Motor split winding forming process and design method

By using a separate winding forming process, the end windings and slot windings are designed separately, which solves the problem of complex winding processes for flat wire motors and achieves high slot fill factor, low resistance and high thermal conductivity, meeting the requirements of new energy vehicles for high power density and high speed performance.

CN122292749APending Publication Date: 2026-06-26王国斌
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Patent Information

Authority / Receiving Office
CN · China
Patent Type
Applications(China)
Current Assignee / Owner
王国斌
Filing Date
2025-07-15
Publication Date
2026-06-26

AI Technical Summary

Technical Problem

The existing flat wire motor winding process is complex, resulting in skin effect and proximity effect, low slot fill factor, high cost, and difficulty in meeting the high power density and high speed performance requirements of new energy vehicles.

Method used

The winding adopts a separate winding forming process, with the end winding and the slot winding designed separately. Electrical connection is achieved by bending copper strip and connecting across slots, combined with pressure mating or welding. Heat dissipation channels and insulating materials are introduced into the winding to improve slot fill factor and thermal conductivity.

Benefits of technology

It simplifies the production process, reduces costs, improves slot fill factor and thermal conductivity, enhances insulation performance, reduces resistance, and improves the high-speed performance and safety of the motor.

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Abstract

This invention discloses a process and design method for independently forming the end windings of a motor slot winding. This application further improves upon prior applications and existing motors, disclosing a series of configuration schemes based on the independent forming of the slot windings and end windings. Key features include: all three-stage end windings are formed by bending thin copper strips, allowing for interleaving to achieve cross-slot wiring of different phases, further optimizing motor performance; they also possess the advantage of being effective windings with equivalent function to the slot windings in participating in excitation, and the end windings have better heat dissipation and thermal conductivity, and there is no crossover issue between windings of different phases, greatly improving the winding withstand voltage safety and simplifying the winding forming process.
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Citation Information

Patent Citations

  • CN117674524A