Design and manufacturing method of non-in-phase winding shifting slot-crossing wire assembling process

Abstract

The invention relates to a non-in-phase winding displacement cross-slot wire assembly process design and manufacturing method, discloses a non-in-phase winding displacement cross-slot wire assembly process design and manufacturing method based on a physical space, and aims at further improvement of a prior application and an existing motor, the non-in-phase winding displacement cross-slot wire assembly process design method based on the physical space is adopted, and the non-in-phase winding displacement cross-slot wire assembly process design method based on the physical space is adopted. Therefore, the problem of slot crossing of the winding is well solved, the integrated winding forming process of the whole winding is greatly simplified, the size of the end winding is shortened, invalid waste of electromagnetic wires is reduced, the end winding can participate in effective excitation, magnetic leakage is reduced, efficiency is improved, windings of different phases are relatively separated, and cost is reduced. The voltage-resistant safety of the motor winding is improved, and the heat dissipation effect of the motor is optimized. The method is particularly suitable for a motor architecture design method based on three-wire four-phase waves, one-phase windings can be reduced, the process can be further simplified, and the radial compactness of the convex-concave iron core is improved.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of motor and new energy vehicle design and manufacturing. BACKGROUND

[0002] With the rapid development of new energy vehicles, 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 put forward for the performance of the motor and related parts. The high-speed performance NVH of the motor rotor and high-speed zone bearing and gear is more demanding, and the cost increases. At the same time, safety, failure rate and other problems come with it. Double-rotor motor, especially contra-rotating double-rotor motor, is a technical direction that can double the power density of the motor. However, contra-rotating double-rotor motor brings a technical proposition, i.e. the current input problem of at least one of the outer rotor or the inner rotor is a technical process difficulty. According to the existing technical means, it is basically necessary to adopt the friction contact mode of brush and electric ring for current conduction. Especially for high-power motors, using the brush scheme will greatly affect the motor life and safety. SUMMARY

[0003] Based on the following prior applications:

[0004] 202211496278.3 Split disc high power density motor and design method

[0005] 202211503563.3 Non-differential disc type equal pole and coil winding high power density motor and design method

[0006] 202211030428.1 Double-rotor motor current dynamic and static physical port

[0007] 202211098410.5 Permanent magnet resistance rotary transformer and core design and manufacturing method

[0008] 202211409893.6 Current dynamic and static port electric conduction device and design method

[0009] 202211411199.8 High power density double disc permanent magnet synchronous motor and design method

[0010] 202310442414.9 Non-cophase winding displacement trans-slot group wire process design method based on physical space

[0011] 202210991519.5 Internal cooling and heat exchange hybrid engine

[0012] The application discloses a physical space non-cophasal winding displacement trans-slot group wire process design and manufacturing method, and is further improved on the basis of the prior application and the existing motor.

[0013] Note: for the outer rotor motor, it is suggested that the outer rotor can be output in a hole structure, because the structure relationship between the outer rotor and the inner stator is equivalent to the hole shaft relationship, and the structure relationship between the conventional inner rotor and the outer stator is the shaft hole relationship, that is, the inner rotor is the shaft, and the outer stator is the hole, therefore, the inner rotor is more suitable for output in the shaft, but the outer rotor is more reasonable for output in the hole structure, and the specific structure scheme can be a hollow shaft structure, and the power flow can be output in the transmission relationship of a flange plate or a gear, a chain wheel or a planetary gear structure;

[0014] Alternatively: the above scheme is also applicable to an axial flux motor, as shown in the accompanying drawings; and is divided into a concentrated winding scheme and a distributed winding scheme; and can be improved into an ultra-flat wire winding structure by using the above scheme.

[0015] The single-layer copper belt can be composed of a plurality of parallel copper belts, and the gap is as small as possible, or a micro-hole punching method is used,

[0016] The circumferential ultra-flat wire adopts a tooth slot gap assembly scheme, and can be finally inserted into a rectangular flat wire or a circular wire to fill the remaining gap.

[0017] The principle is applicable to most motor types, and can be a direct current motor, an alternating current motor, such as a permanent magnet motor, a switched reluctance motor, an induction motor or a hysteresis motor.

[0018] The input current waveform of the motor can be: when the motor is used as an engine, the inductive current waveform generated by driving the motor winding at a constant speed with a stable torque is used to guide the design of the control current waveform,

[0019] That is, when the control current waveform of any motor is the same as the current waveform emitted when the motor is driven to rotate at a constant angular speed with a constant torque when the motor is used as a generator, the output torque of the motor as a motor is constant. This method can be called "energy reverse real-time simulation method", and can be used as an optimization guide method for motor control current waveform. It is applicable to any type of motor. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The present invention will be described in detail below with reference to the accompanying drawings and embodiments:

[0021] Figure 1 、 Three Line four-phase wave (two-phase) convex and concave stator core configuration motor structure diagram

[0022] Figure 2 、 Three Disassembled structure diagram of stator and rotor of motor with four-phase wave (two-phase) convex and concave stator core configuration

[0023] Figure 3 、 Three Disassembled structure diagram of the stator and rotor of a motor with convex and concave stator core configuration

[0024] Figure 4 , rotor core structure diagram without magnetic steel installed

[0025] Figure 5 、 Three Phase convex and concave stator core configuration motor structure diagram

[0026] Figure 6 , Plan view of A-type rotor core punching

[0027] Figure 7 , Plan view of A-type rotor core with magnetic steel installed

[0028] Figure 8 , Plan view of composite B-type rotor core punching sheet with magnetic isolation function (see related prior application)

[0029] Figure 9 , Plan view of composite B-type rotor core with magnetic steel installed

[0030] Figure 10 、 11 :Structural design illustration of adding non-convex and concave cores to the areas adjacent to the end windings on both sides ( Figure 10 、 11 the difference, Figure 11 For the real situation, Figure 10 In order to visually distinguish the two side cores from the middle core, the middle core laminations are simplified as outlines)

[0031] Figure 12 、 Three Cross-sectional view of the motor structure with four-phase wave (two-phase) convex and concave stator core configuration

[0032] Figure 13 、 Three Cross-sectional view of the motor structure with convex and concave stator core configuration

[0033] Figure 14 、15 : Two-phase winding wiring diagram of a three-wire four-phase wave (two-phase) convex-concave stator core configuration motor

[0034] Figure 16 、 17 18: Three-phase winding wiring diagram of a three-phase convex-concave stator core motor

[0035] Figure 19 , Schematic diagram of series connection of windings in different layers in the same slot

[0036] illustrate: Figure 19 Occupied Figure 18 Print space, resulting in Figure 18 The number of cores on the left is reduced, and the actual number of cores (to be precise: the number of core teeth) should be the same as Figure 16 、 17 Consistent Figure 16 、 17 , 18 show different windings in the same core).

[0037] Figure 20 2. External rotor three-wire four-phase wave (two-phase) convex-concave stator core configuration motor structure diagram (Compact, two-phase winding slots have radial overlap, while ensuring that the end windings of different phases can be staggered without interference, the radial misalignment of the slots is minimized to improve compactness)

[0038] Figure 21 , External rotor three-wire four-phase wave (two-phase) convex and concave stator core configuration motor structure diagram

[0039] Figure 22 , External rotor three-phase convex-concave stator core configuration motor structure diagram

[0040] Figure 23 2. External rotor three-phase convex-concave stator core configuration motor structure diagram (Compact, three-phase winding slots have radial overlap areas, while ensuring that the end windings of different phases can be staggered without interference, the radial misalignment of the slots is minimized to improve compactness)

[0041] in:

[0042] 1. Permanent magnet rotor (the figure takes a 6-pole permanent magnet rotor as an example)

[0043] 2. Two-phase convex and concave stator core

[0044] 3. Heat sink (this area can also be closed to form a closed space to introduce cooling and heat dissipation media, such as cooling water, oil, air conditioning, etc.)

[0045] 4. X-phase winding slot (please refer to the attached Figure 14 )

[0046] 5. Y-phase winding slot (please refer to the attachedFigure 15 )

[0047] 6. Cooling medium channel (internal circulation of cooling water, oil, cold air, etc.)

[0048] 7. Permanent magnet rotor (example analysis of 4-pole permanent magnet rotor)

[0049] 8. Radiator (this area can also be closed to form a closed space to introduce cooling and heat dissipation medium, such as cooling water, oil, cold air, etc.)

[0050] 9. V-phase winding slot (reference can be made to the attached Figure 17 )

[0051] 10. W-phase winding slot (reference can be made to the attached Figure 18 )

[0052] 11. U-phase winding slot (reference can be made to the attached Figure 16 )

[0053] 12. Cooling medium channel (internal circulation of cooling water, oil, cold air, etc.)

[0054] 13. High permeability material core (generally made of silicon steel punched sheet)

[0055] 14. High-resistance magnetic material (high strength, high temperature resistance, non-conductive, non-magnetic)

[0056] 15. High-strength material connecting the rotor shaft (used to transmit torque and ensure rotor safety, high strength, steel and other materials allowed)

[0057] 16. Magnetic steel (example of trapezoidal magnetic steel, which can be tightly inlaid in the trapezoidal necked iron core to prevent centrifugal throwing and ensure safety)

[0058] 17, 18, two sides of the non-convex-concave iron core supplemented to optimize the function characteristics of the end winding DETAILED DESCRIPTION

[0059] As shown in the figure:

[0060] The application discloses a physical space non-cophase winding displacement trans-slot group wire process design and manufacturing method, and is further improved on the basis of the prior application and the existing motor.

[0061] In addition, the winding slot closest to the air gap can also be displaced outward to form a cooling space, so that all windings have a dedicated cooling system, and all windings are isolated from the rotor permanent magnet by a heat dissipation system, so that the temperature of the permanent magnet area is further reduced, which is obviously lower than that of the winding area. The super-thin wire can exceed 260 DEG C and still maintain normal working capacity, so the facilities that increase the heat dissipation barrier between the winding and the permanent magnet will help to further improve the overload capacity of the super-thin wire. For vehicle working conditions, the overload condition is not a normal condition, and the efficiency at this time can be ignored. In this way, we can further reduce the motor, and the super-thin wire motor has superior long-time overload capacity to meet the needs of these working conditions.

[0062] Alternatively, in order to reduce the magnetic flux leakage, improve the end winding excitation capacity, and increase the end winding and core heat conduction and heat dissipation capacity, the regions of the convex-concave core with end windings at both ends can be designed as core regions, and the core thickness is determined by the magnetic density generated by the end winding to ensure reasonable magnetic density distribution. Alternatively, in order to reduce eddy current, the core here can be designed as a radial radiation lamination or other axial lamination to reduce eddy current (for reference to the prior application). Note: In order to reduce the weight as much as possible, the increase of the core on both sides only needs to be for the region with end windings, according to the dragon-shaped winding form, the end winding is in the form of discontinuous interval on both sides, then the increased core at the end is also designed in this way. The region without end winding is still designed according to the convex-concave core structure in the middle region, so as to reduce the core usage, reduce the cost, and reduce the weight. Alternatively, a special-shaped core can also be filled between the end winding and the core to enable the magnetic field of the end winding to effectively participate in the overall excitation magnetic circuit, reduce the magnetic flux leakage, improve the motor efficiency and power density, and improve the heat dissipation and heat conduction capacity of the end winding.

[0063] Figure 8 High-magnetic-resistance high-strength reinforced material filled composite permanent magnet rotor core structure schematic diagram

[0064] High magnetic reluctance material is used to isolate magnetic circuit and fill the connection fastening to enhance mechanical characteristics.

[0065] The schematic diagram of the trans-slot group linear motor based on the non-cophase winding displacement in radial physical space, wherein the convex-concave anisotropic stator core can increase the heat dissipation effect, and the cooling medium (water or oil and other cooling fluids) channels are arranged in the internal space, and the channels and the corresponding cooling medium are high magnetic reluctance materials; the two-phase different windings are trans-slot group lines without crossing by the radial physical space winding displacement, so that the complexity of the winding group lines is greatly reduced, and each self-cophase winding can be designed according to the concentric circular winding structure, or the axial dimensions of the windings corresponding to the core from inside to outside of the concentric winding can be designed in sequence to be different in length, so that the end winding also participates in the electromagnetic action and becomes the power output winding of the motor.

[0066] In addition, the teeth and slots of the core where the phase windings of the windings in the non-air gap adjacent area can be designed as anisotropic tooth slots according to the needs to obtain the effect of eliminating or weakening the tooth slot torque.

[0067] Similarly, other pole numbers, such as 8-pole 72-slot, and fractional slot, can be used, and the distributed winding is very suitable for this scheme, which may increase the iron loss a little, but the cost is greatly reduced, the copper loss is reduced, the effective winding is changed, the efficiency is improved, the winding forming difficulty is greatly reduced, and as long as the core magnetic circuit is reasonably designed by finite element, the local core cross section is increased, the effect of not increasing the iron loss can be obtained, because the core magnetic circuit of the recessed winding is wide, because there is no winding in the middle, so it can be very wide, of course, the problem of magnetic leakage short circuit needs to be considered, in short, the magnetic resistance of the recessed winding is smaller than that of other areas, so the magnetic resistance of the recessed winding is not necessarily large, and it is more conducive to arranging the heat dissipation channels and eliminating the tooth slot torque, and the slot can be designed as an inclined type to eliminate the tooth slot torque.

[0068] The concentric circular wiring method can be used, and there is no crossing problem of the trans-slot winding;

[0069] It can be pushed and swung to the upper part of the inner hole of the core to facilitate the assembly of the rotor;

[0070] If the adjacent windings interfere, the axial size can be increased to dislocate each other, that is, the best solution to solve the interference is to lengthen the axial direction, that is, to increase the axial size of the end winding; the end size is as small as possible, the end winding can be dislocated radially up and down to reduce the end winding; note that the assembly sequence of the closed intermediate winding; the intermediate winding without bending bridge needs to be assembled in the middle process; note the assembly sequence;

[0071] Generally speaking: AB phase (XY phase in the figure), A phase takes over-bridge type, gives B phase space, then B phase takes direct plane U type, or both can be interleaved, that is, cross each other, both over-bridge and plane type exist; In short, the principle is to realize the wiring of all windings under the smallest axial winding size by over-bridge type and axial displacement; This end winding is similar to a cooling fin, so it has good heat dissipation, so it can be appropriately narrower than the inside, and can also ensure the same electrical conductivity, but the space is allowed to be larger, reducing the end resistance, and increasing the heat dissipation area;

[0072] If the two phases are bent up and down to avoid each other, the axial size can be minimized, and the resistance will actually increase because it is lengthened, so from the efficiency, it is better to design with the shortest principle; Bridge and plane types can be used interchangeably to make the length shortest and the resistance smallest; Or the best heat dissipation, or the shortest axial end winding size;

[0073] All similar in this patent can be combined to obtain the best slot fullness rate, short end winding, small skin effect, small resistance, simple group line process, low cost, good heat dissipation, and good insulation

[0074] According to the electromagnetic conversion requirements and speed torque characteristics, it can be connected in series, parallel or various series and parallel combination methods;

[0075] Note: The above design principles are also applicable to external rotor motors and axial flux motors. For axial flux motors, different phase windings can be axially displaced and displaced, and the space left by axial displacement can be designed as a heat dissipation channel to achieve the same effect as a radial flux motor.

[0076] This specific implementation can be completed for DC brush motor, DC brushless motor, permanent magnet synchronous motor, and induction asynchronous motor. Due to the multi-disc complementary effect, the rotor and stator pole numbers can be equal, which can increase the density of interaction points between stator and rotor in unit space, increase the electromagnetic torque or magnetic resistance torque density, and use square wave instead of sine wave current. Using timely square wave commutation staggered area for transient power-off can effectively eliminate negative torque. The above comprehensive measures can greatly improve the power density of the motor.

[0077] The core innovation of this scheme is the "physical space shift split phase method", which can replace three-phase alternating current with direct current or square wave or single-phase alternating current, and the problem of entering the "torque zero area" of the mechanical phase relationship of electromagnetic force acting elements (windings and permanent magnets) is solved by timely power failure and double-disc phase complementation. Timely power failure also completely eliminates negative torque effect and saves electricity, and can make the number of rotors and stators equal, greatly increasing the interaction force point density of rotors and stators, maximizing the power potential of each electromagnetic force acting element (windings and permanent magnets) in a unit space, and improving power density.

[0078] Note: The "physical space corner position split phase method" or "split phase method" does not actually shift the phase of the current waveform, but rather splits the phase of the torque and torque, and complements it to obtain stable and sustainable torque output. The split phase of the current or the commutation of the current direction or the waveform shift is to capture the rotor position by means of brush or brushless commutator to change the current direction in time or also called phase shift (for example, phase change of square wave), or through external controller to realize current phase change.

[0079] This "physical space corner position split phase method", "winding slot phase current waveform condensation method", "2 times relative speed method", "bidirectional flux method" is applicable to all types of motors, and can be used for: DC brush motor, DC brushless motor, permanent magnet synchronous motor, induction asynchronous motor, switched reluctance motor, etc. Or, the motor designed by the above-mentioned all methods and combined cross methods can be a radial flux motor or an axial flux motor. Or, it can also be a double-rotor motor with stator, such as winding-fixed inner and outer double-rotor motor or double-inner-rotor or double-outer-rotor or inner-outer-rotor or multi-rotor motor type, such as: double-rotor synchronous-asynchronous motor, squirrel-cage double-rotor motor, counter-rotating double-rotor motor, permanent magnet brushless double-rotor motor, etc. The above-mentioned methods are used alone or in combination with each other, which belongs to the protection scope of the patent.

[0080] The function of the motor can be a motor or a generator. For generators, it can greatly improve the power density of power generation.

[0081] Load speed regulation scheme:

[0082] The above motor can be speed-regulated by load (DC brush motor, brushless motor, AC induction motor, switched reluctance motor with position feedback control, and rotor phase closed-loop permanent magnet synchronous motor can be speed-regulated by load, open-loop control permanent magnet synchronous motor is not suitable), so the transmission ratio is changed by using a multi-gear transmission to shift gears, thereby changing the motor load to achieve load speed regulation, and the complex motor control system such as frequency converter can be removed. In order to make the motor adapt to a wider load speed regulation range, the voltage can be changed, for example: using a tapped power supply scheme for the battery, different input voltages are obtained by switching the battery taps, for example: the motor can be provided with different voltages of 20V, 50V, 100V, 200V, 400V, 600V, 800V, etc., which can make the motor have a wider load speed regulation range; and meet all road conditions under the premise of ensuring that the motor works in the highest efficiency range.

[0083] The principle of the double-disc motor is also applicable to axial flux motors, double-rotor motors, and internal and external double-flux types.

[0084] The axial flux motor can refer to the related scheme of the prior application, that is, two or more relatively independent axial flux windings and permanent magnets (or non-permanent current excitation windings) are arranged according to the corresponding phase difference angle and controlled according to the complementary waveform relationship, and the same effect can be obtained. Due to the large axial force of the axial flux motor, a double-disc and multi-disc method is basically used to balance the axial force, and the axial flux motor has the characteristic of short axial size, so it is more beneficial to design a compact high-power density motor using the double-disc or multi-disc scheme described in the present patent application.

[0085] It can be a single-rotor and double-rotor motor, as well as a two-sided flux double-rotor and a counter-rotating double-rotor,

[0086] The electromagnetic wire can be round wire and flat wire, and the current waveform can be square wave, square wave + composite wave, and sine wave.

[0087] The external introduction method of the rotor winding current of the double-rotor motor can be referred to in the prior application (202211030428.1 Double-rotor motor current dynamic and static physical port, 202211098410.5 Permanent magnet reluctance rotary transformer and core design and manufacturing method) and the related scheme below.

[0088] The above scheme can also be used for conventional single-rotor motors, such as replacing existing brushless schemes, brush schemes, etc.

[0089] Note: The above scheme is applicable 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.

[0090] The three-phase line mentioned above can be the input and output line bundle end of a three-phase motor or a three-phase induction asynchronous motor or a brushless direct current motor or a permanent magnet synchronous motor.

[0091] Alternatively, the dynamic and static port connection method herein can also be a sliding brush method or a sliding carbon brush scheme that is convenient to disassemble and replace.

[0092] Note: The dynamic and static physical port designations described herein are relative, and in specific implementations, they have mutual and interchangeable properties. The internal and external rotors are a relative designation, and they have mechanical properties and mutual interactions, and can be internal and external rotors.

[0093] Note:

[0094] The part number in the drawing is marked, and the common parts in different drawings are marked with the same number, while the relevant equivalent function parts in a specific drawing are marked with different numbers. This is completely to cooperate with the specification to express the working principle more clearly and accurately.

[0095] All the design ideas, structures, methods, and theories presented in this paper can be used to guide the design. The design theory, method, implementation model, structure, principle diagram, structure diagram, schematic diagram, mechanism diagram, specific embodiment, and other expression forms of the disclosed technical content can be used to design and manufacture various types of engines. The implementation mechanisms listed in this patent are typical demonstration examples. The specific facility schemes and mechanism types are not all listed here. Any design theory, idea, method, model, mechanism, and component disclosed in this paper can be used to cross-recombine, mutually borrow design, and combine mechanism schemes in the technical field of this patent. All behaviors that use this principle for design and application are infringing behaviors. For example: the relevant design theory and method are applicable to traditional electric motors, generators, and other similar power sources.

Claims

1. A non-cophasal winding shift across slot group wire process design and manufacturing method, including motor winding, stator, rotor, shell, etc., characterized in that: The super-thin wire section structure with a large aspect ratio makes the softness of the flat wire consistent with the conventional round wire, and can be assembled and inserted into the stator winding slot, which saves the complex process of opening and welding of the flat wire technology, and improves the skin effect of the winding; The physical space-based non-cophase winding displacement trans-slot grouping process design method makes the winding trans-slot problem well solved, not only greatly simplifies the integrated grouping forming process of the overall winding, shortens the size of the end winding, reduces the waste of electromagnetic wire, and makes the end winding also participate in effective excitation, reduces the magnetic leakage, improves the efficiency, and makes the different phase windings relatively separate, improves the motor winding voltage safety, and optimizes the motor heat dissipation effect; especially more suitable for three-wire four-phase wave-based motor architecture design method, which can further simplify the process, improve the radial compactness of the convex and concave core.

2. The non-cophase winding displacement trans-slot grouping process design and manufacturing method according to claim 1, characterized in that: The slot can be a conventional centering type or a biased type; or, a split core is used to separate the tooth and slot area from the choke area, and the split slot teeth and the choke area form a convex-concave inlay structure, so that the winding is combined with the split slot teeth, and then the split slot teeth and the choke area are inserted into one body; since this method can make the contact between the winding and the tooth and slot more closely after the insertion assembly is completed, the winding and the tooth and slot form a mutual dependence relationship after assembly, which further increases the integrated strength and stiffness of the winding and the tooth and slot, so that the tooth and slot width can be further expanded, the size space of the filled winding can be increased, the power density can be increased, and the electromagnetic noise can be reduced; Or, the split core scheme can be used during assembly, the winding can be unfolded into a plane, the split slot teeth and the winding can be combined, and then the winding can be bent and wound to form a 360-degree whole circle, and then inserted into the stator choke to form an integrated stator winding; Or, when the slot density is very large, the tooth and slot opening size of the integrated stator can be enlarged, so that the slot opening size is the same as the slot width size, and the split core design is not needed, so that the flat wire or super-flat wire winding can be inserted into the slot opening once; The wiring form of the super-flat wire winding can be concentric and stacked; Or, it can also be an outer rotor structure, and the opening of the stator core is outward, which is more convenient for wiring; Or, the three-wire four-phase wave scheme of the prior application can be used, and the number of phases of the winding can be changed from three to two, which can further reduce the wiring complexity and reduce the end size; Or, the existing flat wire winding can save a series of complex processes such as hairpin forming, insertion and welding; The above scheme is also applicable to the concentrated winding scheme, and the concentrated winding scheme can be changed from round wire to super-flat wire, which can increase the slot fill rate and can use the conductor and insulation separation scheme to improve the winding temperature resistance, and since the super-flat wire has a large specific surface area and a large contact area, its heat dissipation efficiency is better.

3. The non-cophasal winding shift across-slot group wire process design and manufacturing method of claim 1, wherein: The winding slot closest to the air gap can also be shifted outward to form a cooling space, so that all windings have a dedicated cooling system, and all windings are isolated from the rotor permanent magnet by a heat dissipation system, so that the temperature of the permanent magnet area is further reduced, which is significantly lower than the winding area. The ultra-flat wire can exceed 260℃ and still maintain normal working capacity, so the facilities that increase the heat dissipation barrier between the winding and the permanent magnet will help to further improve the overload capacity of the ultra-flat wire. For vehicle working conditions, overload conditions are not normal conditions and efficiency can not be considered at this time. In this way, we can further reduce the size of the motor, and the ultra-flat wire motor has superior long-time overload capacity to meet these working condition requirements; Alternatively, in order to reduce magnetic leakage, improve the excitation capability of the end winding, and increase the heat conduction and dissipation capability of the end winding and the core, the area of the end winding at both ends of the convex-concave core can be designed as a core area, and the core thickness is determined by the magnetic flux density generated by the end winding to ensure reasonable magnetic flux density distribution. Alternatively, in order to reduce eddy current, the core at this point can be designed as a radial radiation lamination or other axial lamination to reduce eddy current (see previous application). Note: In order to reduce weight as much as possible, the increase of the core on both sides only needs to be for the area with end winding. According to the dragon-shaped winding form, the end winding is in a discontinuous form with a spacing on both sides. Therefore, the added core at the end is designed in this way. The area without end winding is still designed according to the convex-concave core structure in the middle area, in order to reduce the amount of core used, reduce cost, and reduce weight. Alternatively, a special-shaped core can also be filled between the end winding and the core to effectively participate in the overall excitation magnetic circuit of the magnetic field of the end winding, reduce magnetic leakage, improve motor efficiency and power density, and improve the heat dissipation and conduction capability of the end winding. High-magnetic-resistance high-strength reinforced material filled composite permanent magnet rotor core structure schematic diagram, using high-magnetic-resistance material to isolate the magnetic circuit and fill the connection and fastening to play a mechanical property strengthening role; (see related previous application) Based on the radial physical space non-coherent winding shift cross-slot group wire type motor schematic diagram, the convex-concave special-shaped stator core can increase the heat dissipation effect, and the cooling medium (water or oil cooling fluid) channel is arranged in the internal space. Note that the through and the corresponding cooling medium are high-magnetic-resistance materials. Two-phase different windings realize non-crossing cross-slot group wires through radial physical space winding shift, which greatly reduces the complexity of the winding group wire, and allows each same-phase winding to be designed according to the concentric circle winding structure. Alternatively, the corresponding core axial dimensions of the concentric winding from the inside to the outside can be designed as different lengths, so that the end winding also participates in electromagnetic action and becomes a motor power output winding. In addition, the core teeth and slots of the phase winding in the non-air gap adjacent area of the winding can be designed as special-shaped teeth and slots according to the needs to obtain the effect of eliminating or weakening the tooth slot torque. Similarly, other pole numbers can also be used, such as 8-pole 72-slot, etc., as well as fractional-slot, all of which can be used with this scheme. Distributed winding is very suitable for this scheme. It may increase the iron loss a little, but the cost is greatly reduced, and the copper loss is also reduced. It becomes an effective winding, the efficiency is improved, the winding formation difficulty is greatly reduced, and as long as the core magnetic circuit is reasonably designed - finite element, the local core section can be increased to obtain the effect of not increasing the iron loss, because the core magnetic circuit of the recessed winding is very wide, as there is no winding in the middle, so it can be very wide. Of course, the problem of magnetic leakage short circuit needs to be considered. In short, the magnetic resistance of the recessed winding is not necessarily large, and it is more conducive to arranging heat dissipation channels and eliminating cogging torque. The slot opening can be designed as an inclined type to eliminate cogging torque; The concentric circle wiring method can be used, and there is no cross-over problem of cross-slot winding; It can be pushed and swung to the top of the inner hole of the core in order to assemble the rotor; If the adjacent windings interfere, they can be offset by increasing the axial size, that is, the best solution to interference is to lengthen the shaft, that is, to increase the axial size of the end winding. Try to reduce the size of the end, which can be offset radially up and down to reduce the end winding. Note: the assembly sequence of the closed intermediate winding; the intermediate winding without bending bridge needs to be assembled in the middle process; Note the assembly sequence; In general: AB phase (XY phase in the drawing), A phase adopts over-bridge type, gives B phase space, then B phase adopts direct plane U type, or, the two can be interleaved, that is, cross each other, both over-bridge and plane type exist; In short, the principle is: through bridge-arch type and axial offset to offset each other, realize all windings to complete their wiring under the smallest axial winding size; This end winding is similar to a heat sink, so it dissipates heat well, so it can be appropriately narrower than the inside, but the space allows it to be larger, reducing the end resistance and increasing the heat dissipation area; If the two phases are bent up and down to avoid each other, the axial size can be minimized. In fact, the resistance will increase because it will be longer. Therefore, from the efficiency point of view, it is better to design with the shortest principle. Bridge-arch and plane types can be used interchangeably to make the length shortest and the resistance smallest. Or the heat dissipation is the best, or the axial end winding size is the shortest. All similar in this patent can be combined to obtain the best slot fill rate and short end winding, small skin effect, small resistance, simple winding process, low cost, good heat dissipation and good insulation. According to the electromagnetic conversion requirements and speed torque characteristics, series, parallel or various series and parallel combination methods can be used.

4. The non-cophasal winding shift across-slot group wire process design and manufacturing method of claim 1, wherein: The above design principles are also applicable to external rotor motors and axial flux motors. For axial flux motors, different phase windings can be axially displaced, and the space left by the axial displacement can be designed as a heat dissipation channel to achieve the same effect as a radial flux motor.

5. The non-cophasal winding shift across-slot group wire process design and manufacturing method of claim 1, wherein: The core innovation of this solution lies in its use of the "physical space shifting phase splitting method," which allows direct current, square waves, or single-phase alternating current to replace three-phase alternating current. Furthermore, the problem of "crossing the center when the mechanical phase relationship of the electromagnetic force elements (windings and permanent magnets) enters the zero torque zone (the region where the forces acting on the windings and magnets enter zero torque or the forces on both sides are balanced and canceled)" is successfully resolved through timely power outages and dual-disk phase complementarity. This timely power outage also completely eliminates the negative torque effect and saves energy. It can equalize the number of rotor and stator elements, significantly increasing the number of interaction points between the rotor and stator, maximizing the power potential of each electromagnetic force element (windings and permanent magnets) per unit space and improving power density. The physical space splitting method, also known as the "disk splitting method," does not actually shift or split the current waveform in phase. Instead, it achieves a phase splitting method that complements each other in the torque domain, thereby achieving a stable and sustainable torque output. The current phase splitting, current direction commutation, or waveform shifting is achieved by using a brushed or brushless commutator to capture the rotor position and timely change the current direction for commutation, which can also be called phase shifting (for example, a square wave phase change), or by using an external controller to change the current phase. However, the significance of this solution lies in increasing the winding density design and effective work density, or converting three-phase AC into single-phase AC, square wave AC, or pulsating DC, and achieving continuous expansion of electromagnetic potential energy through disk splitting, similar to a cyclotron, into continuous and stable unidirectional torque mechanical energy. Therefore, the effective output power density of the winding is greatly increased. That is, the original requirement of 6 slots is reduced to 2 slots, and the three-phase is converted to single-phase, which increases the effective output power density, and the energy density can be further improved by using square waves. This "physical space angular position splitting method", "winding slot phase current waveform condensation method", "2 times relative speed method" and "bidirectional flux method" are applicable to all types of motors, and can be used for: DC brushed motors, DC brushless motors, permanent magnet synchronous motors, induction asynchronous motors, switched reluctance motors, etc.; or, the motors designed by all the above methods and combined cross-methods can be radial flux motors or axial flux motors; or, it can also be a dual-rotor motor with a stator, such as a dual-rotor motor with fixed inner and outer windings, or a dual inner rotor or dual outer rotor, or an inner and outer rotor, or a multi-rotor motor type, such as: a dual-rotor synchronous-asynchronous motor, a squirrel-cage dual-rotor motor, a counter-rotating dual-rotor motor, a permanent magnet brushless dual-rotor motor, etc.; the use of the above methods alone or in combination with each other falls within the scope of protection of this patent; The function of the motor can be an electric motor or a generator; when used as a generator, the power density of the generated electricity can be greatly improved.

6. The non-cophasal winding shift across-slot group wire process design and manufacturing method of claim 1, wherein: The control strategy for the switched reluctance motor is that the control mode of its double-disc or multi-disc configuration mode must be that the farthest reluctance disc is in a power-off state during the process of crossing the middle position, and the other discs can pull it to the appropriate position to be powered on. The appropriate position is the area where the magnetic pull generated when powered on can generate a positive torque. For the electromagnetic torque scheme, it can be reversed as long as it is reversed. The switched reluctance motor must be powered off, that is, the similar reversing effect is obtained by the power-on and power-off method. Since the magnetic reluctance magnetic pull is independent of the current direction, that is, it has no directionality, only the size of the magnetic reluctance is related, that is, it always moves along the trend of the smallest magnetic reluctance. Therefore, the adjacent magnetic poles must have a certain space distance, and the space distance is used to construct the positive torque magnetic pull, which is the reason why the switched reluctance motor magnetic pole layout density cannot be too large and must be a salient pole. However, through the split disc design, this problem can be well solved, and the design of the control system is also simplified.

7. The non-cophasal winding shift across-slot group wire process design and manufacturing method of claim 1, wherein: The motor assembly is composed of four layers of motor module discs (or the number of layers or discs can be 2, 3, 4, 5, 6, … N layers) arranged coaxially independently of each other. Each layer of motor module disc is composed of its own stator core and stator winding and rotor core (or: it can also be an outer rotor structure, that is: the stator core and stator winding are inside the static, and the rotor core is outside the rotation; or: it can also be an axial flux motor, see below), the stator core of each layer of motor module disc is fixed with the motor shell or is fixed and integrated with each other at a set pitch angle to form a motor assembly stator and motor shell, the rotor shafts of each layer of motor module disc are axially aligned and fixed with each other and with the motor output shaft. Or, the stator windings are axially aligned, and each rotor is fixed and integrated with each other at a set pitch angle to form a motor rotor.

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