Super-flat wire high-power density motor and design method

Abstract

The invention discloses a super-flat wire high-power-density motor and a design method, and belongs to the technical field of motor design and manufacturing. The invention discloses a super-flat wire high-temperature-resistant high-power-density motor and a design method. A super-flat wire section structure with the length-width ratio basically exceeding three times is adopted, so that the softness of a flat wire is consistent with that of a conventional round wire, a common winding scheme is adopted, physical geometric space separation of a winding and a magnetic pole is achieved, a winding process can be adopted, and the high-power-density motor with the super-flat wire can be manufactured. No end winding exists, the effective utilization rate of the winding is close to 100%, the motor is more suitable for high-speed operation, the forming process is simple, the slot fullness rate is higher, the utilization rate of the central area of the motor can be increased, the working principle of the winding belongs to a bidirectional magnetic flux type, the effective working section of the magnetic flux of a magnetic circuit is doubled, and the power density is improved; by adopting a winding process, the flat wire can be made into a very thin copper strip, the skin effect and proximity effect of the electromagnetic winding are improved, the motor efficiency is improved, and the heat dissipation performance is improved; the copper strip is separated from the insulating strip, so that the material selection of the insulating material is not restrained, the rated current and the maximum current of the motor are greatly expanded, and the power density and the overload capacity of the motor are improved.

Description

Technical Field

[0001] The present invention belongs to the technical field of motor design and manufacturing. Background Art

[0002] With the rapid development of the new energy vehicle industry, especially pure electric vehicles, higher requirements are put forward for the high-speed performance and high power density of electric motors. As the motor speed increases, higher requirements are also put forward for the performance of the motor and related components. More stringent requirements are imposed on the high-speed performance NVH of the motor rotor, high-speed area bearings, and gears. The cost increases, and at the same time, problems such as safety and failure rate follow. Hairpin motors can improve the slot fill factor and power density, but the current hairpin winding, iron core structure, and forming and assembly processes result in a relatively large cross-sectional area of the hairpin wire, leading to obvious skin effect and proximity effect, and basically using a fixed shape. The basic production process is slot paper insertion → hairpin manufacturing → hairpin threading → end ring shaping → end ring welding → star point connection → insulation treatment of the welding point, etc. The process is complex and requires special equipment. 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 Constant Reluctance Rotary Transformer and Core Design and Manufacturing Method

[0006] 202211409893.6 Current Dynamic and Static Port Electrical Conduction Device and Design Method

[0007] 202211411199.8 High Power Density Dual Disc Permanent Magnet Synchronous Motor and Design Method

[0008] 202211496278.3 Split Disc High Power Density Motor and Design Method

[0009] 202211503563.3 Non-Differential Disc High Power Density Motor and Design Method

[0010] 202223020083.X High Power Density Dual Disc Permanent Magnet Synchronous Motor

[0011] 202211670694.0 Non-Differential Disc Equal Pole Co-Wound High Power Density Motor and Design Method

[0012] 202211717339.4 Three-Phase Four-Wave Equal Pole Co-Wound Motor and Design Method

[0013] 202310043018.9 Three-Phase Four-Wave Permanent Magnet Synchronous Motor and Electromagnetic Differential Speed Vector Dual Drive System

[0014] 202310050918.6 High-Density Pole-Pair Three-Phase Four-Wire Wave Permanent Magnet Synchronous Motor and Design Method

[0015] 202211670695.5 Non-Differential Disc-Type Equal-Pole Co-Wound Permanent Magnet Synchronous Motor and Design Method

[0016] The present invention discloses a "super-flat wire high-temperature resistant and high-power density motor and design method", which adopts a super-flat wire cross-sectional structure with a very large aspect ratio (basically exceeding 3 times), making the softness of the flat wire the same as that of conventional round wires. And by adopting the co-winding scheme described in the prior application, the physical and geometric spatial separation between the winding and the magnetic pole is achieved. The winding process can be used, there is no end winding, the effective utilization rate of the winding is close to 100%, and it is more suitable for high-speed operation. The forming process is simple, the slot filling rate is higher, the utilization rate of the central area of the motor can be expanded, and the working principle of the winding belongs to the type of bidirectional magnetic flux, doubling the effective working cross-section of the magnetic circuit magnetic flux and improving the power density. In addition, by adopting the winding process, the flat wire can be made into a copper strip similar to tin foil paper, and the thickness can be less than 0.1 mm significantly improves the skin effect and proximity effect of the copper strip in the electromagnetic winding, enhances the motor efficiency and improves the heat dissipation performance. Since the thickness of the copper strip is very thin, heat is basically directly conducted and dissipated to the outside. In addition, an axial ventilation structure can be adopted, allowing the cooling medium (which can be air, water or oil) to pass through the gaps of this copper strip winding, resulting in excellent heat dissipation. Moreover, the contact area between the copper strip and the outside or each other is larger, with better thermal conductivity and rigidity, making it suitable for high-speed operation. Additionally, a winding scheme of parallel combination of bare copper strip without insulating material and insulating material can be adopted. After winding, the insulating material forms an insulating relationship with the bare copper strip. In this way, the cost of the electromagnetic wire can be reduced, the yield rate can be greatly increased, and the process can be further simplified. More importantly, the separation of the bare copper strip and the insulating material allows the selection range of the insulating material to be greatly liberalized, and various high-temperature resistant materials can be selected, such as polytetrafluoroethylene (engineering plastic), silicone rubber, fluororubber; special ceramics: alumina, silicon nitride, silicon carbide, hexagonal boron nitride, cubic boron nitride, refractory cement, magnesite brick, whose heat resistance basically exceeds 1000 degrees Celsius; mica, quartz and other silica materials; or insulating isolation can be carried out with high-temperature resistant glass fiber and other materials. Manufacturing insulating isolation belts and isolation plates with the above materials will greatly improve the high-temperature resistance of the motor winding. If it is used in an induction asynchronous motor or switched reluctance motor without permanent magnet materials, there will be almost no temperature restriction inside the motor, and there is basically no need to deliberately consider the high-temperature characteristics of the motor, and even no need to consider the motor heat dissipation and active cooling problems. At the same time, it also allows the rated current and maximum current range of the motor to be greatly expanded, enhancing the motor power density and overload capacity! Reducing the volume and weight of the motor; and the increase in the allowable value of the motor temperature upper limit will also improve the natural cooling performance of the motor. Just as the greater the temperature gradient, the higher the heat conduction efficiency; this idea can also be deliberately set to concentrate the heat generation area of the motor, increasing the local temperature of the motor under the same heat condition and enhancing the heat conduction characteristics. This characteristic can be used to preheat the warm air for electric vehicles in winter, realizing reasonable energy recovery and utilization; or, the significant increase in the local temperature of its motor can also upgrade it to a steam generation chamber, causing the phase change of the heat conduction medium. For example, if water is vaporized into steam, a heat engine function can be constructed, directly converting this preheat into mechanical energy and further converting it into electrical energy for recovery. For example, high-temperature and high-pressure steam is introduced into a steam engine, steam turbine or turbine to be converted into mechanical energy and drive the motor to generate electricity for secondary electrical energy recovery and utilization.

[0017] Of course, in order to prevent rust, after the parallel combination winding of the bare copper strip and the insulating material is completed, it can also be integrally encapsulated.

[0018] In addition, according to the cross-sectional area size and conductive excitation electromagnetic characteristics requirements of the ultra-flat wire, series or parallel electrical connections can be adopted between different windings of the ultra-flat wire; changing its resistance and electromagnetic characteristics such as excitation characteristics, etc.

[0019] Its principle is applicable to most motor types, which can be DC motors, AC motors, such as: permanent magnet motors, switched reluctance motors, or induction motors, hysteresis motors, etc.;

[0020] The input current waveform of the motor can be: when the role of the motor is changed to an engine, the induced current waveform generated by driving the motor winding with a constant torque at a constant speed is used to guide the design of its control current waveform,

[0021] That is: when the control current waveform of any motor is the same as the current waveform generated when the motor acts as a generator and is driven to rotate with a constant torque and a constant angular velocity, then when the motor acts as a motor, its output torque must be constant; this method can be called the "energy reverse measurement and simulation method", which can be used as a guiding method for optimizing the control current waveform of the motor. It is applicable to any type of motor. Brief Description of the Drawings

[0022] Figure 1 、Schematic Diagram of the Structure of the Co-wound Flat Wire Motor

[0023] Figure 2 、Schematic Diagram of the Structure of the Co-wound Double Ultra-flat Wire Motor

[0024] Figure 3 、Schematic Diagram of the Enlarged Cross-sectional Structure of the Co-wound Double Ultra-flat Wire Motor Winding

[0025] Figure 4 、Schematic Diagram of the Enlarged Cross-sectional Structure of the Co-wound Single Ultra-flat Wire Motor Winding

[0026] Figures 5 to 8 : Diagram Illustrating the Insulation Scheme between Layers of the Ultra-flat Wire Winding

[0027] Figure 9 、Schematic Diagram of the Ultra-flat Wire Winding of the Axial Flux Motor

[0028] Figure 10 、Enlarged Diagram of the Sector Ultra-flat Wire Winding of the Axial Flux Motor

[0029] Among them:

[0030] 1. Left-side Winding Iron Core (Magnetic Pole) 9. Right-side Insulating Tape

[0031] 2. Flat Wire Winding 10. Right-side Insulating Isolation Plate

[0032] 3. Right-side Winding Iron Core (Magnetic Pole) 11. Central Insulating Isolation Ring Tape

[0033] 4. Permanent Magnet Pole or Iron Core Protrusion (Switched Reluctance) 12. Left-side Insulating Isolation Plate

[0034] 5. Ultra-flat Wire Winding (Aspect Ratio Basically Exceeds 3 Times) 13. Left-group Ultra-flat Wire Winding

[0035] 6. Left group insulating tape (high temperature resistant) 14. Single group insulating tape

[0036] 7. Intermediate insulating partition 15. Single group ultra-flat wire winding

[0037] 8. Right group ultra-flat wire winding 16. Insulating needle roller

[0038] 17. Insulating needle roller fixing hole 22. Iron core (for the center iron core of the double-flux winding, there is no yoke)

[0039] 18. Insulating protrusion

[0040] 19. Outer insulating protective layer of the sector ultra-flat wire winding 23. Ultra-flat wires in parallel in different columns of the same layer

[0041] 20. Sector ultra-flat wire winding 24. Ultra-flat wire insulating layer matrix layer (can be with adhesive)

[0042] 21. Inner insulating protective layer of the sector ultra-flat wire winding Detailed implementation mode

[0043] As shown in the figure, the structure and related principle explanations can be combined with the prior application "co-winding" series of solutions; the present invention discloses a "super-flat wire high-temperature resistant and high-power density motor and design method", which adopts a super-flat wire cross-sectional structure with a very large aspect ratio (basically exceeding 3 times), making the softness of the flat wire the same as that of conventional round wires, and adopting the co-winding solution described in the prior application, realizing the physical and geometric spatial separation of the winding and the magnetic pole. The winding process can be adopted, there is no end winding, the effective utilization rate of the winding is close to 100%, and it is more suitable for high-speed operation. The forming process is simple, the slot filling rate is higher, the utilization rate of the central area of the motor can be expanded, and the working principle of the winding belongs to the double-flux type, doubling the effective working cross-section of the magnetic circuit flux and improving the power density. In addition: by adopting the winding process, the flat wire can be made into a copper strip similar to tin foil paper, and the thickness can be less than 0.1 mm, significantly improving the skin effect and proximity effect of the copper strip in the electromagnetic winding, enhancing the motor efficiency and improving the heat dissipation performance; due to the very thin thickness of the copper strip, heat is basically directly conducted and dissipated to the outside. In addition, an axial ventilation structure can be adopted, allowing the cooling medium (which can be air, water or oil) to pass through the gaps of this copper strip winding, resulting in excellent heat dissipation. Moreover, the contact area between the copper strip and the outside or each other is larger, with better thermal conductivity and rigidity, making it suitable for high-speed operation. Additionally, a winding scheme of parallel combination of bare copper strip without insulating material and insulating material can be adopted. After winding, the insulating material forms an insulating relationship with the bare copper strip. In this way, the cost of the electromagnetic wire can be reduced, the yield rate can be greatly increased, and the process can be further simplified. More importantly, the separation of the bare copper strip and the insulating material can greatly liberalize the selection range of the insulating material, and various high-temperature resistant materials can be selected, such as: polytetrafluoroethylene (engineering plastic), silicone rubber, fluororubber; special ceramics: alumina, silicon nitride, silicon carbide, hexagonal boron nitride, cubic boron nitride, refractory cement, magnesite brick, whose heat resistance basically exceeds 1000 degrees Celsius; mica, quartz and other silica materials; or insulating isolation can be carried out with materials such as high-temperature resistant glass fiber. Manufacturing insulating isolation belts and isolation plates with the above materials will greatly improve the high-temperature resistance of the motor winding; if used in induction asynchronous motors or switched reluctance motors without permanent magnet materials, there will be almost no temperature restriction inside the motor, and basically no need to deliberately consider the high-temperature characteristics of the motor, and even no need to consider the motor heat dissipation and active cooling problems; at the same time, it also allows the rated current and maximum current range of the motor to be greatly expanded, enhancing the motor power density and overload capacity! Reducing the volume and weight of the motor; and the increase in the allowable value of the upper limit of the motor temperature will also improve the natural cooling performance of the motor. Just as the greater the temperature gradient, the higher the heat conduction efficiency; this idea can also be deliberately set to make the heat generation area of the motor concentrated, increasing the local temperature of the motor under the same heat condition and enhancing the heat conduction characteristics. This characteristic can be used to preheat the warm air for electric vehicles in winter to achieve reasonable energy recovery and utilization; or, the significant increase in the local temperature of its motor can also upgrade it to a steam generation chamber, causing the phase change of the heat conduction medium. For example, if water is vaporized into steam, a heat engine function can be constructed, directly converting this preheat into mechanical energy and further converting it into electrical energy for recovery. For example, high-temperature and high-pressure steam is introduced into a steam engine, steam turbine or turbine to be converted into mechanical energy and drive the motor to generate electricity for secondary recovery of electrical energy.

[0044] Of course, in order to prevent rust, the parallel combination winding of the bare copper strip and the insulating material can also be integrally encapsulated after completion.

[0045] In addition, according to the cross-sectional area size and conductive excitation electromagnetic characteristics requirements of the ultra-flat wire, series or parallel electrical connections can be adopted between different windings of the ultra-flat wire; changing its resistance and electromagnetic characteristics such as excitation characteristics, etc.

[0046] Figure 1It is a conventional flat wire co-winding scheme;

[0047] Figure 2 and 3 As shown, it is a co-winding double ultra-flat wire scheme. Two sets of ultra-flat wire windings are arranged in parallel within the winding range space of the same iron core disk. It can also be three sets or multiple sets; as can be clearly seen from the partial enlarged view of the cross-section of the winding in Figure 2 , this winding consists of: the left insulating tape, the middle insulating separator, the right ultra-flat wire winding, the right insulating tape, the right insulating separator, the central insulating separator ring tape, the left insulating separator, the left ultra-flat wire winding, etc.; additionally or alternatively, as in Figure 3 shown, the two left and right windings can be connected in parallel or in series, and note that the current rotation directions need to be the same.

[0048] Note: The permanent magnet pole or the iron core salient pole 4 can be a permanent magnet pole or an iron core pole. The iron core pole is generally a salient pole and is mainly used in the switched reluctance scheme;

[0049] Figure 4 It is a co-winding single ultra-flat wire scheme. In this scheme, there is only one set of winding in the entire disk body, and its insulation and isolation measures are more concise. Or, the two side iron core skeletons and the surface of the central iron core can be coated with high-temperature resistant insulating materials, then the corresponding central insulating separator ring tape and the two side insulating separators can be removed; the ultra-flat wire and the insulating tape can be directly wound therein. The ultra-flat wire can be a copper strip or other conductor materials, and its thickness can be very thin, less than 0.1 mm is acceptable.

[0050] Or, the ultra-flat wire can also adopt the conventional enameled wire insulation process; or, adopt the single-sided coated insulating material scheme. At this time, its function is similar to that of the insulating tape. As long as there is an insulating isolation layer on one side, it can play the insulation function between layers after winding.

[0051] Or, the insulation scheme between layers of the ultra-flat wire winding can adopt the scheme as shown in Appendix Figures 5 to 8 ;

[0052] Figure 5 In it: insulating rolling needles are used to insulate between layers of the ultra-flat wire winding. The insulating rolling needles can be made of special high-temperature resistant insulating materials, and the cross-section of the rolling needles can be circular, rectangular, trapezoidal, triangular, polygonal, curved surface shape, fan-shaped, etc.; or, for safety and reliability, the rolling needles can be fixed through the corresponding fixing holes processed on the surfaces of the two side skeletons (which can be insulating plates or iron cores + insulating layers); or, the assembly process of the winding and the rolling needles can be: during the winding process of the winding, the rolling needles are inserted layer by layer in a timely manner while winding;

[0053] Or, insulating protrusions can be set on one side of the ultra-flat wire winding, as shown in Figure 7 .

[0054] Alternatively, two or more insulating spiral brackets can be used to support the independent copper strip winding. The insulating spiral brackets are relied on to position the winding conductor strip, ensuring no contact between layers to guarantee insulation. As shown in Figure 8 the side skeleton of the winding can be provided with a ring groove for positioning the winding copper strip, or the casting method can be adopted for encapsulation and curing.

[0055] Note: To simplify the drawing, in the above figures, the winding is drawn as concentric circles. In the actual implementation, it is basically a winding structure. Of course, it can also be a concentric circle structure, and then connected in series or parallel. Generally, when adopting this method, very thin materials can be used, so that the skin effect is very small, the thermal conductivity is very good, and it is basically surface heating, which can dissipate heat quickly. Multiple layers of very thin copper strips similar to tinfoil can be used and isolated by insulating tapes and then wound in parallel to ensure a large enough conductive cross-section.

[0056] In the above corresponding scheme, there is an isolation gap between layers of the ultra-flat wire winding. A cooling medium can be introduced into this gap to increase the heat dissipation effect. For details, please refer to the relevant text.

[0057] To minimize the skin effect as much as possible, the ultra-flat wire conductors in the same layer are also subdivided into multiple columns in parallel as much as possible (as shown in Figure 10 each layer has 5 columns of ultra-flat wires); in addition, multiple columns of ultra-flat wires in the same layer are preferably in a parallel relationship. In this way, the voltage between different columns of parallel wires in the same layer is zero, so that the gap between multiple columns of wires can be set as small as possible to improve the slot fill factor. Moreover, no insulation treatment is required between different columns of ultra-flat wires in the same layer, and only air or vacuum insulation is needed, which can reduce costs and minimize their mutual gaps as much as possible to improve the copper fill factor. For example, the gap can be as small as 0.2 or 0.1 mm or even smaller. And adopting the concentric circle winding method as shown can make the voltage difference between different layers also show a uniform voltage division relationship. Therefore, this method is more significant for high-voltage motors. Although the terminal voltage of the input and output lines of the motor winding is very high, the voltage difference between adjacent layers inside the winding is not large, which can reduce the insulation grade requirements, or is beneficial to making the isolation insulation layer between different layers very thin to improve the slot fill factor. Or, an adhesive backing can be added to the insulation layer in advance, so that when the ultra-flat wire conductor layer and the insulation layer are combined, they are only bonded at one place to play a role in fixing and positioning. Or the potting method can also be adopted to improve the overall insulation performance, thermal conductivity, stability and mechanical strength reliability. After overall potting, the overall ultra-flat wire will be insulated externally, which can meet the requirements of the motor for working in water.

[0058] Figure 9 Schematic diagram of the ultra-flat wire winding of the axial flux motor

[0059] Figure 10 Enlarged view of the sector ultra-flat wire winding of the axial flux motor

[0060] Figure 9 Shown is a schematic diagram of the ultra-flat wire winding of an axial-flux motor. Each sector winding is an ultra-flat wire winding, which can significantly improve the slot fill factor and reduce the skin effect. This ultra-flat wire winding method can be independently wound in advance. During winding, by controlling the pre-tightening force, the density between layers of the ultra-flat wire can be kept in the best state, improving safety, stability and thermal conductivity. In addition, the lead-out method of the lead-out end of the ultra-flat wire winding at the innermost side can be to lead out after bending 90 degrees or other angles and then folding in half, as Figure 10 shown. In this example, there are 5 columns of ultra-flat wires per layer.

[0061] Note: The above-mentioned motor can also be designed as a counter-rotating dual-rotor motor configuration (reference can be made to prior applications, such as: related prior applications such as the three-phase four-phase wave permanent magnet synchronous motor and the electromagnetic differential vector dual-drive system 202410043909.9), or it can be: a single dual-rotor motor, a double dual-rotor motor, a triple dual-rotor motor, a multi-dual-rotor motor; a single dual-rotor motor: one inner rotor and one outer rotor; a double dual-rotor motor: including two outer rotors or inner rotors with the same rotation direction.

[0062] The above principle also applies to axial-flux motors; and counter-rotating dual-rotor motors; and internal and external dual-flux types;

[0063] For axial-flux motors, reference can be made to the relevant solutions in prior applications, that is: two or more relatively independent axial-flux windings and permanent magnets (or non-permanent magnet current-excited windings) are arranged according to the corresponding phase difference angles and controlled according to the complementary waveform relationship, and the same effect can also be obtained. Since the axial force of the axial-flux motor is very large, the double-disk and multi-disk methods are basically used to balance the axial force, and the axial-flux motor has the characteristic of a short axial dimension in geometric size. Therefore, it is more conducive to designing a compact high-power density motor using the double-disk or multi-disk solutions described in this patent application.

[0064] It can be a single-rotor and dual-rotor motor, as well as a double-rotor with two-side flux and a counter-rotating dual-rotor,

[0065] Its electromagnetic wire can be round wire and flat wire; the current waveform can be: square wave, square wave + composite wave, sine wave;

[0066] Regarding the way of introducing the rotor winding current of the dual-rotor motor from the outside, reference can be made to prior applications (202211030428.1 Dual-rotor motor current dynamic and static physical ports, 202211098410.5 Constant magnetoresistance resolver and iron core design and manufacturing method) and the relevant solutions below.

[0067] The above solutions can also be used for conventional single-rotor motors, such as replacing existing brushless solutions, brushed solutions, etc.

[0068] Note: The above scheme is applicable to all types of motors and generators, including asynchronous motors, synchronous motors, brushless motors, brushed motors, induction motors, permanent magnet motors, switched reluctance motors, etc.

[0069] The three-phase line mentioned above can be the input and output wiring harness end of a three-phase motor, a three-phase induction asynchronous motor, a brushless DC motor, or a permanent magnet synchronous motor.

[0070] Alternatively, the dynamic and static port connection method of this article can also be a sliding brush method, or a sliding carbon brush solution that is easy to disassemble and replace.

[0071] Note: The names of the dynamic and static physical ports described in this article are relative, and they are mutual and interchangeable in their specific implementation; the inner and outer rotors are relative names, and they have interactive mechanical properties and can be each other's inner and outer rotors.

[0072] To keep the illustration simple and with few lines, it is not drawn according to standard engineering drawings. It is only a schematic diagram for explanation. The content described can be accurately identified by combining the contextual drawings;

[0073] Notes:

[0074] The part numbers in the drawings are marked with the same serial numbers for common parts in different drawings, while different serial numbers are used for related equivalent functional parts in specific drawings. This is entirely for the purpose of cooperating with the instructions to more clearly and accurately describe the working principles.

[0075] All the design ideas, structures, methods, and theories given in this article can be used to guide the design. The technical contents disclosed in the form of design theories, methods, implementation models, structures, principle diagrams, structural diagrams, schematic diagrams, mechanism diagrams, specific embodiments, etc. can be used to specifically design and manufacture various types of engine devices. The implementation mechanisms listed in this patent are all typical examples. The specific facility plans and mechanism types are not listed here in full. Any cross-reorganization, mutual reference design, combination mechanism plan and various application field examples of any design theory, idea, method, model, mechanism, component disclosed in this article are all within the scope of protection of this property right. Any behavior of using this principle for design and application without authorization is an infringement. For example: the relevant design theories and methods are applicable to traditional motors, generators and other similar power sources.

[0076] The purpose of the attached drawings of this patent is only to briefly illustrate the facility concept, principle structure of this patent. It aims to clearly show the disclosed content of the patent with the least number of drawings, clearly express the key structures, and adopt a "combination of detailed and concise" expression method, that is, it is drawn in a combination of simple drawings and detailed drawings; at the same time, to reduce the number of drawing sheets, the illustrations of similar structures no longer show other direction views, sectional views, enlarged detailed drawings, etc.; for the standard parts, general parts, and components without specific meaning and special functions in the text, the same names and part numbers are adopted in different drawings for greater conciseness and clarity. Please refer to each other before and after when looking at the drawings.

Claims

1. An ultra-flat wire high power density motor and design method, including motor windings, stators, rotors, housings, etc., characterized by: By adopting an ultra-flat wire cross-section structure with a large aspect ratio, a winding process and a bidirectional magnetic flux structure can be used, and the flat wire can be made into a very thin copper strip, thereby improving the skin effect and proximity effect of the electromagnetic winding, improving the motor efficiency and improving the heat dissipation; the separation of the copper strip and the insulating strip can make the selection of insulating materials unconstrained, and ultra-high temperature resistant materials can be used to greatly expand the rated current and maximum current of the motor, thereby improving the motor power density and overload capacity.

2. The ultra-flat wire high power density motor and design method according to claim 1 is characterized in that: The ultra-flat wire cross-sectional structure with a length-to-width ratio of more than 3 times is adopted, so that the softness of the flat wire is consistent with that of the conventional round wire, and the common winding scheme described in the prior application is adopted to realize the physical geometric space separation of the winding and the magnetic pole. The winding process can be adopted, and the endless winding can be wound. The effective utilization rate of the winding is close to 100%, and it is more suitable for high-speed operation. The molding process is simple and the slot fill rate is higher. The utilization rate of the central area of ​​the motor can be expanded. The working principle of the winding belongs to the bidirectional magnetic flux type, which doubles the effective working cross-section of the magnetic circuit magnetic flux and improves the power density. The winding process can be used to make the flat wire into a very thin copper strip, improve the skin effect and proximity effect of the electromagnetic winding, improve the motor efficiency and improve the heat dissipation. The separation of the copper strip and the insulating strip can make the selection of the insulating material unconstrained, and the ultra-high temperature resistant material can be used to greatly expand the rated current and maximum current of the motor, and improve the power density and overload capacity of the motor.

3. The ultra-flat wire high power density motor and design method according to claim 1 is characterized in that: The ultra-flat wire cross-section structure with a large aspect ratio (basically more than 3 times) is adopted, so that the softness of the flat wire is consistent with that of the conventional round wire, and the co-winding scheme described in the prior application is adopted to realize the physical geometric space separation of the winding and the magnetic pole, and the winding process can be adopted, the end winding is non-end winding, the effective utilization rate of the winding is close to 100%, and it is more suitable for high-speed operation, the molding process is simple, the slot fill rate is higher, and the utilization rate of the central area of ​​the motor can be expanded. The working principle of the winding belongs to the bidirectional magnetic flux type, which doubles the effective working cross-section of the magnetic circuit magnetic flux and improves the power density. In addition: the winding process can be used to make the flat wire into a copper strip similar to tin foil, and the thickness can be less than 0.1mm, which significantly improves the skin effect and proximity effect of the electromagnetic winding copper tape, improves motor efficiency and improves heat dissipation; due to the thin thickness of the copper tape, the heat is basically directly conducted and dissipated to the outside, and the axial ventilation structure can be used to allow the cooling medium (which can be air, water or oil) to pass through the copper tape winding gap, which has excellent heat dissipation, and the contact area between the copper tape and the outside world or each other is larger, and the thermal conductivity and rigidity are better, which is suitable for high-speed operation; in addition, a bare copper tape with no insulating material on the surface and an insulating material can be used in parallel to wind the strip. After the winding is completed, the insulating material and the bare copper tape form an insulating relationship. In this way, the cost of the electromagnetic wire can be reduced, the yield rate is greatly increased, and the process is further simplified. More importantly, the separation of the bare copper tape and the insulating material can greatly liberalize the selection range of the insulating material, and various types of materials can be selected. High temperature resistant materials, such as: polytetrafluoroethylene (engineering plastics), silicone rubber, fluororubber; special ceramics: alumina, silicon nitride, silicon carbide, hexagonal boron nitride, cubic boron nitride, refractory cement, magnesia bricks, these temperature resistance basically exceeds 1000 degrees Celsius; mica, quartz, and other silica materials; or use high temperature resistant glass fiber and other materials for insulation isolation, and use the above materials to make insulating isolation belts and isolation plates, which will greatly improve the high temperature resistance of the motor windings; if used in induction asynchronous motors or switched reluctance motors without permanent magnetic materials, there is almost no temperature restriction inside the motor, and there is basically no need to deliberately consider the high temperature characteristics of the motor, and there is no need to consider the heat dissipation and active cooling of the motor; at the same time, it also makes the rated current and maximum current range of the motor can be greatly expanded, improving the motor power density and overload capacity! Reduce the size and weight of the motor; the increase in the upper limit of the motor temperature will also improve the natural cooling performance of the motor. As the saying goes, the greater the temperature gradient, the higher the heat conduction efficiency. This idea can also be intentionally set to centralize the heating area of ​​the motor, increase the local temperature of the motor under the same heat conditions, and improve the heat conduction characteristics. This characteristic can be used to preheat the electric car in winter to achieve reasonable energy recovery and utilization; or, the significant increase in the local temperature of the motor can also allow it to be upgraded to a steam generation chamber, so that the heat transfer medium undergoes a physical change, such as allowing water vapor to be transformed into water vapor, which can construct a heat engine function, directly convert this preheating into mechanical energy, and can be further converted into electrical energy recovery, such as introducing high-temperature and high-pressure water vapor into a steam engine or steam turbine or turbine to convert it into mechanical energy and drive the motor to generate electricity for secondary electrical energy recovery and utilization;. Alternatively, to prevent rust, the bare copper strip and the insulating material may be packaged as a whole after being wound in parallel; Alternatively, different windings of the ultra-flat wire may be electrically connected in series or in parallel according to the cross-sectional area of ​​the ultra-flat wire and the requirements of the conductive excitation electromagnetic characteristics; and the resistance and electromagnetic excitation characteristics of the ultra-flat wire may be changed.

4. The ultra-flat wire high power density motor and design method according to claim 1, characterized in that: Its structure can be: Conventional flat wire co-winding solution; Or: for the common winding double super flat wire scheme, two groups of super flat wire windings are arranged in parallel in the winding range space of the same core disk, or three or more groups; or, the winding is composed of: a left group of insulating tape, a middle insulating isolation plate, a right group of super flat wire windings, a right group of insulating tape, a right insulating isolation plate, a central insulating isolation ring belt, a left insulating isolation plate, a left group of super flat wire windings, etc.; or, the left and right groups of windings can be connected in parallel or in series, and it is noted that the current rotation direction must be consistent; Or: the permanent magnet poles or iron core salient poles of the motor can be permanent magnet poles or iron core poles. The iron core poles are generally salient poles and are mainly used in the switched reluctance scheme; Or: a common winding single super flat wire solution, in which there is only one set of windings in the entire disk, and its insulation and isolation measures are simpler, or the iron core skeletons on both sides and the surface of the central iron core can be coated with high temperature resistant insulating materials, and the corresponding central insulating isolation ring belt and the insulating isolation plates on both sides can be removed; the super flat wire and the insulating tape can be directly wound therein, and the super flat wire can be a copper tape or other conductive material, and its thickness can be very thin; or, it can be less than 0.1 mm; Alternatively, the ultra-flat wire can also adopt the conventional enameled wire insulation process; or, adopt the single-sided insulation material solution, in which case the function is similar to that of an insulating tape. As long as there is an insulating isolation layer on one side, it can play the role of insulation between layers after winding; Alternatively, the insulation scheme between the layers of the ultra-flat wire winding can be to use insulating needle rollers to insulate the layers of the ultra-flat wire winding. The insulating needle rollers can be made of special high-temperature resistant insulating materials, and the cross-section of the needle rollers can be circular, rectangular, trapezoidal, triangular, polygonal, curved, fan-shaped, etc.; or, for safety and reliability, the needle rollers can be fixed by machining corresponding fixing holes on the surfaces of the two side skeletons (which can be insulating plates or iron cores + insulating layers); or, the assembly process of the winding and the needle rollers can be: during the winding process, the needle rollers of each layer are inserted layer by layer at any time while the winding is being wound; Alternatively, an insulating protrusion may be provided on one side of the ultra-flat wire winding; Alternatively, two or more insulating spiral brackets can be used to support the independent copper coiling and forming, and the winding conductor strip can be positioned by the insulating spiral bracket to ensure that the layers do not contact each other to ensure insulation. The side frame of the winding can be provided with an annular groove for positioning the winding copper strip, or it can be encapsulated and solidified by casting; Alternatively, it can be a concentric circle structure, and then connected in series or parallel. Generally, when this method is adopted, very thin materials can be used, so that the skin effect will be very small, the thermal conductivity is very good, basically the surface heat is generated, and the heat can be dissipated quickly; multiple layers of very thin copper foil similar to tin foil can be used with insulation tape for isolation and winding, and then connected in parallel to ensure a sufficiently large conductive cross-section; In the above corresponding solutions, there are isolation gaps between the layers of the ultra-flat wire windings, and cooling medium can be introduced into the gaps to increase the heat dissipation effect.

5. The ultra-flat wire high power density motor and design method according to claim 1, characterized in that: The above scheme is applicable to all types of motors and generators, which can be DC motors and AC motors; including asynchronous motors, synchronous motors, brushless motors, brushed motors, permanent magnet motors, induction motors, switched reluctance motors, hysteresis motors, etc.; It can also be designed as a counter-rotating double-rotor motor configuration, or it can be: a single double-rotor motor, a double double-rotor motor, a three-double-rotor motor, or a multi-double-rotor motor; a single double-rotor motor: one inner rotor and one outer rotor; a double double-rotor motor: including two outer rotors or inner rotors with the same rotation direction, as shown in Figures 26 and 27, Figure 26 includes an intermediate single-winding rotor with a bidirectional magnetic flux and an inner and outer double-magnetic steel rotor. Since the inner and outer double-magnetic steel rotors rotate in the same direction, they can be fixedly connected as one, and a counter-rotating double-rotor motor is formed with the intermediate single-winding rotor through a reversing mechanism, and the power density can be doubled; Figure 27: includes an intermediate single-magnetic steel rotor with a 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 fixedly connected as one, and a counter-rotating double-rotor motor is formed with the intermediate single-magnetic steel rotor through a reversing mechanism, and the power density can be doubled; or, according to the schemes shown in Figures 20 to 25, a two-side power flow output architecture is formed, which has an electromagnetic differential torque vector distribution function, light weight and high power density; This principle also applies to axial flux motors; and contra-rotating twin-rotor motors; and internal and external dual flux types; Alternatively, the axial flux motor may be a motor that arranges two or more relatively independent axial flux windings and permanent magnets (or non-permanent magnet current excitation windings) according to corresponding phase difference angles and controls them according to a complementary waveform relationship, which can also achieve the same effect. Since the axial force of the axial flux motor is very large, a double-disc and multi-disc method is basically used to balance the axial force, and the geometric dimensions of the axial flux motor have the characteristics of short axial dimensions. Therefore, it is more conducive to designing a compact high-power density motor using the double-disc or multi-disc solution described in this patent application; Alternatively, it can be a single-rotor and dual-rotor motor, as well as a dual-rotor and a counter-rotating dual-rotor motor; The electromagnetic wire can be round wire or flat wire; the current waveform can be: square wave, square wave + composite wave, sine wave; In order to further stabilize the torque and reduce vibration and noise, the core on the non-winding side or the core on the winding side can be designed as a skewed slot structure; Alternatively, the core poles may be of a shoe-type structure or a salient pole or a hidden pole structure, so as to increase the magnetic flux area in a limited space as much as possible, or a full-disk core layout may be adopted; Alternatively, in an axial flux motor, the magnets on both sides are arranged in an asymmetrical manner with unbalanced axial force. Then, the axial force will be different when the magnetic resistance changes, but as long as it can be maintained as a unidirectional axial force, only the axial stress of the bearing will change, but there will be no back-and-forth vibration, thus reducing vibration and noise. Alternatively: the motor windings may also be assembled and welded using a hairpin type forming process.

6. The ultra-flat wire high power density motor and design method according to claim 1, characterized in that: The input current waveform of the motor can be: when the motor role is changed to an engine, the induced current waveform generated by driving the motor winding to rotate at a constant speed with a stable torque is used to guide the design of its control current waveform. That is, 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 when the motor acts as a generator, then the output torque of the motor must be constant when it acts as a motor. This method can be called "energy reverse measurement simulation method" and can be used as a guidance method for optimizing the control current waveform of the motor. It is applicable to any type of motor. Alternatively, the load damping control method can be used to remove the inverter and use load + transmission control. The addition of the transmission consumes almost no energy because its mechanical efficiency is close to that of direct drive.

7. The ultra-flat wire high power density motor and design method according to claim 1, characterized in that: The ultra-flat wires on the same layer are also subdivided into multiple columns in parallel as much as possible, such as 5 columns of ultra-flat wires on each layer; in addition, multiple columns of ultra-flat wires on the same layer are connected in parallel as much as possible, so that the voltage between different columns of parallel wires on the same layer is zero, and the gap between multiple columns of wires can be set as small as possible to improve the slot fill rate, and the ultra-flat wires on the same layer and different columns can be insulated without insulation treatment and only rely on air or vacuum insulation, which reduces the cost and minimizes the gap between them as much as possible to improve the copper fill rate. For example, the gap can be as small as 0.2 or 0.1 mm or even smaller; and the concentric circle winding method shown in the figure can make the voltage difference between different layers also present a uniform voltage division relationship, so this method This method is more meaningful for high-voltage motors. Although the terminal voltages of the motor windings are very high, the voltage difference between adjacent layers inside the windings is not large, which can reduce the requirements for insulation polarity, or help to make the isolation insulation layer between different layers very thin, thereby increasing the slot fill rate; or, adhesive backing can be added to the insulation layer in advance, so that when the super-flat wire conductor layer and the insulation layer are combined, the two are only bonded at one place to strengthen the positioning, or potting can be adopted to improve the overall insulation performance and thermal conductivity, as well as stability and mechanical strength reliability; after overall potting, the entire super-flat wire will be insulated from the outside, which can meet the motor's wading work requirements.

8. The ultra-flat wire high power density motor and design method according to claim 1, characterized in that: The ultra-flat wire winding of the axial flux motor may include: each sector winding is an ultra-flat wire winding, which can significantly improve the slot fill rate and reduce the skin effect. The ultra-flat wire winding can be independently wound in advance. By controlling the preload force during winding, the density between the layers of the ultra-flat wire can be maintained at the best state, thereby improving safety, stability and thermal conductivity. In addition, the lead-out method of the innermost ultra-flat wire winding can be achieved by bending 90 degrees or other angles and then folding in half before leading out.

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