole common winding, and magnetic circuit optimization design scheme 4.19 for permanent magnet synchronous motor).

[0162] Alternatively, the inner and outer winding frames (such as the parts marked 82, 84, 104, and 106) and numerous isolation blocks and disks can be made of non-magnetic and non-conductive materials, such as ceramics, mica, glass, glass fiber; high-strength carbon fiber, polypropylene, basalt fiber composites; or, through a reasonable magnetic circuit shielding design, they can also be made of non-magnetic metal materials such as aluminum alloy, magnesium alloy, and copper. Note: If it is a common configuration motor (such as a single-rotor unidirectional flux motor), there is no need to consider the frame design.

[0163] "Equal-pole common winding radial flux permanent magnet synchronous counter-rotating dual-rotor ultra-flat wire motor", analyzed with 8 poles; the axial dimension is very short, only 2-3 discs of winding are needed, no end windings, switched reluctance - 30 poles - 3 discs are sufficient; one type is sufficient, its radial flux magnetic circuit is more complex, and the electromagnetic action area is not as large as the axial one, the axial one is bidirectional flux, the magnetic circuit is the shortest, so category 10 is changed to category 11; or, make a smaller diameter dual-disc or three-disc permanent magnet synchronous motor that can be connected to three-phase power; if the power density of this solution is greater than that of the existing three-phase (comparing power density is sufficient, but the axial flux may be greater, the axial flux can also be made into a three-phase), then it is the most practical, directly using the existing vehicle controller, directly replacing the motor, or it can be a dual permanent magnet rotor, bidirectional flux;

[0164] The difference between D and E type motors and the difference between 8 and 16 poles is used to verify that the quickness of pole setting and performance of this level of common winding are not affected - it can achieve a similar effect to distributed winding, that is: the number of pole pairs can be very small to reduce frequency and loss. However, this scheme can achieve good torque stability even with a small number of pole pairs because the iron core is originally a whole, only the salient poles are distinguished. Therefore, the salient poles can be designed to be finely fragmented to obtain stable torque.

[0165] (Two-phase – short axial dimension, radial flux, bidirectional flux, easy core design, non-universal magnetic poles because the permanent magnets have complementary phase differences, using 80 layers of flat wire wound in one layer); bidirectional flux can further simplify the core structure.

[0166] Another advantage is the absence of cogging torque. Cogging torque is canceled out between different phases through the axial split-disc structure (two phases are sufficient for cancellation, three phases are more effective, and more than three phases are even better). There is no need to specifically consider measures to eliminate cogging torque. The same-pole core does not need to have open slots or the open slots are very small. Alternatively, it can be completely eliminated through an effective control scheme. There is no cogging torque in this direction. Another advantage is that due to the characteristics of the shared winding, its back electromotive force is a standard sine wave, which minimizes the negative factors of harmonics.

[0167] The magnetic circuit and winding spatial layout of this structure are very neat and simple, which is conducive to heat dissipation and facilitates the design of heat dissipation channels.

[0168] Furthermore, the common winding design results in better dynamic balance of the windings, making it easier to manufacture a dual-rotor motor.

[0169] The intermediate gap area can be filled with lightweight material or used as a heat dissipation channel; alternatively, the iron core is preferably a radially fan-shaped sheet.

[0170] The windings are evenly distributed layer by layer, and the windings of different phases are not in the same area. Reasonable winding can make the voltage between adjacent layers of windings the smallest and most uniform, while the windings in the maximum voltage area are the farthest apart, thus improving the withstand voltage and safety factor.

[0171] It is also easier to design the switching between series and parallel winding relationships. That is, in the low-speed range, the windings are connected in series, and when entering the high-speed range, the windings can be gradually changed to parallel to reduce back electromotive force and increase torque in the high-speed range. This is also a very important requirement for new energy vehicles.

[0172] When the windings of the same layer of ultra-flat wires are connected in parallel, the voltage between adjacent flat wires in the same layer is zero, which greatly improves safety. The advantage of its same layer of separated parallel flat wires is to improve the skin effect.

[0173] For ease of description, they are named as follows: ABCDE type motors. Motors A and C can be controlled by sinusoidal AC power. By removing the commutator, they can be compared and tested. DC switched reluctance motors are the opposite of AC motors.

[0174] The motor's winding pole separation feature allows for arbitrary design of the number of poles. Because it is not constrained by the windings, it can be designed with a very high number of pole pairs, making it suitable for low-speed, high-torque motors, such as those used in wind power and other fields. Moreover, the waveform is a standard sine wave.

[0175] Demonstration of series and parallel speed control, back EMF detection, pulsation detection, dual rotor differential speed function - double speed demonstration, heat dissipation demonstration, DC / AC dual-purpose motor; initially, only the AC structure is installed, which is very simple. Adding a commutator transforms it into a DC motor. Its series and parallel winding switching works for both AC and DC.

[0176] The system can switch between three levels of series and parallel connection – 6 columns in series, 3 columns in series, and all 6 columns in parallel – to perform ultra-high-speed demonstrations; it can also be used for switched reluctance systems.

[0177] The resistance is generated by powering an electric heater or light bulb to produce a load (much more efficient and seemingly safer than using a fan). The output power of this load can be measured with a multimeter; it's best to use two multimeters to measure the current and voltage simultaneously, with automatic calculation.

[0178] Advantages: Back electromotive force approximates a standard sine wave; zero-end winding - high efficiency; weight reduction; good heat dissipation (end windings are the hottest); good processability and highest yield; low cost; good dynamic balance; mutual constraint; good thermal conductivity - good heat dissipation; planar air gap - spray cooling; centrifugal force has no negative impact; can support dual rotors at high speeds with a constant air gap - shape memory alloy; insulation and conductor layers separated - improved heat resistance; open permanent magnet - direct external heat dissipation and central atomized cooling; low voltage between layers, zero voltage within the same layer; high temperature resistance.

[0179] Advantages: The magnetic circuit design is achieved through convex and concave poles, resulting in good manufacturability, the shortest magnetic circuit, low iron loss, absolutely uniform magnetic circuit distribution, and lightweight design without a yoke.

[0180] The axial and radial flux motors have no yoke, the core power-to-weight ratio is the highest, and the magnetic fields do not cross each other, each is independent, the magnetic energy density is the most uniform, the total magnetic energy is the largest when the magnetic saturation is reached, the total magnet air gap surface area seems to be no larger than now, the effective utilization rate is high, almost all of them are effective areas, and they do not interfere with each other.

[0181] DC / AC integrated model - speed can be adjusted by load, only the voltage needs to be controlled at the front end, and it can be one of a few fixed voltages, which can be obtained by connecting batteries in series and parallel;

[0182] The voltage difference between multiple layers of ultra-flat wire, and the staggered arrangement between these layers, facilitates heat conduction. This staggered arrangement forms a bridge for heat transfer, similar to the staggered placement of bricks in a wall.

[0183] Temperature memory alloy gaskets allow for gap adjustment, ensuring a constant air gap despite temperature changes – an advantage of axial flux motors.

[0184] The concentric winding method of ultra-flat wire results in very low and uniform voltage between layers, making it safer. The numerous insulation layers between multiple layers naturally provide excellent insulation. The multi-layer, multi-column structure is solely for reducing the skin effect. Since the layers are connected in parallel, there is no voltage between them, allowing for air isolation. At low speeds, it can be connected in series, while at high speeds and high voltages, it remains in parallel. Materials: good thermal conductivity, good insulation, high magnetic reluctance, high mechanical strength.

[0185] It is also possible for the two sides of a switched reluctance motor to be complementary salient poles, that is, the two sides are not in phase but complementary differential relationship, which can further increase torque stability.

[0186] Alternatively, it can be made into the best material core that is non-conductive but only thermally conductive and magnetically conductive but not conductive. By adjusting its anisotropy, it can be made to have anisotropy of being conductive or non-conductive. Non-conductive - no eddy currents, but thermally conductive and non-magnetic, carbon fiber, ceramic glass fiber, polypropylene, basalt fiber composite materials.

[0187] BDE class motors have a 4-5.4 times higher power density (bidirectional flux + dual rotor, power density comparison between 8-pole and 16-pole), so there is no need to pursue high speeds. This is beneficial for mechanical efficiency, noise, and safety. The lower frequency is conducive to designing multi-pole pairs, and losses are also reduced (because multi-pole pairs have low efficiency at high speeds). With improved efficiency, there is no need to pursue low harmonic characteristics of distributed windings - it's simply a matter of improving efficiency and reducing ripple; and multi-pole pairs can reduce ripple even more effectively.

[0188] Power density can be obtained by measuring current under the same voltage and rotation speed;

[0189] Motor power density is essentially a comparison of heat resistance and efficiency;

[0190] The air gap of the axial flux motor can be compensated for by temperature, always maintaining a minimum air gap; automatic control of memory material;

[0191] The limiting factor for power density in motors is current, not voltage. Bidirectional magnetic flux allows the current to remain unchanged even when the voltage is doubled, which is equivalent to doubling the power density. The number of pole pairs improves stability, while ultra-flat wire zero-end winding and chuckless iron core improve efficiency. At the same time, the chuckless iron core reduces weight, so it can completely outperform distributed winding and has a higher power density.

[0192] It dissipates heat easily; our structure makes it easier to dissipate heat, so air cooling is sufficient.

[0193] Inverter energy consumption: This type can be used without an inverter, DC drive + 9XZT load speed regulation;

[0194] Advantages: The common winding with equal poles can be very fine, and with the differential principle, the switched reluctance motor can also become very precise. In this case, the switched reluctance motor uses a DC planar commutator, which demonstrates its advantages.

[0195] High temperature resistance means increased power density and improved reliability;

[0196] It is resistant to high temperatures, has good processing, and low cost, and is equivalent to a claw pole type, with negligible magnetic leakage in the concave pole region.

[0197] Brushed motors with non-rotating windings and planar contact increase the contact area by tens or hundreds of times.

[0198] Rolling brushes produce no electrical sparks and are made of copper and carbon rods, etc.

[0199] This motor (whether it is axial or radial flux, it is an equal pole common winding structure and is a disc type, so it has the following common advantages: it is easy to make a hollow motor, add a coaxial reducer and differential, the axial flux has good heat dissipation, each is an independent very flat module, the heat dissipation is good, and the middle section of the winding has direct heat dissipation.

[0200] Reduce copper usage, braided windings, fewer solder joints, axial dimensions, and weight;

[0201] When parallel axial flux motors are connected in parallel, the magnets of adjacent rotor discs can be shared; they can be modularly combined; modular combinations can be made according to power requirements, as seen in the racing motors at previous exhibitions, which have hollow shafts and can be freely spliced ​​and combined in parallel.

[0202] For example, the only difference between DE class motors is the number of pole pairs. This verifies that the quickness of pole pairing and the performance of this class of common winding are not affected. It can achieve a similar effect to distributed winding. That is, the number of pole pairs can be very small to reduce frequency and losses. However, this scheme can achieve good torque stability even with a small number of pole pairs because the iron core is a single piece, only the salient poles are distinguished. Therefore, the salient poles can be designed to be finely scattered to obtain stable torque.

[0203] By rationally designing its winding scheme, ultra-flat wire can achieve small voltage gradients between layers and zero voltage between layers, thereby improving its withstand voltage safety level.

[0204] Figures 29-33 The spatial spiral winding scheme is illustrated as follows: a 3-phase motor type with 6 layers, each phase and each pole corresponding to 3 slots, which can be used without welding, without end windings, and all windings participate in electromagnetic interaction.

[0205] The iron core and copper ultra-flat wire are wound in a composite manner in one go. The winding materials include ultra-flat wire + insulation layer + silicon steel integrated and wound in one go. It has a spatial spiral tire-shaped structure. After the silicon steel is wound, there is an integral protrusion. With the addition of central integrated potting, a rigid stator with a skeleton can be formed. The rotor is an open hollow tire-shaped ring permanent magnet, which is equivalent to a magnetic flux motor in all directions. It has no end windings and no solder joints.

[0206] The cross-section can also be rectangular instead of circular; the skeleton design is very important.

[0207] Alternatively: a double-helix motor, figuratively speaking: a space tire-type winding, its cross-sectional diagram is attached. Figures 29-33 (Among them: Appendix) Figure 31 , 32 33 uses a split diagram or a staggered diagram to visually show the spatial relationship between different phase windings. Alternatively, its cross-section can be square, rectangular, triangular, polygonal, circular, elliptical, etc.; the winding and the iron core are integrally wound and formed, or the pure winding has no iron core structure.

[0208] It represents different wiring schemes, which can be different relationships of the number of phase winding groups, or different numbers of phases, or two-phase, three-phase or multi-phase, or different numbers of slots in the same phase, etc.

[0209] The tire-type winding motor can design the corresponding air gap areas of the dual rotors on both sides into a concave semi-tire shape, which matches the tire-type winding core to form a spatial tire-type air gap, maximizing the air gap space and outputting greater power. This design has no solder joints in the windings, and except for the inner and outer ring areas of the tire-type core's cross-section which provide positioning support, the remaining areas are all air gaps. The windings are also almost entirely effective windings, which can greatly improve power density. Note: The forming process of this type of tire-type winding can adopt similar principles to the flat wire inductor forming process and the production process of helical springs or irregular springs. A specific extrusion and spinning device can be set at the straight flat wire's advancing position to automatically bend it into a specific spiral shape and a spatial tire-type spiral shape, naturally and cleverly interlocking and embedding it into the spatial tire-type core slots. To reduce weight, without affecting the magnetic flux density distribution, the central annular area of ​​the spatial tire-type core can be removed or a weight-reducing hollow design can be adopted.

[0210] Alternatively, the tire-type winding can be axially flattened into a disc shape to form an axial bidirectional flux dual rotor motor; or the tire-type winding can be radially flattened into a cylindrical shape to form a radial bidirectional flux dual rotor motor. Note: The bidirectional flux in these two schemes corresponds to different side windings after flattening, so there is a yoke in the middle area.

[0211] As shown in the figure, the pink winding can be first wound in concentric circles, then stretched and deformed into a spiral shape. During stretching, a rolling roller can be used to perform micro-plastic deformation while ensuring effective and safe insulation of the insulation layer and uniform voltage drop between layers. Then, the nine independently pre-wound concentric circle windings shown in the figure are stretched into a spiral winding and then spirally interwoven to form a nine-spiral structure (similar to a multi-head worm gear).

[0212] Reanalysis: The winding should follow a spiral framework, specifically a space tire-type spiral framework, which should be flattened after winding. Alternatively, the winding itself should follow a flattened space tire-type spiral framework, similar to W-PIN but with superior features. Alternatively, the winding method can be referenced from W-PIN; each layer of ultra-flat wire should be completed according to W-PIN principles before being interlocked.

[0213] Alternatively, it can be implemented according to the patent scheme of 2023.3.13; after flattening and bending, it is similar to W-PIN, but the difference is that this method can be made into an ultra-flat wire structure (this is the key point of this invention, the ultra-flat wire can be wound in a spiral shape, then flattened and bent into a ring before being placed in the iron core - or the iron core can be split - for example, it can be divided into 4-6 half-fan-shaped iron cores combined together. This method is similar to the ancient wisdom arch bridge structure, with good mechanical properties and greatly improves the ease of assembly. It is even possible to directly wind the winding in the form of a flattened spiral. The key point of this method is that the conductor and insulator of the ultra-flat wire can be separately synthesized; and it causes little damage to the winding, does not require pre-bending, can be ultra-flat wire, and ultra-flat wire has good flexibility, making it more convenient to use this method. It also has the advantage of uniform voltage drop at each layer and greatly improves the voltage resistance). And the end winding seems to be able to be utilized as much as possible and turned into an effective winding; it seems not, but even if it is not possible, at least the size of the end winding can be reduced. Since it is X-PIN and there are no solder joints, this advantage alone is huge.

[0214] Problems or phenomena may occur with the end windings when they are flattened:

[0215] This can result in a large proportion of end windings with a large outer ring radius and a small proportion of end windings with a small inner bending radius.

[0216] Because ultra-flat wire is very thin, it is easier to plastically deform. Therefore, during the spiral winding and end flattening process, it will undergo timely and natural plastic deformation to meet the cross-slot bending requirements of the distributed winding of the end winding.

[0217] It is the optimal linear electromagnetic railgun, used for military purposes or satellite launches (with an extremely long ground acceleration time, allowing its horizontal linear velocity to reach cosmic speed, and then turning to vertical or horizontal centrifugal launch; atmospheric friction must be considered, so it is not advisable to have too high a speed within the atmosphere, but it can be used as a military electromagnetic railgun to replace artillery fire, and can continuously and densely fire non-explosive iron balls for close-range protection); it is also used in aircraft carrier electromagnetic catapults, and the iron core is also spiral-shaped.

[0218] In summary, the above-mentioned motor can be a scheme with different phase windings interleaved and complementary, and permanent magnets radially aligned; or it can be a scheme with different phase permanent magnets arranged in complementary phases and different phase windings aligned, as can be found in the prior application.

[0219] Alternatively: the above motors can all be of the following types: external rotor, internal rotor, dual rotor, or counter-rotating dual rotor; or, the above motors can all be of the following types: synchronous reluctance, switched reluctance, permanent magnet synchronous, induction asynchronous, or DC.

[0220] Setting the winding side of an axial flux motor as an outer rotor is beneficial for space utilization and is also safer. If the inner rotor is the winding end, two layers of centrifugal force protection devices are required. However, the magnet side itself has protection. Therefore, this is beneficial for space utilization, reducing volume, or maximizing the electromagnetic radius of action to increase torque.

[0221] Used in wind power generation and helicopters, multi-pole logarithmic motors with no waste, no end windings, and no yoke core.

[0222] Two-phase (three-wire four-phase wave motor) and three-phase motors are both acceptable; please refer to prior application documents.

[0223] Alternatively, the iron core can be coiled and then wire-cut, which can cut off the eddy current. It has good processability, and the winding can be continuously coiled in a large manner without the problem of butt joints or overlaps. (A simple bending mold can be designed. Each time it is manually inserted and then squeezed to form a smooth arc. It can be formed from the outside open first and then the outer iron core can be inserted from the shaft side. All windings are evenly spaced from the iron core, which has good heat dissipation, no end windings, and a large iron core space, which can withstand strong currents.)

[0224] It is basically a toroidal winding, but circular or toroidal magnets can also be used; a cooling water jacket or air-cooled channel can also be added to the serpentine area;

[0225] The concentric ring layer area of ​​the winding and iron core can be filled with low-density, high-temperature resistant, and thermally conductive materials, or a cooling water jacket can be installed; or a hollow air duct or air-cooling channel can be installed, which also serves as a magnetic shielding function. The large-scale use of the middle area is equivalent to saving space and improving the power-to-volume ratio and energy density.

[0226] The internal windings and core radii can be adjusted at will. The goal is to achieve the best utilization rate of each core while ensuring that the three windings generate equal torque.

[0227] Wiring diagrams for three-phase sinusoidal permanent magnet synchronous motors and three-phase switched reluctance motors; all are designed according to the specifications of three-phase motors or three-wire four-phase wave motors.

[0228] Analysis basis:

[0229] a. When the current intensity of each winding multiplied by the number of turns is inversely proportional to its effective electromagnetic working radius, equal torque can be obtained.

[0230] b. When the angular velocities of the same winding are equal, and the number of turns is equal, their back electromotive force is proportional to the radius. Therefore, when the number of turns is set to be inversely proportional to the radius, equal back electromotive forces can be obtained. When the back electromotive forces are equal, the same positive voltage can be obtained. When the influence of the number of winding turns on the resistance is ignored, the currents can be considered equal.

[0231] c. Torque is directly proportional to current intensity and number of turns, and inversely proportional to radius. Therefore, when the number of turns of each winding is inversely proportional to the radius, the same torque can be obtained.

[0232] (Note: The number of turns mentioned above is based on the premise that the circumference is a constant value. That is, the number of turns ratio mentioned above is actually the ratio of the winding circumference. However, the circumference is inversely proportional to the radius. Therefore, the number of turns ratio of each winding is the square of the inverse ratio of the radius.)

[0233] It is obvious that the winding turns in the small diameter region will be very thick. In order to obtain the equivalent magnetic reluctance, the winding in the small diameter region can be designed as a multi-layer iron core winding with alternating phases. The currents of adjacent windings need to be reversed. This does not matter for switched reluctance motors, but for permanent magnet synchronous motors, it needs to be set as a multi-ring concentric permanent magnet.

[0234] In summary, the pre-set target parameter relationships are as follows: the ratio of the number of turns of each winding is the square of the inverse radius, the ratio of the electromagnetic wire length of each winding is the inverse radius, the currents of each winding are nearly equal when entering the stable speed region, the ratio of the excitation intensity of each winding is the inverse radius, so the ratio of the cross-sectional area of ​​each core should be the inverse radius.

[0235] Note: The peak magnetic field strength of adjacent windings relative to the shared core does not occur at the same time point. That is, the excitation cycle of each winding corresponds to a phase difference. Therefore, the cross-sectional area of ​​the shared core does not need to be superimposed according to the excitation strength of adjacent windings, in order to maximize space utilization. Switched reluctance exhibits slight peak overlap.

[0236] The radial radius ratio of each winding and the core, and the optimal space utilization setting for the core with unsaturated magnetic circuit under peak current.

[0237] Adjacent windings can share an intermediate core ring, but the number of shared core ring layers must be sufficient.

[0238] In addition, the rotor permanent magnets corresponding to the shared iron core layer of different phases should be set according to their working principle to ensure that the optimal electromagnetic torque force between the two phases is obtained. Alternatively, each phase can use its own iron core and magnet independently.

[0239] The diagram shows a three-wire four-phase wave scheme, but it can also be a traditional three-phase motor scheme;

[0240] Adding concentric windings radially is equivalent to increasing the number of electromagnetic poles of the stator and rotor, but without changing the speed and frequency. This can increase power density without increasing the frequency, and reduce iron loss and copper loss.

[0241] It can be pushed and swung to the top of the inner hole of the iron core for rotor assembly;

[0242] If adjacent windings interfere, they can be misaligned by increasing their axial dimensions. In other words, the best solution to resolve interference is to lengthen the winding axially, i.e., increase the axial dimension of the end winding. Minimize the end dimensions as much as possible, which can be achieved by radially offsetting the end windings vertically. Note the assembly sequence of the windings enclosed in the middle. The middle windings without curved bridges should be assembled in the middle process. Just pay attention to the assembly sequence.

[0243] Generally speaking: For two-phase windings A and B, phase A adopts a bridge-type design to make room for phase B, so phase B adopts a direct planar U-shaped design. Alternatively, the two can be interleaved, i.e., cross-leaving, both of which have bridge-arch type and planar type. In short, the principle is to achieve the wiring of all windings with the minimum axial winding size by interleaving them with the bridge-arch type and axial offset. This end winding is similar to a heat sink, so it has good heat dissipation. Therefore, it can be appropriately narrower than the internal winding to ensure the same conductivity characteristics. However, if space allows, it is better to make it larger to reduce the end resistance and increase the heat dissipation area.

[0244] If the two phases bend vertically and wrap around each other, the axial dimension can be minimized. However, the resistance will increase because the length increases. Therefore, from an efficiency point of view, it is better to design according to the principle of shortest length. Bridge arch and planar types can be used interchangeably to achieve the shortest length, the lowest resistance, the best heat dissipation, or the shortest axial end winding dimension.

[0245] All similar designs in this patent can be cross-combined to obtain the optimal slot fill factor and short end windings, with small skin effect, low resistance, simple wiring process, low cost, good heat dissipation, and good insulation.

[0246] Based on the electromagnetic conversion requirements and the characteristics of speed and torque, the windings in the same phase can be connected in series, in parallel, or in a combination of multiple series and parallel connections to obtain the highest efficiency conversion in different speed ranges and the best torque output, which can make up for the shortcomings of insufficient torque at high speeds in motors.

[0247] Alternatively, another approach to the radial physical space misalignment phase shifting method can be to use the core structure of a traditional radial flux or axial flux motor. By setting different phase windings between different layers, radial physical space misalignment is achieved, eliminating the problem of cross wiring between different phase windings. At the same time, since the same phases are all in the same layer area, the end windings can also participate in the excitation effect, turning the end windings into effective excitation windings.

[0248] Advantages: 1. Reduces skin effect; 2. Simplifies wiring difficulty; 3. Transforms end windings into effective windings; 4. Improves temperature resistance. These four advantages are significant. The result is: increased power density and efficiency, reduced cost, and extended lifespan.

[0249] It has better heat dissipation, transforms the end winding into an effective winding, makes good use of the internal space of the shaft for external rotor motors, and is lightweight. Furthermore, the internal rotor winding process is easier to assemble, and the open design, especially the open slot, is more convenient.

[0250] Note: Two-phase motors are preferred as they simplify winding wiring.

[0251] For ease of description, this patent application unfolds the iron core into a plane to illustrate its structural principle.

[0252] In the above-mentioned solutions, there are isolation gaps between the layers of the ultra-flat wire winding. Cooling medium can be introduced into these gaps to increase the heat dissipation effect. Please refer to the relevant text.

[0253] Note: The rotor described above can be a permanent magnet rotor or an induction rotor. The stator and rotor core can also be made of nanocrystalline or amorphous materials; the above motor design principles can be applied to electric motors and generators.

[0254] Note: The motor described above can also be designed as a counter-rotating dual-rotor motor (see prior application), or it can be: a single dual-rotor motor, a double dual-rotor motor, a triple dual-rotor motor, or a multi-dual-rotor motor; a single dual-rotor motor: one inner rotor and one outer rotor; a double dual-rotor motor: includes two outer rotors or inner rotors rotating in the same direction, as shown in the figure, including a middle single-winding rotor with bidirectional magnetic flux and inner and outer double-magnet rotors. Since the inner and outer double-magnet rotors rotate in the same direction, they can be fixed together and form a counter-rotating dual-rotor motor with the middle single-winding rotor through a reversing mechanism, which can double the power density; Figure 27 It includes a central single-magnet rotor with bidirectional magnetic flux and an inner and outer double-winding rotor; similarly, since the inner and outer double-winding rotors rotate in the same direction, they can be fixed together and form a counter-rotating dual-rotor motor with the central single-magnet rotor through a reversing mechanism, which can double the power density; or, it can form a two-sided power flow output architecture with electromagnetic differential torque vector distribution function, which is lightweight and has high power density.

[0255] The above principle also applies to axial flux motors; counter-rotating dual rotor motors; and internal and external dual flux types;

[0256] Axial flux motors can refer to the relevant solutions in the prior application, namely: arranging two or more relatively independent axial flux windings and permanent magnets (or non-permanent magnet current excitation windings) according to the corresponding phase difference angles, and controlling them according to the complementary waveform relationship, can achieve the same effect. Since the axial force of the axial flux motor is very large, it is basically used in the form of double disks or multiple disks to balance the axial force. Moreover, the axial flux motor has the characteristic of short axial dimension. Therefore, it is more advantageous to use the double disk or multiple disk scheme described in this patent application to design a compact high power density motor.

[0257] It can be a single-rotor or dual-rotor motor, as well as a dual-rotor motor with magnetic flux on both sides and a counter-rotating dual-rotor motor.

[0258] Its electromagnetic wires can be round or flat; the current waveform can be: square wave, square wave + composite wave, or sine wave.

[0259] Regarding the method of externally introducing rotor winding current for dual-rotor motors, please refer to prior applications (202211030428.1 Dual-rotor motor current dynamic and static physical ports, 202211098410.5 Constant reluctance rotary transformer and core design and manufacturing method) and related solutions below. The above solutions can also be used for conventional single-rotor motors, such as replacing existing brushless and brushed solutions.

[0260] Note: The above solution applies to all types of electric motors and generators, including asynchronous motors, synchronous motors, brushless motors, brushed motors, induction motors, permanent magnet motors, switched reluctance motors, etc.

[0261] The three-phase lines mentioned above can be the input / output harness terminals of a three-phase motor, a three-phase induction asynchronous motor, a brushless DC motor, or a permanent magnet synchronous motor. Alternatively, the dynamic and static port connection method described in this article can also be a sliding brush method, or a sliding carbon brush solution that is easy to replace. Note: The names of the dynamic and static physical ports described in this article are relative and are mutually interchangeable in specific implementations; inner and outer rotors are relative designations, and they have interactive mechanical properties and can be used interchangeably as inner and outer rotors. For the sake of simplicity and fewer lines, the diagram is not drawn according to standard engineering drawings, but only to illustrate the principle. The content can be accurately identified by referring to the accompanying drawings.

[0262] Note:

[0263] The part numbering in the attached drawings uses the same numbering for common parts in different drawings, while different numbering is used for related equivalent functional parts in specific drawings. This is entirely to help the instruction manual to more clearly and accurately describe their working principles.

[0264] All design ideas, structures, methods, and theories presented in this document can be used to guide design. The technical content disclosed in its design theories, methods, implementation models, structures, schematic diagrams, structural diagrams, simplified diagrams, mechanism diagrams, and specific embodiments can be used to design and manufacture various types of engine devices. The implementation mechanisms listed in this patent are typical examples; not all specific facility schemes and mechanism types are listed here. Any cross-reorganization, mutual reference, combination, or arrangement of design theories, ideas, methods, models, mechanisms, or components disclosed in this document, as well as various application examples of this technical category, fall within the scope of this intellectual property protection. Any unauthorized use of these principles in design or application constitutes infringement. For example, the relevant design theories and methods are applicable to traditional electric motors, generators, and other similar power sources.

[0265] The purpose of the accompanying drawings in this patent is solely to concisely illustrate the concept and principle of the patent's facilities. The aim is to clearly represent the patent's disclosed content with a minimal number of drawings, explicitly expressing key structural elements. A "combination of detailed and concise" approach is adopted, using a combination of simplified and detailed diagrams. Furthermore, to reduce the number of drawings, similar structures are not shown in other directional views, sectional views, or enlarged details. Standard parts, general-purpose parts, and components without specific meaning or dedicated function are given uniform names and part numbers across different drawings for greater clarity. Please refer to the drawings for cross-referencing.

Claims

1. A common-winding motor with ultra-flat wire and its design method, including motor windings, stator, rotor, and housing, characterized by: The stator and rotor have the same number of magnetic poles, and all stator or rotor poles on the same disk are energized through the same toroidal coil winding. This winding can be made of conventional round wire, flat wire, or extra-flat wire; alternatively, there can be two or more concentric circular winding units on the same disk, such as outer winding units and inner winding units. Radially adjacent iron cores can share a common core or be arranged independently. Considering magnetic saturation, the radial dimension of the shared core can be wider, or the radial dimension of the core and winding in the small-diameter region can be larger. Its working principle can be reluctance, switched reluctance, or other types. The permanent magnet synchronous type can be a DC motor or an AC motor; the DC motor can be a commutator, a planar commutator, or a brushless control scheme; the AC motor can be a square wave, a sine wave, or other waveforms; it can be a three-phase AC with a phase difference of 120 degrees; or a two-phase or four-phase AC with a phase difference of 90 degrees or other phase difference currents; the winding wiring method is a concentric circle or serpentine routing around the motor shaft, which makes the winding very compact, without iron core yoke, without end windings, all windings participate in excitation, with high power density, high efficiency, and simple processing and assembly wiring process; Its characteristics are: there is only one or one set of windings in the same phase of the motor, different magnetic pole anisotropy is obtained through the magnetic circuit design of salient pole and concave pole, and torque is obtained through spatial misalignment and displacement with permanent magnet or inductor, or the principle of minimum magnetic reluctance. Generally speaking, it is an equal pole common winding structure, or it can be non-equal pole misalignment or round wire instead of flat wire. This method is applicable to radial flux and axial flux motors. This article focuses on radial flux motors and uses a radial bidirectional flux configuration as an example. It can also be a counter-rotating dual rotor configuration in which the stator windings also participate in the opposite rotation, which can greatly increase the power density of the motor in a multiplicative ratio. A common-pole motor with ultra-flat wire and its design method, including motor windings, stator, rotor, and housing, is characterized by: the number of magnetic poles of the stator and rotor on each disc being equal or an integer multiple; all stator or rotor magnetic poles on the same disc (in the same phase) being energized through the same ring coil winding (generally a one-disc-one-phase structure, i.e., the same disc is the same phase winding; to increase power, each phase can also be composed of multiple discs). This winding can be conventional round wire, flat wire, or ultra-flat wire (for the structure, process, and principle of ultra-flat wire, please refer to relevant prior applications); or, there can be one or two or more concentric circular winding units on the same disc, such as: outer winding unit, inner winding unit, whose radially (or axially, for axial flux configuration) adjacent iron cores can be shared, or can be arranged independently; at the same time, considering the magnetic saturation problem, the radial dimension of the shared iron core can be wider, or the iron core and winding in the small-diameter region can have a larger radial dimension. Generally speaking: the component in the winding area is the stator, which can be a common winding configuration with equal poles; the rotor side can be a permanent magnet rotor, an electrically excited rotor (an electrically excited rotor can also use a common winding configuration with equal poles), or an induction rotor; or, the stator on the winding side can also participate in the rotation to achieve a counter-rotating dual rotor configuration, reducing the absolute speed of the rotor or increasing the relative speed between the stator and rotor, thereby increasing the power density; Note: when the winding side is designed as a rotatable winding structure, the power supply principle of its winding can adopt various schemes such as rolling brushes and induction brushes; Explanation of the concept of equal-pole common winding configuration: The excitation current of all magnetic poles comes from the same winding, as shown in the figure. Advantages: The winding has a concentric disk structure, which can be formed by concentric winding of ultra-flat wire. The winding process can control its preload to ensure a high and reasonable preload density between layers, improve slot fill factor, thermal conductivity, and safety, reduce electromagnetic noise, optimize dynamic balance, and all windings are effective windings with no end windings. The winding utilization rate is close to 100%, and it realizes the arbitrary free design of the number of magnetic poles. No matter how many magnetic poles there are, they all correspond to the same set of windings. This advantage completely surpasses the traditional centralized winding and distributed winding, and the process is greatly simplified. Note: Generally, the poles are equal, meaning the stator and rotor have the same number of poles. This can also be an integer multiple or a fractional multiple (fractional pole relationships can also be used to eliminate cogging torque). Because the staggered and complementary magnetic poles of different phases in a disk-type motor cleverly eliminate cogging torque, the stator and rotor can have an equal pole relationship to optimize harmonics, and the back EMF is essentially a sine wave. Since a spatial configuration of different phases on different disks is achieved, the magnetic circuits of different phases no longer intersect (although adjacent phases can share magnetic poles). Furthermore, it avoids the problem of long and thick yokes in traditional motors with fewer pole pairs. The magnetic circuits in this configuration can all be closed-loop with the shortest possible length, greatly reducing iron losses and the yoke, thus reducing weight and increasing power density and efficiency. For bidirectional flux types, a yoke-less structure can be achieved; see the attached diagram. Alternatively, another important feature is that the winding wiring can be a concentric circle or serpentine route around the motor shaft, which makes the winding very compact, without iron core yoke, without end winding, and all windings participate in excitation, resulting in high power density, high efficiency, and simple processing and assembly wiring processes. Note: For external rotor motors, it is recommended that the external rotor output power via a hole structure. This is because the structural relationship between the external rotor and the inner stator is equivalent to a hole-shaft relationship, while the conventional structural relationship between the inner rotor and the outer stator is a shaft-hole relationship. That is, the inner rotor is the shaft and the outer stator is the hole. Therefore, it is more suitable for the inner rotor to output power via a shaft, but it is more reasonable for the outer rotor to output power via a hole structure. Specific structural solutions can include a hollow shaft structure, with output power via a flange or gear / sprocket transmission relationship; or a planetary gear structure to output power flow. Alternatively: The above scheme is also applicable to axial flux motors, see attached figure; it is also divided into centralized winding and distributed winding schemes; all of them can be improved into ultra-flat wire winding structure by adopting the above scheme. Its single-layer copper strip can be composed of several parallel copper strips with the smallest possible gaps, or it can be made using micro-hole drilling. The circumferential ultra-flat wire adopts an assembly scheme from the tooth groove gap, which can fill the remaining gap by inserting a rectangular flat wire or a round wire at the end. Its working principle can be reluctance, synchronous reluctance, switched reluctance, permanent magnet synchronous, or asynchronous induction type; it can be a DC motor or an AC motor; the DC motor can be a brushless control scheme, a brushed commutator, or a planar commutator scheme; the AC motor can be a permanent magnet synchronous or induction asynchronous scheme, and its control waveform can be a square wave, a sine wave, or other waveforms; it can be a three-phase AC with a phase difference of 120 degrees; or a two-phase or four-phase AC with a phase difference of 90 degrees or other phase difference currents. Switched reluctance motors typically consist of three or more discs, with each disc having a phase difference that is arranged at equal intervals to obtain a uniform, continuous, and stable torque output. They can have a large number of poles to ensure a more stable torque output, such as 30 or other numbers. Permanent magnet synchronous motors generally consist of two or more disks (e.g., a three-wire four-phase wave equal-pole common winding motor type). The phase difference of each disk is arranged in equal intervals to obtain a uniform, continuous and stable torque output. The number of poles can be large to ensure a more stable torque output, such as 30 or other numbers. Alternatively, it can be composed of a single disk, which uses independent inner and outer ring windings and iron core magnetic circuit units to achieve continuous and stable torque output through phase complementary alternating operation. Its magnetic circuit is a spatial magnetic circuit. The concentric circular magnetic circuit in the winding area is composed of concentric circular iron cores wound together. In order to eliminate eddy currents, the concentric circular iron cores are radially cut off. The magnetic circuit in the non-winding area is generally arranged radially and axially. The radial iron cores can be glued together or tightly attached by mechanical means, or grooves or baffles can be opened between the iron core and the iron core frame to enhance safety. The magnetic circuit area is made of a core material with very high magnetic permeability, such as a thin layer of silicon steel sheets; the rest of the core skeleton support frame is made of a magnetically resistive material with very low magnetic permeability (+materials shown at the commercial vehicle exhibition), such as: aluminum, aluminum alloy, magnesium-aluminum alloy, titanium alloy, carbon fiber, ceramics, mica and other high-temperature resistant, high magnetic resistance, high resistance and high strength composite materials and other metal or non-metal materials. This core layout can be either a fan-shaped core arranged radially or a rectangular core arranged radially. Its characteristic is that it can be a dual-rotor configuration, with concentric inner and outer iron cores forming a dual-rotor structure. Its principle applies to most types of motors, including DC motors, AC motors such as permanent magnet motors and switched reluctance motors, as well as induction motors and hysteresis motors. The input current waveform of the motor can be: when the motor is transformed into an engine, the induced current waveform generated by driving the motor windings with stable torque at a constant speed can guide the design of its control current waveform. In other words, if the control current waveform of any motor is the same as the current waveform generated when the motor is driven to rotate with constant torque and constant angular velocity as a generator, then the output torque of the motor as a motor must be constant. This method can be called the "energy reverse measurement simulation method" and can be used as a guide for optimizing the control current waveform of a motor. It is applicable to any type of motor. Alternatively, its characteristics are: there is only one or a group of windings in the same phase of the motor, different magnetic pole anisotropy is obtained through the magnetic circuit design of salient pole and concave pole, and torque is obtained through spatial misalignment and displacement with permanent magnet rotor or induction rotor or the principle of minimum magnetic reluctance. Generally speaking, the stator and rotor magnetic poles are of equal pole and common winding structure, or the stator and rotor magnetic poles are of non-equal pole or integer multiple or fractional multiple differential misalignment relationship. The winding wiring is simple, requiring only concentric circle winding, making it suitable for ultra-flat wires. It has good dynamic balance, is easy to manufacture as a dual-rotor motor, has no end windings, good heat conduction, axial magnetic flux, radial magnetic flux, and no magnetic yoke. The magnetic circuit is simple, the back electromotive force is sinusoidal, and there is no cogging torque. Note: The difference between a commutator and a phase commutator is that a switched reluctance motor uses a phase commutator to switch the current on and off of different phase windings, while a DC motor uses a commutator to switch the direction of the winding current. Therefore, a commutator requires switching between positive and negative electrodes and requires two circuits, while a phase commutator only needs one circuit to switch the current on and off of different phases; see the attached diagram for details, or refer to the prior application. Basic principle: The same phase iron core is uniformly embedded by using an integrated winding, and the specific magnetic circuit required is formed by relying on the convex and concave relationship of the iron core. A claw pole scheme can also be adopted. If a claw pole scheme is adopted, the corresponding permanent magnet structure will be further simplified. Alternatively, it can be designed as a shared magnetic circuit. For example, the middle iron core can also be shared, that is, the concentric ring iron cores of adjacent windings can be merged and shared as shown in the figure... It can also be an inductive method, where electromagnetic excitation replaces permanent magnets; Advantages: It achieves a separate design of winding and magnetic poles, and can obtain any number of magnetic poles using the same integral winding. For switched reluctance motors, the number of pole pairs can be designed to be very close, reducing torque ripple. This approach can be used for ultra-low-speed motors, such as wind turbines, as well as low-speed, high-torque motors and generators. It allows for the design of any number of magnetic poles or optimal efficiency and power parameters within a limited space. Endless windings improve winding utilization and heat dissipation performance; The accompanying drawings of this application show that the motor types are roughly divided into: A, B, C, D, and E types; for ease of description, they are named as follows: Class A, B, C, D, and E motors, and are shown in the accompanying drawings in order: Type A "Equal-pole common winding bidirectional axial flux-switched reluctance ultra-flat wire motor", see attached Figure 1-2. Type B "Equal-pole common winding bidirectional axial flux permanent magnet synchronous counter-rotating dual rotor ultra-flat wire motor", see attached Figure 3-5. Type C "Dragon-shaped bidirectional axial flux permanent magnet synchronous ultra-flat wire motor", see attached figures 6-7. Note: Some types of this application (mainly referring to types A, B, and C) are further and fully disclosed and described in the prior application "202410741743.8 Ultra-flat wire axial flux motor and design method". For ease of reading, some of the text, figures, and part number markings are adopted from the prior application. You can also refer to the relevant text and figures of the prior application 202410741743.

8. Note: Types A, B, and C all involve the problem of concentric arrangement of multiple windings. This application only discloses the spatial structure layout and does not analyze the electromagnetic field relationship. This scheme can make the spatial structure more compact and make full use of the internal space of the motor. However, considering the magnetic flux density distribution, the spatial and radial dimensions of each phase will be discussed later. For types A, B, and C, please refer to the relevant text and figures in the prior application 202410741743.

8. Alternatively, the two, three, or more magnetic circuits arranged in concentric circles can be axially shifted and separated to form two-phase, three-phase, or multi-phase axially parallel windings and closed magnetic circuits, as described in the prior application's disc-type configuration and description; and the structure shown in Figure 8 of this application, where windings 24 and 25 are two different windings arranged in an axially disc (phase) separation manner. This example is a radial bidirectional magnetic flux two-phase motor type (which can be a three-wire four-phase wave motor, see the relevant prior application), with a 90-degree phase difference between the currents of the two-phase windings; it can also be a three-disc three-phase winding, with a conventional sinusoidal three-phase AC input. (Note: This embodiment is an ultra-flat wire winding. As shown in Figure 8, windings 24 and 25 are ultra-flat wire windings formed by winding three columns of ultra-flat wire per layer. See the enlarged view in Figure 8 and Figures 14, 15 and 16. Alternatively, it can be formed by winding one or more columns of ultra-flat wire per layer. See Figures 10, 11, 12 and 13. Note: For clarity, the figures are enlarged as much as possible. Therefore, some components are omitted in many figures such as Figures 10-16. See Figure 16 for the specific positions of the components. Related content can also be found in prior applications.) Figures 1 and 2 show the axial flux bidirectional flux-switched reluctance type, the full name of which is "equal pole common winding bidirectional axial flux-switched reluctance ultra-flat wire motor". You can also refer to Figures 9-14 and the description in the prior application 202410741743.

8. The switched reluctance rotor disks 26 and 45 are connected by an outer spline to output torque. They are made of high reluctance and high strength material. Their windows are assembled one-to-one with the iron cores of each phase. Note: Except for the iron cores, the remaining areas are made of high reluctance and high strength material. A cooling channel can be set in the middle gap. Alternatively, if the magnetic poles of adjacent different phases are designed to be of the same polarity, there is no need to worry about magnetic short circuits. This middle channel space can be reduced. Or, since the different phases of the switched reluctance do not work at the same time, and the working mechanism of the switched reluctance is based on the principle of minimum reluctance, which is not closely related to the polarity of the magnetic poles, a certain amount of space isolation should still be provided to prevent magnetic short circuits. As shown in the figure, this is a 30-pole case, divided into 3-phase windings to achieve torque phase connection. The phase difference between each phase is 1 / 3 to obtain continuous torque connection. In order to obtain continuous power flow, the phase differences of different phases can also have a certain degree of overlap to obtain a certain degree of overlap of torque between different phases. Considering the working principle of switched reluctance, adjacent iron cores of different phases are not shared, and the iron cores are: 3 sets * 2 = 6 sets of iron cores. Each set of iron cores is made of multiple layers of silicon steel laminations concentrically wound. Alternatively, they can be shared, which can reduce two sets of iron cores. Alternatively, it can be a counter-rotating double rotor structure in which the windings also participate in the rotation. Figures 3, 4, and 5: "Equal-pole common winding bidirectional axial flux permanent magnet synchronous counter-rotating dual-rotor ultra-flat wire motor". As shown in the embodiments, Figure 3 is a 12-pole two-phase motor, Figures 5 and 17 are the assembly drawings of the model in Figure 3 (Figure 5 is a cross-sectional view), and Figure 4 is a 24-pole motor. All are illustrated using a two-phase motor as an example (it can also be a three-phase motor). It uses 4 sets of concentric circular iron cores, with one phase winding in the middle of every two sets. Generally speaking, the middle iron cores cannot be shared because the permanent magnets cannot be shared, and the two phase permanent magnets need to be staggered. Note: This embodiment is a two-phase structure with a phase difference of 90 degrees. See the previous application "Related Description of Three-Wire Four-Phase Wave Motor". Considering the limited space in three-phase motors, this application will not elaborate further. Generally, three-phase models are implemented with a split-disc structure, as shown below (such as the configuration in Figure 8) and related applications. If it is changed to a claw pole structure, the middle iron cores can be shared. See also Figures 1-8 and descriptions in prior application 202410741743.8; Wherein: Figure 4 shows that the winding excitation magnetic field passes through the iron core where the winding is located and is guided by the corresponding fan-shaped claw pole iron core arranged with salient poles on both sides and axially attached. After forming a large area of ​​air gap magnetic flux cross section, it interacts with the rotor permanent magnet with magnetic force. The air gap area is large; as shown in the part number markings 2, 3, 4, 5, 6; 16, 17, 18, 19, 20 in Figure 4, corresponding to the structural description. Alternatively, the salient poles of the winding core can directly interact magnetically with the permanent magnet rotor, resulting in a smaller air gap area and more concentrated magnetic flux density. This reduces the amount of permanent magnets used and eliminates the need for claw-type cores and claw-type core skeleton disks, simplifying the structure. As shown in Figure 3, the two sides of the annular cores 9, 10, 11, and 12 are both salient-concave pole shapes, forming bidirectional flux core salient poles (the embodiment shown in this figure is a bidirectional flux core without a yoke), corresponding to the permanent magnet rotors on both sides. Note: Generally speaking, the inner and outer ring core salient poles of the same phase winding need to be staggered; however, for the type of core without claw poles, they can be aligned, but it is necessary to ensure that the inner and outer ring permanent magnets of the corresponding rotor permanent magnets need to be further layered, each further divided into narrower inner and outer ring permanent magnets (see the part numbers 21.1, 21.2, 22.1, and 22.2 in Figure 53 of the prior application 202410741743.8), and it is necessary to ensure that the magnetic poles correspond one-to-one and have opposite polarities. Figures 6 and 7: "Dragon-shaped axial flux permanent magnet synchronous counter-rotating dual rotor ultra-flat wire motor." As the name suggests, its winding spatial structure presents a dragon-shaped structure. Its advantages include 100% utilization of the ultra-flat wire windings, no end windings, and a counter-rotating dual rotor structure. As shown in the figures: Figure 6 shows a 20-pole motor, and Figure 7 shows a 22-pole motor, but the basic structural principle is the same; the difference lies in the number of poles and the shape of the windings. Figure 6 shows a trapezoidal or rectangular winding, while Figure 7 shows an arc or petal-shaped winding, with the overall orientation resembling a dragon. As the name suggests, it is a dragon-shaped winding motor; or it can be a motor with two or more dragon-shaped windings, or a three-dimensional 3D double-dragon or multi-dragon motor. It can be powered by two-phase, three-phase or multi-phase AC power to the dragon-shaped windings of different phases, and can be spatially staggered. The windings can be made of flat wire or ultra-flat wire. For example, part number 60 in Figure 6 corresponds to 6 columns of ultra-flat wire per layer (for a description of ultra-flat wire, please refer to the relevant application). It can also be a combination of flat wire and round wire to obtain more diverse winding configurations. The attached diagram shows a scheme where the winding core interacts directly with the rotor permanent magnet, or a scheme where the magnetic flux cross-section is expanded by deforming magnetic poles; or a scheme where the winding core and the external core are integrated into a single design, optimizing the magnetic circuit, reducing magnetic leakage, and maximizing the introduction of the winding excitation magnetic field into the effective magnetic circuit. This structure is also safer, provides more effective axial positioning of the winding and itself, and helps to improve high-speed performance and reduce the air gap. Figure 17 shows the assembly diagram of the models in Figures 3 and 5. It is a counter-rotating dual-rotor model, and the winding current is introduced through the rolling brush assembly. Figures 18 and 19 are assembly drawings of the model shown in Figure 6. Figure 18 is an AC model, and the case of this application is a two-phase AC motor. Figure 19 shows a permanent magnet DC model that uses a commutator. Figure 20 is the assembly drawing of the model in Figure 1 (Figure 20 shows four angle views. The model in Figure 1 can use a dedicated switched reluctance controller or a commutator. As shown in Figure 20, a commutator is used). Figures 21 and 22 are the general assembly drawing and half-sectional view of the model in Figure 8. For detailed planar sectional assembly drawings, please refer to Figure 16. The difference between a commutator and a phase commutator: Generally speaking, a phase commutator is used in DC switched reluctance motors (AC phase commutators can also be used in non-critical specific situations) to switch the on and off states of different phase currents as needed; a commutator is used in permanent magnet DC motors to change the direction of winding current as needed. Figures 23 and 24 are exploded views of the commutator assembly. Figures 25 and 26 are exploded views of the commutator assembly, which is generally used in switched reluctance motors; Note: The commutator and phase commutator components described in 23, 24, 25, and 26 above all include a rolling brush assembly with conductive rolling elements, which can enable the windings to not participate in rotation. As long as the corresponding rotating parts of the commutator or phase commutator are fixedly connected to the rotor to collect the phase relationship between the rotor and stator, the commutation or phase commutation function can be realized in a timely manner. This is also an advantage of this application (traditional DC motors using commutators basically require the windings to participate in rotation, that is: the permanent magnet is the stator, and the windings and commutator are the rotor). As shown in the attached diagram, the commutator or phase commutator structure can achieve efficient and lossless electrical connection through the rolling brush structure, and realize the function of a brushed motor with non-rotating windings (generally speaking, the windings of a brushed motor rotate, but the solution in this paper realizes a brushed motor with non-rotating windings). It can also be a brushless motor solution, which uses an angle sensor to collect the rotor angle and then controls the power semiconductor switching circuit to realize the commutation or phase commutation of the winding current. Figures 27 and 28 are exploded views of the three-phase rolling brush assembly, which can transmit current without sliding friction through the rolling conductor 119. The figure shows the three-phase rolling brush assembly, which can transmit three-phase current simultaneously. See Figures 27 and 28 and the assembly drawing of Figure 16.

1. in:

1. Left-side permanent magnet rotor disc (output torque via external spline connection; alternatively, an induction external rotor) 2. Left-side claw-pole core skeleton disk (made of high-resistivity and high-strength material, its windows are assembled one-to-one with the claw-pole core, and its central inner hole is connected to the winding shaft by splines or cylindrical keys to form concentric positioning and transmit torque) 3. The claw-type iron core corresponding to the left salient pole of the outer ring iron core of the outer ring group (made of stacked thin silicon steel sheets).

4. The claw-type iron core (made of stacked thin silicon steel sheets) corresponding to the left salient pole of the inner ring iron core corresponding to the outer ring group.

5. The claw-type iron core (made of stacked thin silicon steel sheets) corresponding to the left salient pole of the outer ring iron core of the inner ring group.

6. The claw-type iron core (made of stacked thin silicon steel sheets) corresponding to the left salient pole of the inner ring iron core of the inner ring group.

7. Left salient pole positioning plate of the toroidal iron core (made of high magnetic resistance and high strength material, its window is assembled to correspond to the left salient pole).

8. Winding Shaft (In this embodiment, a bidirectional flux winding rotor is used, meaning the winding also participates in the rotation, forming a counter-rotating dual-rotor configuration with the permanent magnet rotors on both sides. This means both the winding rotor and the permanent magnet rotor can rotate in opposite directions to output torque, effectively doubling the magnetic field speed. Furthermore, the bidirectional flux configuration doubles the air gap area, resulting in a 4-fold increase in power density overall. Note: This shaft is hollow in the center for weight reduction and wire transmission. If the winding participates in the rotation, it is electrically connected to the outside via a rolling brush or other means; see relevant prior applications for details.) 9. The outer ring core corresponding to the outer ring assembly (made of thin silicon steel sheets wound and stacked, with salient poles on both sides; to reduce eddy currents, narrow slits are cut radially into the wound core to isolate eddy current circulation;) 10. The inner ring core corresponding to the outer ring assembly (made of thin silicon steel sheets wound and stacked, with salient poles on both sides, whose salient poles are offset and complementary to the salient poles corresponding to part number 9; in order to reduce eddy currents, a narrow gap is cut radially into the wound core to block the eddy current circulation). Note: This toroidal core can be shared with toroidal core number 11, but the radial dimension of the core can be appropriately widened for a reasonable magnetic flux density distribution.

11. The outer ring core corresponding to the inner ring group (is made of thin silicon steel sheets wound and stacked together, with salient poles on both sides. In order to reduce eddy currents, a narrow gap is cut radially into the wound core to block the eddy current circulation. Note: This toroidal core can be shared with the toroidal core marked 10, but the radial dimension of the core can be appropriately widened for a reasonable magnetic flux density distribution.

12. The inner ring core corresponding to the inner ring assembly (made of thin silicon steel sheets wound and stacked, with salient poles on both sides, whose salient poles are offset and complementary to the salient poles corresponding to part number 11; in order to reduce eddy currents, a narrow gap is cut radially into the wound core to isolate the eddy current circulation).

13. Inner winding group (In this embodiment, it is an ultra-flat wire winding, as shown in the figure. The example shown in the figure is an ultra-flat wire winding formed by winding 6 columns of ultra-flat wire in each layer. See the prior application for details.) 14. Outer winding assembly (In this embodiment, it is an ultra-flat wire winding assembly, as shown in the figure. The example shown in the figure is an ultra-flat wire winding assembly formed by winding 6 columns of ultra-flat wire per layer. See the prior application for details.) 15. Right-side salient pole positioning plate of the toroidal core (made of high-resistivity, high-strength material, with its window corresponding to the right-side salient pole).

16. Right-side claw-pole core skeleton disk (made of high-resistivity and high-strength material, its windows are assembled one-to-one with the claw-pole core, and its central inner hole is connected to the winding shaft by splines or cylindrical keys to form concentric positioning and transmit torque) 17. The claw-type iron core corresponding to the right salient pole of the outer ring iron core of the outer ring group (made of stacked thin silicon steel sheets).

18. The claw-type iron core (made of stacked thin silicon steel sheets) corresponding to the right salient pole of the inner ring iron core corresponding to the outer ring group.

19. The claw-type iron core (made of stacked thin silicon steel sheets) corresponding to the right salient pole of the outer ring iron core corresponding to the inner ring group.

20. The claw-type iron core corresponding to the right salient pole of the inner ring iron core of the inner ring group (made of stacked thin silicon steel sheets).

21. The outer ring magnetic circuit corresponds to the outer ring permanent magnet (composed of concentrically arranged fan-shaped permanent magnets with alternating N and S polarities; in this embodiment, it has 24 poles and 12 pole pairs).

22. The inner ring magnetic circuit corresponds to the inner ring permanent magnet (composed of concentrically arranged fan-shaped permanent magnets with alternating N and S polarities; in this embodiment, it has 24 poles and 12 pole pairs).

23. Right-side permanent magnet rotor disk (output torque is connected via an outer spline; it can also be an induction outer rotor). Note: This application implements a two-phase motor (it can also be a three-wire four-phase wave motor, see earlier applications). The phase difference between the inner and outer winding currents is 90 degrees. Therefore, the magnetic pole arrangement of the inner ring permanent magnet 22 and the outer ring permanent magnet 21 is a staggered, centered, and complementary relationship, that is, satisfying the magnetic force relationship with a 90-degree phase difference. If it is a three-phase motor, then there are three sets of windings corresponding to three sets of permanent magnets, and their phase difference and magnetic pole arrangement relationship must satisfy a 120-degree relationship. 24, 25: Windings 24 and 25 are two different phase windings arranged separately in an axially split (phase) configuration. This illustration represents a radial bidirectional flux two-phase motor type (it could be a three-wire four-phase wave motor, see relevant prior applications), with a 90-degree phase difference between the currents in the two-phase windings. It could also be a three-disc, three-phase winding, with a conventional sinusoidal three-phase AC input. 26, 45 Switched reluctance rotor disk (output torque is connected via an external spline, made of high reluctance and high strength material, with its windows corresponding to the cores of each phase). Iron cores on rotor discs of different phases: 27, 28, 29, 42, 43, 44 30 and 40 winding core salient pole positioning disks (made of high resistance and high strength material, with windows that are assembled one-to-one with the salient poles of the winding core). 31, 32, 33, Three-phase winding (In this embodiment, it is an ultra-flat wire winding, as shown in the figure. The example shown in the figure is an ultra-flat wire winding made of 6 columns of ultra-flat wire per layer. See the prior application for details.) The toroidal cores with salient poles on both sides corresponding to each of the windings in phases 34, 35, 36, 37, 38, and 39.

41. Shaft 46. ​​Windings, core, and winding side shaft assembly 47. Switched reluctance iron core rotor side hub (connecting the two rotor discs via splines to form an integrated output torque) 48, 59, Dragon-shaped winding motors with rotor discs on both sides 49. Rotor shaft (connected to 48 and 59 via a key) 50, 51 Two-phase dragon-shaped winding (This embodiment is a two-phase motor, but it can also be a three-phase winding type) 52-55: Bidirectional flux non-magnetic yoke iron core (forming a close interlocking relationship with the dragon-shaped winding).

56. Winding side hub 57, 58 permanent magnet 60. Six columns of ultra-flat wire per layer (Refer to relevant ultra-flat wire patent applications. Note: Part numbers 60, 61, and 62 are specific part numbers and are general-purpose ultra-flat wire part numbers. They do not conflict with part numbers 76 and 77. It can be understood that the 76 and 77 dragon-shaped windings use six columns of ultra-flat wire. Other arbitrary number of columns can also be selected according to space and process to reduce the skin effect.) 61. Conductor portion of ultra-flat wire 62. Insulation substrate of ultra-flat wire 63 and 64 combine to form the permanent magnet frame of the rotor. Permanent magnets are embedded in the four concentric windows on 64 to form a permanent magnet rotor. This model has bidirectional magnetic flux, so there is also a permanent magnet rotor on the other side (the permanent magnet is hidden in this illustration for clarity of the structure); or it can be an induction rotor.

65. Motor stator or winding rotor skeleton disc sleeve (Figure 3 shows a counter-rotating dual-rotor motor structure in which the windings participate in rotation, so it is a winding rotor skeleton disc sleeve) 66. Torque output disc fixedly connected to the motor winding rotor frame 67. Brake disc, fixedly connected to 66. When 67 brakes, the motor winding rotor transforms into the stator. At this moment, if the motor frequency remains unchanged, rotor components such as 63 and 64 will rotate at twice the speed.

68. The rolling brush assembly is an important component that provides current to the windings in a rotatable winding rotor.

69. Bearings 70. The external limit protection disc of the switched reluctance rotor disk, combined with the switched reluctance rotor disk 26, provides installation positioning constraints for each phase core.

71. Motor stator winding frame base 72 and 78 together form the permanent magnet frame of the rotor. Permanent magnets are embedded in the two concentric windows on 72 to form a permanent magnet rotor. This model has bidirectional magnetic flux, so there is also a permanent magnet rotor on the other side (the permanent magnet is hidden in this illustration for clarity of the structure); or it can be an induction rotor.

73. Winding core salient pole positioning plate (made of high resistance and high strength material, with its windows corresponding one-to-one with the salient poles of the winding core). 74 and 75 correspond to the inner and outer ring dragon-shaped winding cores, respectively. 76 and 77 correspond to the inner and outer ring serpentine windings, respectively (this embodiment is a two-phase motor, but it can also be a three-phase winding type).

79. Commutator assembly (for brushed DC motors; not required for AC motors) 80. Radial bidirectional flux winding rotor power output shaft (hollow in the middle to accommodate wires and concentrically assembled with the rolling brush assembly to achieve rotor current transmission).

81. Winding bobbin protection disc 82. Winding inner frame 83. Inner skeleton isolation arc block 84. Winding outer frame 85. Exoskeleton isolation arc block 86. M-phase left-side permanent magnet inner rotor (the illustration shows a two-phase or "three-wire four-phase wave" motor, see prior application; for ease of description, M and N are used to represent specific names for two-phase motors; it can also be a three-phase motor) 87. The left core of the M-phase winding 24 (in this embodiment, it is a radial bidirectional magnetic flux configuration. The inner and outer circumferences of the core are both salient pole structures, and there are two types: 8 poles and 16 poles. Figure 10 shows the 8-pole type, and Figure 11 shows the 16-pole type).

88. Right side core of M-phase winding 24 89. Isolation disc (can be removed, corresponding to claw pole structure, the intermediate iron cores of M and N phases can be shared, that is: 88 and 90 can be combined, and the rotor can also be combined, such as combining 86 and 111; combining 112 and 113; see prior application); Examples include: Magnetic circuit optimization design scheme 4.3 for high power density motors with equal pole common windings, and magnetic circuit optimization design scheme 4.19 for permanent magnet synchronous motors.

90. Left side core of N-phase winding 25 91. Right side core of N-phase winding 25 92, 93 Inter-rotor isolation disc 94. Winding inner and outer frame closing plate 95. Safeguard ring 96. External rotor protection disc 97. M-phase left-side permanent magnet external rotor 98. Isolation tray 99. M-phase right-side permanent magnet external rotor 100, N-phase left-side permanent magnet external rotor 101. N-phase right-side permanent magnet external rotor 102. External rotor power closing output plate (fixed to 103) 103. Power output shaft of internal and external permanent magnet rotor (or induction rotor) 104, 105, 106, 107, 108, 109, and 110 correspond to the corresponding components of a 16-pole motor. Their composition and function are the same as those of an 8-pole motor, and will not be described again.

111. M-phase right-side permanent magnet inner rotor 112. N-phase left-side permanent magnet inner rotor 113. N-phase right-side permanent magnet inner rotor 114 and 115 motor brackets and bases (for bench testing models; the actual product has an integrated housing).

116. Rolling brush non-rotating disk limit block The following part number markings correspond to Figures 27, 28, and 16.1: 117 and 126 are insulator rotating disks fixedly connected to shaft 80 and rotating together. The right side of 117 is in close contact with the conductive flat disk 118 (a conductive material disk such as a copper or silver disk), and the left and right sides of 126 are in close contact with conductive flat disks 125 and 127, respectively. 122 and 130 are insulator non-rotating disks concentric with shaft 80 but not fixedly connected. They are positioned by their outer circumferential protrusions and limiting blocks 116, and are in a stationary, non-rotating state. The left side of 130 is in close contact with conductive flat disk 129, and the left and right sides of 122 are in close contact with conductive flat disks 121 and 125, respectively. The conductive flat disks 118 and 121, 123 and 125, and 127 and 129 are respectively fitted with freely rotatable rolling element isolation and positioning cages 120, 124, and 128, along with a number of corresponding conductive rolling elements 119. These conductive rolling elements 119 are the core components of the rolling brush and can be made of conductive materials such as copper, silver, aluminum, and graphite. Their shapes can be cylindrical, conical, spherical, drum-shaped, etc. Through the above assembly and operational relationships, the power supply function to the rotating winding is achieved. The core component of the rolling brush—the conductive rolling element 119—is shown in the attached diagram. In counter-rotating motors, when the inner and outer rotors rotate at equal speeds in opposite directions, the rolling element only rotates on its own axis and does not revolve around the central axis, keeping its needle roller cage stationary, which helps extend its lifespan. For single-rotor motors or dual-rotor motors with a large difference in speed between the inner and outer rotors, and for types where the rolling element's revolution speed is high and its cage speed is fast, the needle roller structure of the rolling brush can be replaced with a tapered bearing or ball bearing structure. The above A, B, and C types are introduced using axial flux configurations. The following D and E types are introduced using radial flux configurations as examples to describe their structure and working principle. However, they all have common winding characteristics and winding-pole separation structural characteristics. Types D and E, "equal-pole common winding bidirectional radial flux permanent magnet synchronous counter-rotating dual-rotor ultra-flat wire motors", see Figures 8-16 (+Figures 21 and 22). In this application, the D and E types disclosed correspond to 8-pole and 16-pole motors respectively, for analysis (where: Figures 8, 9, 10, and 12 show 8 poles; Figures 11 and 13 show 16 poles. The motor has synchronously rotating permanent magnet rotors in the area near the shaft center and the area near the outer ring of the housing. The windings are located in the middle area and it is a counter-rotating dual rotor structure. Therefore, the power density can be increased by 4 times compared to conventional motors (5.4 times in this case model, the inner rotor can provide 2.7 times the power of the inner rotor, and the counter-rotating dual rotor is multiplied by 2 = 2.7 * 2 = 5.4 times). It can also be a motor with permanent magnets designed only internally or externally, or a single inner rotor or single outer rotor unidirectional flux motor with non-rotating windings (equivalent to a conventional motor), or a radial bidirectional flux motor with inner and outer dual permanent magnet rotors (or induction rotors) with non-rotating windings. The winding power supply system of the counter-rotating dual rotor motor disclosed in this application adopts a rolling brush structure, as shown in the attached figure, which can obtain excellent conductivity and long life. This structure can also be used in synchronous motors where electrical excitation replaces permanent magnets. Alternatively, the radial bidirectional magnetic flux structure of the model shown in Figure 16 can be changed to radial unidirectional magnetic flux. That is, one of the salient poles inside or outside the iron core in the corresponding area of ​​the winding is removed, and a corresponding magnetic yoke is added on the removed side to form a closed magnetic circuit. The corresponding outer rotor or inner rotor is removed, thus becoming a pure inner rotor or outer rotor motor. Alternatively, the winding iron core can be fixed to become a common radial magnetic flux motor. See also the prior application and figures (Magnetic circuit optimization design scheme 4.3 for high power density motor with equal pole common winding, and magnetic circuit optimization design scheme 4.19 for permanent magnet synchronous motor). Alternatively, the inner and outer frames of the winding (such as the marked elements with part numbers 82, 84, 104, and 106) and many isolation blocks and isolation disks can be made of non-magnetic and non-conductive materials, such as ceramics, mica, glass, glass fiber; high-strength carbon fiber, polypropylene, basalt fiber composite materials; or, through reasonable magnetic circuit shielding design, they can also be made of non-magnetic metal materials such as aluminum alloy, magnesium alloy, and copper. Note: If it is a conventional motor (such as a single-rotor unidirectional flux motor), there is no need to consider the frame design. "Equal-pole common winding radial flux permanent magnet synchronous counter-rotating dual-rotor ultra-flat wire motor", analyzed with 8 poles; the axial dimension is very short, 2-3 discs of winding are sufficient, no end windings, switched reluctance - 30 poles - 3 discs are sufficient; one type is sufficient, its radial flux magnetic circuit is more complex, and the electromagnetic action area is not as large as the axial one, the axial one is bidirectional flux, the magnetic circuit is the shortest, so category 10 is changed to category 11; or, make a smaller diameter dual-disc or three-disc permanent magnet synchronous motor that can be connected to three-phase power; if the power density of this solution is greater than that of the existing three-phase (comparing power density is sufficient, but the axial flux may be greater, the axial flux can also be made into a three-phase), then it is the most practical, directly using the existing vehicle controller, directly replacing the motor, or it can be a dual permanent magnet rotor, bidirectional flux; The difference between D and E type motors and the difference between 8 and 16 poles is used to verify that the quickness of pole setting and performance of this level of common winding are not affected - it can achieve a similar effect to distributed winding, that is: the number of pole pairs can be very small to reduce frequency and loss. However, this scheme can achieve good torque stability even with a small number of pole pairs because the iron core is originally a whole, only the salient poles are distinguished. Therefore, the salient poles can be designed to be finely fragmented to obtain stable torque. (Two-phase - short axial dimension, radial flux, bidirectional flux, good core design, non-universal magnetic poles because the phase difference of the permanent magnets is complementary, 80 layers are wound with 1 layer of flat wire) Bidirectional magnetic flux can further simplify the core structure. Another advantage is that there is no cogging torque. The cogging torque is canceled out by different phases through the axial split-disc structure (two phases can cancel it out, three phases are better, and more than three phases are even better). There is no need to specifically consider measures to eliminate cogging torque. The same pole iron core does not need to have an opening slot or the opening slot is very small. Alternatively, it can be completely eliminated through an effective control scheme. There is no cogging torque in this direction. Another advantage is that, due to the shared winding characteristics, its back electromotive force is a standard sine wave, which minimizes the negative factors of harmonics. The magnetic circuit and winding spatial layout of this structure are very neat and simple, which is conducive to heat dissipation and facilitates the design of heat dissipation channels. Furthermore, the common winding design results in better dynamic balance of the windings, making it easier to manufacture a dual-rotor motor. The intermediate gap area can be filled with lightweight material or used as a heat dissipation channel; alternatively, the iron core is preferably a radially fan-shaped sheet. The windings are evenly distributed layer by layer, and the windings of different phases are not in the same area. Reasonable winding can make the voltage between adjacent layers of windings the smallest and most uniform, while the windings in the maximum voltage area are the farthest apart, thus improving the withstand voltage and safety factor. It is also easier to design the switching between series and parallel winding relationships. That is, in the low-speed range, the windings are connected in series, and when entering the high-speed range, the windings can be gradually changed to parallel to reduce back electromotive force and increase torque in the high-speed range. This is also a very important requirement for new energy vehicles. When the windings of the same layer of ultra-flat wires are connected in parallel, the voltage between adjacent flat wires in the same layer is zero, which greatly improves safety. The advantage of its same layer of separated parallel flat wires is to improve the skin effect. For ease of description, they are named as follows: ABCDE type motors. Motors A and C can be controlled by sinusoidal AC power. By removing the commutator, they can be compared and tested. DC switched reluctance motors are the opposite of AC motors. The motor's winding pole separation feature allows for arbitrary design of the number of poles. Because it is not constrained by the windings, it can be designed with a very high number of pole pairs, making it suitable for low-speed, high-torque motors, such as those used in wind power and other fields. Moreover, the waveform is a standard sine wave. Demonstration of series-parallel speed control, back EMF detection, pulsation detection, and dual-rotor differential speed function—demonstrating double speed, heat dissipation, and a DC / AC dual-purpose motor! —Intentionally, only an AC structure is installed initially; it's very simple. Adding a commutator transforms it into a DC motor. Its series-parallel winding switching works for both AC and DC. The system can switch between three levels of series and parallel connection – 6 columns in series, 3 columns in series, and all 6 columns in parallel – to perform ultra-high-speed demonstrations; it can also be used for switched reluctance systems. The resistance is generated by powering an electric heater or light bulb to produce a load (much more efficient and seemingly safer than using a fan). The output power of this load can be measured with a multimeter; it's best to use two multimeters to measure the current and voltage simultaneously, with automatic calculation. Advantages: Back electromotive force approximates a standard sine wave; zero-end winding - high efficiency; weight reduction; good heat dissipation (end windings are the hottest); good processability; highest yield; low cost; good dynamic balance; mutual constraint; good thermal conductivity - good heat dissipation; planar air gap - spray cooling; centrifugal force has no negative impact; can support dual rotors at high speeds with a constant air gap - shape memory alloy; insulation and conductor layers separated - improved heat resistance; open permanent magnet - direct external heat dissipation and central atomized cooling; low voltage between layers, zero voltage within the same layer; high temperature resistance. Advantages: The magnetic circuit design is completed through convex and concave poles, which has good manufacturability, the shortest magnetic circuit, low iron loss, absolutely uniform magnetic circuit distribution, and no magnetic yoke - lightweight; The axial and radial flux motors have no yoke, the core power-to-weight ratio is the highest, and the magnetic fields do not cross each other, each is independent, the magnetic energy density is the most uniform, the total magnetic energy is the largest when the magnetic saturation is reached, the total magnet air gap surface area seems to be no larger than now, the effective utilization rate is high, almost all of them are effective areas, and they do not interfere with each other. DC / AC integrated model - speed can be adjusted by load, and the front end only needs to control the voltage, which can be a few fixed voltages, which can be obtained by connecting batteries in series and parallel; The voltage difference between multiple layers of ultra-flat wires and the staggered arrangement between the layers of ultra-flat wires are conducive to heat conduction. The staggered arrangement forms a bridge for heat conduction, similar to the staggered arrangement of bricks in building a wall. Temperature memory alloy gaskets allow for gap adjustment, ensuring a constant air gap despite temperature changes – an advantage of axial flux motors. The concentric winding method of ultra-flat wire results in very low and uniform voltage between layers, making it safer. The numerous insulation layers between multiple layers naturally provide excellent insulation. For a single-layer, multi-row structure, the purpose is simply to reduce the skin effect. Since the layers are connected in parallel, there is no voltage between them, so air isolation is sufficient. At low speeds, it can be connected in series; at high speeds and high voltages, it is connected in parallel. Materials: Good thermal conductivity, good insulation, high magnetic resistance, high mechanical strength It is also possible to have complementary salient poles on both sides of a switched reluctance motor, that is, the two sides are not in phase but have a complementary differential relationship, which can further increase torque stability! Alternatively, it can be made into an iron core that is non-conductive but only conductive, magnetic but not conductive. By adjusting its anisotropy, it can be made to have either conductive or non-conductive properties... Non-conductive - no eddy currents, but thermally conductive, non-magnetic, carbon fiber, ceramic glass fiber, polypropylene, basalt fiber composite materials; BDE class motors offer a 4-5.4 times increase in power density (bidirectional flux + dual rotors, power density compared to 8-pole vs. 16-pole), eliminating the need for high speeds. This benefits mechanical efficiency, noise, and safety, resulting in lower frequencies that are advantageous for multi-pole pair designs. Losses are also reduced (because multi-pole pair motors have low efficiency at high speeds). With increased efficiency, there's no need to pursue low harmonic characteristics in distributed windings – the goal is simply to improve efficiency and reduce ripple; and multi-pole pair motors are even better at reducing ripple. Power density can be obtained by measuring current under the same voltage and rotation speed; Motor power density is essentially a comparison of heat resistance and efficiency; The air gap of the axial flux motor can be compensated for by temperature, always maintaining a minimum air gap; automatic control of memory material; The limiting factor for power density in motors is current, not voltage. Bidirectional magnetic flux allows the current to remain unchanged even when the voltage is doubled, which is equivalent to doubling the power density. The number of pole pairs improves stability, while ultra-flat wire zero-end winding and chuckless iron core improve efficiency. At the same time, the chuckless iron core reduces weight, so it can completely outperform distributed winding and has a higher power density. It dissipates heat easily; our structure makes it even easier to dissipate heat, so air cooling is sufficient. Inverter energy consumption: This type can be used without an inverter, DC drive + 9XZT load speed regulation; Advantages: The common winding with equal poles can be very fine, and with the differential principle, the switched reluctance motor can also become very precise. In this case, the switched reluctance motor uses a DC planar commutator to demonstrate its advantages. High temperature resistance means increased power density and improved reliability. High temperature resistance, good manufacturing process, low cost, equivalent to claw pole type, leakage flux, leakage flux in concave pole region. Brushed motors with non-rotating windings and planar contact increase the contact area by tens or hundreds of times. Rolling brushes produce no electrical sparks and are made of copper and carbon rods, etc. This motor (both axial and radial flux use an equal-pole common winding architecture and are disc-type) shares the following common advantages: easy to manufacture as a hollow motor, with coaxial reducer and differential, good axial flux heat dissipation, each winding is an independent, very flat module with good heat dissipation, and direct heat dissipation at the middle cross section of the winding. Reduce copper usage, use braided windings, reduce solder joints, decrease axial dimensions, and reduce weight. When parallel axial flux motors are connected in parallel, the magnets of adjacent rotor discs can be shared! They can be modularly combined; modular combinations can be made according to power requirements. Referencing the racing car motors shown at previous exhibitions, which feature hollow shafts, they can be freely spliced ​​and combined in parallel! For example, the only difference between DE class motors is the number of pole pairs. This verifies that the quickness of pole pairing and the performance of this class of common winding are not affected. It can achieve a similar effect to distributed winding, that is: -- The number of pole pairs can be very small to reduce frequency and losses. However, this scheme can achieve good torque stability even with a small number of pole pairs because the iron core is a single piece, only the salient poles are distinguished. Therefore, the salient poles can be designed to be finely scattered to obtain stable torque. By rationally designing its winding scheme, ultra-flat wire can achieve small voltage gradients between layers and zero voltage between layers, thereby improving its withstand voltage safety level. Figure 29-33 shows a spatial spiral winding scheme. The illustration shows a 3-phase motor type with 6 layers, each phase and each pole corresponding to 3 slots. It can be installed without welding, without end windings, and all windings participate in electromagnetic interaction. The iron core and copper ultra-flat wire are wound in a single composite process. The winding materials include ultra-flat wire + insulation layer + silicon steel, which are wound in one piece. The structure is a spatial spiral-tire type. After the silicon steel is wound, there is an integral protrusion. With the addition of a central integrated potting, a rigid stator with a skeleton can be formed. The rotor is an open hollow tire-shaped annular permanent magnet, which is equivalent to a magnetic flux motor with up, down, left, and right sides. It has no end windings and no solder joints. The cross-section can also be rectangular instead of circular; the skeleton design is very important. Alternatively, it could be a double-helix motor, figuratively described as a space tire-type winding, with cross-sectional views shown in Figures 29-33 (where Figures 31, 32, and 33 use split or misaligned diagrams to visually show the spatial relationship between different phase windings). Its cross-section could be square, rectangular, triangular, polygonal, circular, elliptical, etc.; the winding and core are integrally wound, or it could be a pure winding structure without a core. It represents different wiring schemes, which can be different relationships of the number of phase winding groups, or different numbers of phases, or two-phase, three-phase or multi-phase, or different numbers of slots in the same phase, etc. The tire-type winding motor can design the corresponding air gap areas of the dual rotors on both sides into a concave semi-tire shape, which matches the tire-type winding core to form a spatial tire-type air gap, maximizing the air gap space and outputting greater power. This design has no solder joints in the windings, and except for the inner and outer ring areas of the tire-type core's cross-section which provide positioning support, the remaining areas are all air gaps. The windings are also almost entirely effective windings, which can greatly improve power density. Note: The forming process of this type of tire-type winding can adopt similar principles to the flat wire inductor forming process and the production process of helical springs or irregular springs. A specific extrusion and spinning device can be set at the straight flat wire's advancing position to automatically bend it into a specific spiral shape and a spatial tire-type spiral shape, naturally and cleverly interlocking and embedding it into the spatial tire-type core slots. To reduce weight, without affecting the magnetic flux density distribution, the central annular area of ​​the spatial tire-type core can be removed or a weight-reducing hollow design can be adopted. Alternatively, the tire-type winding can be axially flattened into a disc shape to form an axial bidirectional flux dual rotor motor; or the tire-type winding can be radially flattened into a cylindrical shape to form a radial bidirectional flux dual rotor motor. Note: The bidirectional flux in these two schemes corresponds to different side windings after flattening, so there is a yoke in the middle area. As shown in the figure, the pink winding can be first wound in concentric circles, then stretched and deformed into a spiral shape. During stretching, a rolling roller can be used to perform micro-plastic deformation while ensuring effective and safe insulation of the insulation layer and uniform voltage drop between layers. Then, the nine independently pre-wound concentric circle windings shown in the figure are stretched into a spiral winding and then spirally interwoven to form a nine-spiral structure (similar to a multi-head worm gear). Reanalysis: It should be wound according to a spiral skeleton, which is a space tire-type spiral skeleton. After winding, it should be flattened; or -- during winding, it should be wound according to a flattened space tire-type spiral skeleton. This method is similar to W-PIN, but has advantages over its characteristics. Alternatively, refer to the W-PIN method for winding; complete each layer of ultra-flat wire using the W-PIN method before inserting them together. Alternatively, it can be implemented according to the patent scheme of 2023.3.13; This flattening and bending process is similar to W-PIN, but with a key difference: it allows for an ultra-flat wire structure (this is the core of the invention; the ultra-flat wire can be wound in a spiral, then flattened and bent into a ring before being placed in the core – or the core can be split – for example, 4-6 half-fan-shaped cores can be combined. This method is similar to the ancient wisdom of arched bridge structures, with excellent mechanical properties and greatly improved assembly convenience. The winding can even be directly wound in a flattened spiral shape. The key point is that the conductor and insulator of the ultra-flat wire can be separately assembled! It causes minimal damage to the winding, requires no pre-bending, and can be ultra-flat wire with good flexibility, making this method even more convenient. It also has the advantage of uniform voltage drop across layers and significantly improved voltage resistance). Furthermore, the end windings seem to be utilized as much as possible, becoming effective windings; however, even if not, the size of the end windings can at least be reduced. Due to the X-PIN and the absence of solder joints, this advantage alone is significant! Problems or phenomena may occur with the end windings when they are flattened: This can result in a large proportion of end windings with a large outer ring radius and a small proportion of end windings with a small inner bending radius. Because ultra-flat wire is very thin, it is easier to plastically deform. Therefore, during the spiral winding and end flattening process, it will undergo timely and natural plastic deformation to meet the cross-slot bending requirements of the distributed winding at the end! It is the optimal linear electromagnetic railgun—used for military purposes or satellite launches (with an extremely long ground acceleration time, allowing its horizontal linear velocity to reach cosmic speed, before turning to vertical or horizontal centrifugal launch; atmospheric friction must be considered, so it is not advisable to have too high a speed within the atmosphere, but it can be used as a military electromagnetic railgun to replace artillery fire, and can continuously and densely fire non-explosive iron balls for close-range protection); it is also used in aircraft carrier electromagnetic catapults, and the iron core is also spiral-shaped.

2. The ultra-flat wire common winding motor and design method according to claim 1, characterized in that: The aforementioned motor can be a scheme with different phase windings interleaved and complementary, and permanent magnets radially aligned; or it can be a scheme with different phase permanent magnets arranged in complementary phases and different phase windings aligned, as can be found in the prior application. Alternatively: the above motors can all be of the following types: external rotor, internal rotor, dual rotor, or counter-rotating dual rotor; or, the above motors can all be of the following types: synchronous reluctance, switched reluctance, permanent magnet synchronous, induction asynchronous, or DC. Setting the winding side of an axial flux motor as an outer rotor is beneficial for space utilization and is also safer. If the inner rotor is the winding end, two layers of centrifugal force protection devices are required. However, the magnet side itself has protection. Therefore, this is beneficial for space utilization, reducing volume, or maximizing the electromagnetic radius of action to increase torque. Used in wind power generation and helicopters, multi-pole logarithmic motors with no waste, no end windings, and no yoke core. Two-phase (three-wire four-phase wave motor) and three-phase motors are both acceptable; please refer to prior application documents. Alternatively, the iron core can be coiled and then wire-cut, which can cut off the eddy current. It has good processability, and the winding can be continuously coiled in a large manner without the problem of butt joints or overlaps. (A simple bending mold can be designed. Each time it is manually inserted and then squeezed to form a smooth arc. It can be formed from the outside open first and then the outer iron core can be inserted from the shaft side. All windings are evenly spaced from the iron core, which has good heat dissipation, no end windings, and a large iron core space, which can withstand strong currents.) It is basically a toroidal winding, but round or toroidal magnets can also be used; The serpentine area can also be fitted with a cooling water jacket or an air-cooled aisle; The concentric ring layer area of ​​the winding and core can be filled with low-density, high-temperature resistant, and thermally conductive material, or a cooling water jacket can be installed. Alternatively, it can be a hollow air duct or air-cooled channel, which also serves as a magnetic shield. It makes extensive use of the middle area, which is equivalent to saving space and improving the power-to-volume ratio and energy density. The internal windings and core radii can be adjusted at will. The goal is to achieve the best utilization rate of each core while ensuring that the three windings generate equal torque. Wiring diagrams for three-phase sinusoidal permanent magnet synchronous motors and three-phase switched reluctance motors; all are designed according to the specifications of three-phase motors or three-wire four-phase wave motors. Analysis basis:

1. When the current intensity multiplied by the number of turns of each winding is inversely proportional to its effective electromagnetic working radius, equal torque can be obtained; 2. When the angular velocities of the same winding are equal, and the number of turns is equal, their back electromotive force is proportional to the radius. Therefore, when the number of turns is set to be inversely proportional to the radius, equal back electromotive forces can be obtained. When the back electromotive forces are equal, the same positive voltage can be obtained. When the influence of the number of winding turns on the resistance is ignored, the currents can be regarded as equal.

3. Torque is directly proportional to current intensity and number of turns, and inversely proportional to radius. Therefore, when the number of turns of each winding is inversely proportional to the radius, the same torque can be obtained. (Note: The number of turns mentioned above is based on the premise that the circumference is a constant value. That is, the number of turns ratio mentioned above is actually the ratio of the winding circumference. However, the circumference is inversely proportional to the radius. Therefore, the number of turns ratio of each winding is the square of the inverse ratio of the radius.) It is obvious that the winding turns in the small diameter region will be very thick. In order to obtain the equivalent magnetic reluctance, the winding in the small diameter region can be designed as a multi-layer iron core winding with alternating phases. The currents of adjacent windings need to be reversed. This does not matter for switched reluctance motors, but for permanent magnet synchronous motors, it needs to be set as a multi-ring concentric permanent magnet. In summary, the pre-set target parameter relationships are as follows: the ratio of the number of turns of each winding is the square of the inverse radius, the ratio of the electromagnetic wire length of each winding is the inverse radius, the currents of each winding are nearly equal when entering the stable speed region, the ratio of the excitation intensity of each winding is the inverse radius, so the ratio of the cross-sectional area of ​​each core should be the inverse radius. Note: The peak magnetic field strength of adjacent windings relative to the shared core does not occur at the same time point. That is, the excitation cycle of each winding corresponds to a phase difference. Therefore, the cross-sectional area of ​​the shared core does not need to be superimposed according to the excitation strength of adjacent windings, in order to maximize space utilization. Switched reluctance exhibits slight peak overlap. The radial radius ratio of each winding and the core, and the optimal space utilization setting for the core with unsaturated magnetic circuit under peak current. Adjacent windings can share an intermediate core ring, but the number of shared core ring layers must be sufficient. In addition, the rotor permanent magnets corresponding to the shared iron core layer of different phases should be set according to their working principle to ensure that the optimal electromagnetic torque force between the two phases is obtained. Alternatively, each phase can use its own iron core and magnet independently. The diagram shows a three-wire four-phase wave scheme, but it can also be a traditional three-phase motor scheme; Adding concentric windings radially is equivalent to increasing the number of electromagnetic poles of the stator and rotor, but without changing the speed and frequency. This can increase power density without increasing the frequency, and reduce iron loss and copper loss. It can be pushed and swung to the top of the inner hole of the iron core for rotor assembly; If adjacent windings interfere, they can be misaligned by increasing their axial dimensions. In other words, the best solution to resolve interference is to lengthen the winding axially, i.e., increase the axial dimension of the end winding. Minimize the end dimensions as much as possible, which can be achieved by radially offsetting the end windings vertically. Note the assembly sequence of the enclosed intermediate windings. Intermediate windings without curved bridges should be assembled in the intermediate process. Just pay attention to the assembly sequence. Generally speaking: For two-phase windings A and B, phase A adopts a bridge-type design to make room for phase B, so phase B adopts a direct planar U-shaped design. Alternatively, the two can be interleaved, i.e., cross-leaving, both of which have bridge-arch type and planar type. In short, the principle is to achieve the wiring of all windings with the minimum axial winding size by interleaving them with bridge-arch type and axial offset. This end winding is similar to a heat sink, so it has good heat dissipation. Therefore, it can be appropriately narrower than the internal winding to ensure the same conductivity characteristics. However, if space allows, it is better to make it larger to reduce end resistance and increase heat dissipation area. If the two phases bend vertically and wrap around each other, the axial dimension can be minimized. However, the resistance will increase because the length increases. Therefore, from an efficiency point of view, it is better to design according to the principle of shortest length. Bridge arch and planar types can be used interchangeably to achieve the shortest length, the lowest resistance, the best heat dissipation, or the shortest axial end winding dimension. All similar designs in this patent can be cross-combined to achieve optimal slot fill factor, short end windings, low skin effect, low resistance, simple wiring process, low cost, good heat dissipation, and good insulation. Based on the electromagnetic conversion requirements and the characteristics of speed and torque, the windings in the same phase can be connected in series, in parallel, or in a combination of multiple series and parallel connections to obtain the highest efficiency conversion in different speed ranges and the best torque output, which can make up for the shortcomings of insufficient torque at high speeds in motors. Alternatively, another approach to the radial physical space misalignment phase shifting method can be to use the core structure of a traditional radial flux or axial flux motor. By setting different phase windings between different layers, radial physical space misalignment is achieved, eliminating the problem of cross wiring between different phase windings. At the same time, since the same phases are all in the same layer area, the end windings can also participate in the excitation effect, turning the end windings into effective excitation windings. Advantages:

1. Reduces skin effect; 2. Simplifies wiring difficulty; 3. Turns end windings into effective windings; 4. Improves temperature resistance. These four advantages are significant. The result is: increased power density and efficiency, reduced cost, and extended lifespan! It has better heat dissipation, transforms the end winding into an effective winding, makes good use of the internal space of the shaft for external rotor motors, and is lightweight. Furthermore, the internal rotor winding process is easier to assemble, and the open design, especially the open slot, is more convenient. Note: Two-phase motors can be used preferentially, as the winding wiring will be simpler. For ease of description, this patent application unfolds the iron core into a plane to illustrate its structural principle. In the above-mentioned solutions, there are isolation gaps between the layers of the ultra-flat wire winding. Cooling medium can be introduced into these gaps to increase the heat dissipation effect. Please refer to the relevant text. Note: The rotor described above can be a permanent magnet rotor or an induction rotor. The stator and rotor core can also be made of nanocrystalline or amorphous materials; the above motor design principles can be applied to electric motors and generators.

3. The ultra-flat wire common winding motor and design method according to claim 1, characterized in that: The motor described above can also be designed as a counter-rotating dual-rotor motor (see prior application), or it can be: a single dual-rotor motor, a double dual-rotor motor, a triple dual-rotor motor, or a multi-dual-rotor motor; a single dual-rotor motor: one inner rotor and one outer rotor; a double dual-rotor motor: includes two outer rotors or inner rotors rotating in the same direction, as shown in the figure, including a middle single-winding rotor with bidirectional magnetic flux and inner and outer double-magnet rotors. Since the inner and outer double-magnet rotors rotate in the same direction, they can be fixed together and form a counter-rotating dual-rotor motor with the middle single-winding rotor through a reversing mechanism, which can further double the power density; Figure 27: including a middle single-magnet rotor with bidirectional magnetic flux and inner and outer double-winding rotors; similarly: since the inner and outer double-winding rotors rotate in the same direction, they can be fixed together and form a counter-rotating dual-rotor motor with the middle single-magnet rotor through a reversing mechanism, which can further double the power density; or, forming a two-sided power flow output architecture, with electromagnetic differential torque vector distribution function, lightweight and high power density. The above principle also applies to axial flux motors; counter-rotating dual rotor motors; and internal and external dual flux types; Axial flux motors can refer to the relevant solutions in the prior application, namely: arranging two or more relatively independent axial flux windings and permanent magnets (or non-permanent magnet current excitation windings) according to the corresponding phase difference angles, and controlling them according to the complementary waveform relationship, can achieve the same effect. Since the axial force of the axial flux motor is very large, it is basically used in the form of double disks or multiple disks to balance the axial force. Moreover, the axial flux motor has the characteristic of short axial dimension. Therefore, it is more advantageous to use the double disk or multiple disk scheme described in this patent application to design a compact high power density motor. It can be a single-rotor or dual-rotor motor, as well as a dual-rotor motor with magnetic flux on both sides and a counter-rotating dual-rotor motor. Its electromagnetic wires can be round or flat; the current waveform can be: square wave, square wave + composite wave, or sine wave; Regarding the method of introducing rotor winding current from the outside for dual-rotor motors, please refer to the prior applications (202211030428.1 Dual-rotor motor current dynamic and static physical ports, 202211098410.5 Constant reluctance rotary transformer and core design and manufacturing method) and the related solutions below. The above solution can also be used for conventional single-rotor motors, such as replacing existing brushless or brushed solutions. Note: The above solution applies to all types of electric motors and generators, including asynchronous motors, synchronous motors, brushless motors, brushed motors, induction motors, permanent magnet motors, switched reluctance motors, etc. The three-phase wires mentioned above can be the input / output harness terminals of a three-phase motor, a three-phase induction asynchronous motor, a brushless DC motor, or a permanent magnet synchronous motor. Alternatively, the dynamic and static port connection method described in this article can also be a sliding brush method, or a sliding carbon brush solution that is easy to replace. Note: The terms used for the dynamic and static physical ports in this article are relative and interchangeable in practice. The terms for inner and outer rotors are relative and have interactive mechanical properties, and they can be used interchangeably as inner and outer rotors.

4. The ultra-flat wire common winding motor and design method according to claim 1, characterized in that: Switched reluctance motors typically consist of three or more discs, with each disc having a phase difference that is arranged at equal intervals to obtain a uniform, continuous, and stable torque output. They can have a large number of poles to ensure a more stable torque output, such as 30 or other numbers.

5. The ultra-flat wire common winding motor and design method according to claim 1, characterized in that: Permanent magnet synchronous motors typically consist of two or more discs, with each disc having a phase difference that is arranged at equal intervals to obtain a uniform, continuous, and stable torque output. They can have a large number of poles to ensure a more stable torque output, such as 30 or other numbers. Alternatively, it can be composed of a single disk, which uses independent inner and outer ring windings and iron core magnetic circuit units to achieve continuous and stable torque output through phase complementary alternating operation.

6. The ultra-flat wire common winding motor and design method according to claim 1, characterized in that: Its magnetic circuit is a spatial magnetic circuit. The concentric circular magnetic circuit in the winding area is composed of concentric circular iron cores wound together. In order to eliminate eddy currents, the concentric circular iron cores are radially cut off. The magnetic circuit in the non-winding area is generally arranged radially and axially. The radial iron cores can be glued together or tightly attached by mechanical means, or grooves or baffles can be opened between the iron core and the iron core frame to enhance safety. The magnetic circuit region is made of a core material with very high permeability, such as stacked silicon steel sheets with very thin thickness; the rest of the core skeleton support frame is made of a magnetically blocking material with very low permeability, such as aluminum, aluminum alloy, magnesium-aluminum alloy, titanium alloy, carbon fiber and other metallic or non-metallic materials.

7. The ultra-flat wire common winding motor and design method according to claim 1, characterized in that: This core layout can be either a fan-shaped core arranged radially or a rectangular core arranged radially.

8. The ultra-flat wire common winding motor and design method according to claim 1, characterized in that: It can be a dual-rotor configuration, with concentric inner and outer iron cores forming a dual-rotor structure.

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