Two-order three-phase end winding process design and manufacturing method

Abstract

The invention relates to a process design and manufacturing method of a second-order three-phase end winding, in particular to a process design and manufacturing method of an inner-cooling heat exchange second-order three-phase winding motor, which aims at further improvement of a previously applied and existing motor, in particular to improvement of a process design and manufacturing method of an inner-cooling heat exchange second-order three-phase winding motor, and unifies in-slot windings of a previously applied high-order winding and a previously applied low-order winding in the same radial space. In other words, all the in-groove windings are evenly distributed in the same diameter area concentric with the air gap, only the end windings are divided into the high-order end windings and the low-order end windings, and the performance of the motor is further optimized; the winding is characterized in that the winding has an effective winding advantage that the end winding participates in excitation and has an equivalent function with an in-slot winding, the end winding has better heat dissipation and heat conductivity, and the winding has no crossing problem of windings of different phases, so that the voltage-withstanding safety of the winding is greatly improved, and the winding forming process is simplified.

Description

Technical Field

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

[0002] With the rapid development of the new energy vehicle industry, especially the pure electric vehicle industry, higher demands are being placed on the high-speed performance and high power density of electric motors. As motor speeds increase, higher requirements are being placed on the performance of motors and related components. More stringent requirements are being placed on the high-speed performance NVH of motor rotors, high-speed bearings, and gears, leading to increased costs and the emergence of issues such as safety and failure rates. Flat wire motors can improve slot fill factor and power density, but current flat wire windings, core structures, and forming and assembly processes result in a large cross-sectional area of ​​flat wires, leading to significant skin effect and proximity effect. Furthermore, they are basically made in a fixed shape, and the basic production process involves slot paper → hairpin manufacturing → hairpin insertion → end ring shaping → end ring welding → star point connection → insulation treatment at the welding point, etc., which is a complex process requiring specialized equipment. Winding schemes for flat wire motors include: Hair-pin, i-pin, x-pin, w-pin, etc. W-pin is a continuous wave winding. Its advantages are that there are almost no solder joints in the entire winding except for the current output and input ports. However, it requires the use of open slots for assembly, which increases the cogging torque. For permanent magnet rotors, in order to minimize magnetic leakage and improve the high-speed mechanical performance of the rotor, the design of the magnetic blocking slots in the rotor core structure is very demanding. In order to ensure sufficient safety, it is unavoidable to form a certain magnetic circuit closure, which leads to magnetic leakage and reduces electromechanical conversion efficiency. Another approach is to use a structure with high-strength carbon fiber wound externally, which increases costs and increases the air gap, also affecting its performance. Summary of the Invention

[0003] Based on the following prior and related applications:

[0004] 202310442414.9 Design Method for Cross-Slot Line Assembly Based on Physical Space Non-Synchronous Winding Shifting

[0005] 202410494805.x Design and Manufacturing Method for Non-Synchronous Winding Shifting Slot-Connecting Wire

[0006] 202410566893.x Process Design and Manufacturing Method of Internal Cooling Heat Exchange Second-Order Three-Phase Winding Motor

[0007] This invention discloses a process design and manufacturing method for a second-order three-phase end winding. This invention further improves upon prior applications and existing motors, particularly the "process design and manufacturing method for an internally cooled, heat-exchange-type second-order three-phase winding motor." It unifies the "in-slot windings" (specifically referring to traditional in-slot windings; the end windings in this application are also in the slot, but for ease of explanation, the traditional terminology is used to define end windings and in-slot windings) of the high and low order windings in the prior applications into the same radial space. That is, all "in-slot windings" are evenly distributed in the same diameter region concentric with the air gap. Only the end windings are divided into high-order and low-order end windings, further optimizing motor performance. It also possesses the advantage of the end windings participating in excitation with equivalent function to the in-slot windings, and the end windings have better heat dissipation and thermal conductivity. Furthermore, there is no crossover issue between different phase windings, greatly improving the winding withstand voltage safety and simplifying the winding forming process.

[0008] Generally speaking, the types are mainly divided into: M-type windings with low-order end windings and N-type windings with high-order end windings; in addition, they can also be divided into: N-type windings with E-type high-order end windings and N-type windings with F-type high-order end windings, which correspond to different types of E-type stator cores and F-type stator cores (Note: the letters M, N, E, and F do not have specific meanings; they are just specific code names for the convenience of patent description, representing different types. Please refer to the corresponding drawings for details). Consistent with the winding classification and wiring principle of the earlier application "Process Design and Manufacturing Method of Internal Cooling Heat Exchange Two-Order Three-Phase Winding Motor", each phase winding of the U, V, and W three-phase windings will be alternately located in the high and low order regions. In this application, each phase winding of the U, V, and W three-phase windings will alternately have M-type windings with low-order end windings and N-type windings with high-order end windings; see the attached diagram for a detailed wiring relationship. Figure 24-27 The equivalent inductance and resistance of each phase winding can be obtained.

[0009] Note: For ease of drawing and description, the bends of the windings in the accompanying drawings of this patent application are all right-angle bends. In practical applications, rounded bends can be used for a natural transition, and the depth of the hollowing-out area at the end of the iron core should be minimized to improve the magnetic flux density distribution of the iron core. In addition, the fully embedded process of the end iron core and the end winding described above can be a similar hollowing-out process. In practical applications, the iron core laminations in the end area are generally pre-designed into specific shapes and then stacked to present the corresponding concave and convex shapes that fully match and fit the shape of the end winding. Alternatively, the convex and concave irregular end iron cores corresponding to the end windings can be installed separately from the main iron core stator, i.e., they can be installed before the windings are installed, or they can be inserted after the windings are installed. In addition, in order to minimize eddy currents, the direction of the iron core laminations corresponding to the end windings should be as close as possible to the magnetic circuit axis to ensure that eddy current iron losses are minimized. For details, please also refer to the prior application "Independent Forming Process and Design Method of End Windings in Motor Slots".

[0010] Furthermore, for ease of drawing and description, the windings in the three-dimensional views of the accompanying drawings of this application are all represented by schematic diagrams of the same or similar shapes using linear or circular arrays to concisely depict their overall structural form. In actual wiring, this is to realize the series and parallel relationship according to the circuit method. For specific wiring diagrams, please refer to the attached drawings. Figure 24-28 ;

[0011] Alternatively, the winding can also be made using a similar hairpin flat wire process (H-PIN), forming an independent, non-closed, single-sided opening. After insertion into the iron core, the other side is overlapped or welded and then treated with varnish or potting insulation. The difference is that the winding shape in this scheme is basically a standard rectangle. The end winding can be tightly fitted to the iron core to participate in excitation and become an effective winding. The non-welded side can fit perfectly with the iron core without any dead angles, fully utilizing the end winding's function of participating in excitation. The welded side can also be bent into a standard rectangle before butt welding or bent at an angle for butt welding (this can be butt welding with the end faces facing each other, or welding after staggered overlap at the ends, or using a mechanical pre-pressure contact electrical connection method after staggered overlap; or...). (This can be achieved by bending the wire at a 90-degree angle or other angles in the welding area before butt welding or by using mechanical pre-tightening to achieve electrical connection). In short, the welded side can also fit well with the iron core, allowing the end winding to participate in the excitation work. Moreover, since there is no problem of cross-slot proximity effect between different phases of the traditional winding, the same type of hairpin winding can be inserted synchronously at one time, which not only improves assembly efficiency but also reduces the risk of damage to the insulation layer caused by frequent interlocking and relative friction between adjacent windings. It can also further improve the density, increase the slot fill factor and thermal conductivity, and reduce electromagnetic noise. The voltage of adjacent windings basically decreases in a gradient, which can improve the withstand voltage safety level. Alternatively, the insulation layer thickness of the electromagnetic wire can be reduced, which is equivalent to increasing the slot fill factor.

[0012] Alternatively, since this scheme does not involve the complex process of cross-wiring and misalignment of different phase windings, each phase winding is cyclically wound in its own trajectory area and arranged neatly. Therefore, the winding can also be wound back and forth two or more turns from both sides of the stator slot opening in a large looping manner before welding, so as to reduce the number of solder joints, or even the entire winding can be wound as a whole before finally entering the busbar for welding, which is equivalent to the distributed winding realizing the centralized winding process.

[0013] Alternatively, the post-synthesis process of separating the conductor layer and insulation layer of the ultra-flat wire disclosed in this series of applications can be adopted to use a more heat-resistant insulation layer, thereby improving the high-temperature resistance of the winding. Meanwhile, the conductor layer can be bare copper, aluminum, or other conductors, further reducing the cost of raw materials and processes for the winding, and improving the yield rate. Note: In the current scheme, windings of different phases do not cross, and windings of the same phase are arranged neatly and regularly. This configuration is conducive to using post-synthesis of the conductor layer and insulation layer or online synthesis (online synthesis on the production line, followed by direct entry into the winding for mutual shaping or further potting and curing). In this scheme, the slots on the air gap side of the core can be made into semi-open or closed slots.

[0014] In addition, to simplify the installation process, this solution can generally be made with open slots. All windings can be pre-wound and then inserted into the slots through radial open slots. Alternatively, the open slots can be formed after the winding assembly is completed, and then the closed slot or semi-open slot element can be inserted by interference fitting or by casting. See Appendix. Figure 29 (For details, please refer to the prior application 202310792777.5, "An Optimized Design Process for Split Embedded Magnetic Circuit");

[0015] Alternatively, ultra-flat wire can be used to slide into the slot (Note: When ultra-flat wire slides into the slot from the slot, it needs to be twisted at an angle as it passes through the slot. Therefore, the last layer or several layers of windings located at the edge of the slot can be inserted from the side, or it can be inserted back and forth around the slot from the side, or it can be cut into independent winding layers and installed and welded in a manner similar to hairpin flat wire; or, the remaining space near the slot can be left as a heat dissipation channel without adding windings, as can be seen in the prior application, which can also eliminate the slot effect problem), similar to the winding unwinding process of current round wire motors. Alternatively, the transition bend between the slot winding and the end winding of the ultra-flat wire can also be a 45-degree folding bend process. Alternatively, in order to reduce the impact of the stack thickness after folding, a staggered process with different axial dimensions can be adopted to reduce the increase in the radial dimension of the winding stack caused by folding. The windings can also adopt a parallel winding scheme to improve the high current carrying capacity. Alternatively, the series and parallel connection relationship of the windings can be changed in a timely manner to obtain different back EMFs and thus meet the high efficiency operation in different speed ranges.

[0016] Alternatively, there is even a solution where the winding is inserted through openings on both sides and then soldered, such as I-PIN, H-PIN, X-PIN, W-PIN, etc.

[0017] Alternatively, radial flux and axial flux motors can also use windings similar to W-PIN. Round wire, flat wire, or round wire can be pre-formed using a W-PIN winding bending process before being extruded into flat wire. This makes bending easier and avoids the difficulty of forming flat wire during vertical bending. Bending and then extruding into flat wire improves slot fill factor, enhances thermal conductivity, and reduces tip discharge. Alternatively, to prevent plastic deformation during extrusion from damaging the insulation film, bare copper can be bent and formed before extruding into flat wire, followed by insulation treatment. This can be achieved using an impregnation process or an insulation film isolation process. See the previous applications in this series on "ultra-flat wire" for related content. Separating the conductor and insulator and then synthesizing them later offers advantages such as reducing the space occupied by the insulation film and allowing the use of more heat-resistant materials for the insulation film to improve the overall temperature resistance of the motor. Note: Related text and figures in this section can be found in the relevant previous applications.

[0018] Alternatively, the axial flux motor type produced by stamping can also adopt an end winding shape similar to X-PIN, which can reduce the size of the end winding. Pressure butt welding or soldering can be used without affecting its electrical connection characteristics. Alternatively, the winding mother-daughter layer scheme of the axial flux motor type can also adopt a transverse or longitudinal arrangement, i.e., transverse insertion or longitudinal insertion. If longitudinal insertion is adopted, I-PIN, H-PIN or X-PIN configurations can be preferred, and electrical connection can be achieved by immersion soldering or pressure butt welding. Note: The relevant text and figures in this paragraph can be found in the relevant prior applications.

[0019] In addition, this solution is applicable to round wire motors, conventional flat wire motors, ultra-flat wire motors of this series of applications, as well as all types of external rotor radial flux motors and axial flux motors;

[0020] As attached Figure 30 As shown, if used in an axial flux motor with the winding in the middle and the rotor on both sides, the middle winding core can be divided into two halves along the axial vertical plane of the centering. In this way, the slots on the air gap side of the two halves of the stator core can be closed slots or semi-open slots. The winding can be pre-formed, and then the stator can be joined from both sides. This ensures that the winding has no solder joints, similar to a continuous wave winding, and also solves the problem of open slots, becoming closed slots to improve motor performance. Note: The joined two halves of the stator core can be locked mechanically, or they can be mainly attracted by electromagnetic force. Because the direct contact at the middle joining point is equivalent to zero air gap, while the two sides are air gaps, the electromagnetic attraction force in the middle is much greater than that on the air gap side, which can stably attract and ensure safe and reliable operation. This mechanical locking method can be an auxiliary solution.

[0021] Similarly, this application employs a slot-crossing wiring process design method for non-phase windings in the physical space of the end windings, effectively solving the winding slot-crossing problem. This not only greatly simplifies the integrated wiring forming process of the entire winding, shortens the size of the end windings and reduces ineffective waste of electromagnetic wires, but also allows the end windings to participate in effective excitation, reducing leakage flux and improving efficiency. Furthermore, it separates different phase windings, improving the voltage withstand safety of the motor windings, and optimizes the motor's heat dissipation. Compared to prior applications, this method can satisfy the slot-crossing wiring of three-phase windings using a two-order method, i.e., high-order, low-order, or inner and outer two-layer misalignment. See the appendix for specific wiring schemes. Figure 24-27 As shown (where: Appendix) Figure 24 In the diagram, the dotted-line windings represent higher-order windings; the dashed-line windings represent lower-order windings. Clearly, in this scheme, in-phase windings will be located in slots of different orders, but this does not affect cross-slot wiring. (See attached diagram.) Figure 25-27 In this diagram, different line types represent different phase windings, divided into three phases: A, B, and C. The letters A, B, C, and C followed by numbers represent windings in different slot regions. This numbering is for easy reference when referring to the appendix. Figure 24 One-to-one correspondence analysis and interpretation, including the appendix Figure 25-27 In this design, longer end windings represent higher-order windings, and shorter end windings represent lower-order windings. Clearly, in this scheme, in-phase windings are alternately arranged in the slots of higher-order and lower-order windings. However, by properly arranging the end windings so that all end windings are close to the stator core and by ensuring proper wiring to guarantee that the current direction of the end windings is consistent with the excitation direction of the windings in the slots, a unified positive superposition and enhanced excitation magnetic field can be formed. This transforms the function of the end windings into effective windings; that is, the end windings not only serve as connecting wires but also function as excitation windings along with the windings in the slots, thus improving motor efficiency.

[0022] Also note: Ensure that the inductance of each phase winding is the same to eliminate circulating current. Alternatively, have the end windings at both ends of the same winding have different high- and low-order structures, i.e., design the left end winding as a low-order structure and the right end winding as a high-order structure. This makes it easier to ensure equal inductance and equal resistance characteristics of all windings.

[0023] In addition, to improve the assembly efficiency of series-connected windings, multiple series windings can be first assembled in parallel as a single unit, and then the ends of each layer of windings can be sequentially connected in series or welded to achieve a series electrical connection, as shown in the attached figure. Figure 28 The diagram shows a series connection of the same phase ultra-flat wire windings. The arc area represents a U-shaped bend jumper. In actual connection, parallel connection, vertical connection, or angled connection can be adopted. Alternatively, they can be wound in parallel or partially in parallel; or wound in parallel on the same layer (to increase the ability to conduct large currents). This is beneficial to reduce iron loss, improve efficiency, and reduce volume and weight.

[0024] Note: This scheme is also applicable to the design method of motor architecture based on three-wire four-phase wave, which allows different phase windings to be arranged in high-order and low-order slots respectively, and can be wired using dragon-shaped windings, see prior application.

[0025] Note: For external rotor motors, it is recommended that the external rotor output power via a hole structure. This is because the structural relationship between the external rotor and the inner stator is equivalent to a hole-shaft relationship, while the conventional structural relationship between the inner rotor and the outer stator is a shaft-hole relationship. That is, the inner rotor is the shaft and the outer stator is the hole. Therefore, it is more suitable for the inner rotor to output power via a shaft, but it is more reasonable for the outer rotor to output power via a hole structure. Specific structural solutions can include a hollow shaft structure, with output power via a flange or gear / sprocket transmission relationship; or a planetary gear structure to output power flow.

[0026] Alternatively: The above scheme is also applicable to axial flux motors, see attached figure; it is also divided into centralized winding and distributed winding schemes; all of them can be improved into ultra-flat wire winding structure by adopting the above scheme.

[0027] Its single-layer copper strip can be composed of several parallel copper strips with the smallest possible gaps, or it can be made using micro-hole drilling.

[0028] The circumferential ultra-flat wire adopts an assembly scheme from the tooth groove gap, which can fill the remaining gap by inserting a rectangular flat wire or a round wire at the end.

[0029] Its principle applies to most types of motors, including DC motors, AC motors such as permanent magnet motors and switched reluctance motors, as well as induction motors and hysteresis motors.

[0030] The input current waveform of the motor can be: when the motor is transformed into an engine, the induced current waveform generated by driving the motor windings with stable torque at a constant speed can guide the design of its control current waveform.

[0031] In other words, if the control current waveform of any electric motor is the same as the current waveform generated when the motor is driven to rotate with constant torque and constant angular velocity as a generator, then the output torque of the motor as an electric motor will definitely be constant. This method can be called the "energy reverse measurement simulation method" and can be used as a guiding method for optimizing the control current waveform of an electric motor. It is applicable to any type of motor. Attached Figure Description

[0032] The present invention will now be described in detail with reference to the accompanying drawings and embodiments:

[0033] Figure 1-10 Explanation diagram of M-type winding with low-order end winding, N-type winding with E-type high-order end winding, and E-type stator core assembly.

[0034] Figure 11-17Explanation diagram of M-type winding with low-order end winding, N-type winding with F-type high-order end winding, and F-type stator core assembly.

[0035] Figure 18-23 Explanation diagram of M-type winding with low-order end winding, N-type winding with F-type high-order end winding, and lightweight F-type stator core assembly.

[0036] Figure 24 Wiring diagram of a second-order three-phase winding motor

[0037] Figure 25 , 26 27: Analytical diagram of the three-phase winding wiring plan of a second-order three-phase winding motor

[0038] Figure 28 A schematic diagram of series connection of in-phase ultra-flat wire windings (parallel winding or partial parallel winding is also possible; or parallel winding in the same layer and parallel connection to increase the ability to conduct large currents).

[0039] Figure 29 Schematic diagram of the optimized design structure of stator core slot opening

[0040] Figure 30 Schematic diagram of axial flux motor combined iron core

[0041] in:

[0042] 1. M-type winding of low-order end winding; 11. Winding (flat wire winding)

[0043] 2. N-type winding with E-type high-order end winding; 12. Split-type embedded flared tooth block (Type A).

[0044] 3. Type E stator core; 13. Split-type embedded flared tooth block (Type B)

[0045] 4. Schematic diagram of stator core made of thin laminations (14. Split embedded flared tooth block C-type)

[0046] For the sake of simplicity in the illustrations, the iron core is basically not shown in the 15-type A-type tooth block magnetic guide block area.

[0047] (Laminated structure) 16. Non-magnetic block area of ​​type A tooth block

[0048] 5. N-type winding containing F-type high-order end winding; 17. B-type tooth block magnetic block area.

[0049] 6. F-type stator core 18. B-type tooth block non-magnetic block area

[0050] 7. Lightweight F-type stator core (removing the outer 19-type tooth block magnetic guide block area)

[0051] Iron core (can reduce weight and increase heat dissipation surface area) 20. C-shaped tooth block non-magnetic block area

[0052] 8. Stator winding core chuck 21. Axial flux motor left half split core

[0053] 9. Stator winding core teeth 22. Axial flux motor right half split core

[0054] 10. Stator winding core slot section; 23. Axial flux intermediate winding Detailed Implementation

[0055] As shown in the figure: This invention discloses a process design and manufacturing method for a second-order three-phase end winding. This invention further improves upon prior applications and existing motors, employing a physical space-based non-phase winding shifting and slot-crossing wiring process design method. This effectively solves the winding slot-crossing problem, greatly simplifying the integrated wiring forming process of the entire winding, shortening the end winding size and reducing ineffective electromagnetic wire waste, allowing the end winding to participate in effective excitation, reducing leakage flux and improving efficiency. Furthermore, it separates different phase windings, improving the motor winding voltage withstand safety, and optimizing the motor's heat dissipation. Compared to prior applications, this method uses a second-order method (i.e., high-order, low-order, or inner and outer two-layer misalignment) to meet the slot-crossing wiring requirements of the three-phase winding. See the appendix for specific wiring schemes. Figure 24-27 As shown (where: Appendix) Figure 24 In the diagram, the dotted-line windings represent higher-order windings; the dashed-line windings represent lower-order windings. Clearly, in this scheme, in-phase windings will be located in slots of different orders, but this does not affect cross-slot wiring. (See attached diagram.) Figure 25-27 In this diagram, different line types represent different phase windings, divided into three phases: A, B, and C. The letters A, B, C, and C followed by numbers represent windings in different slot regions. This numbering is for easy reference when referring to the appendix. Figure 24 One-to-one correspondence analysis and interpretation, including the appendix Figure 25-27 In this design, longer end windings represent higher-order windings, and shorter end windings represent lower-order windings. Clearly, in this scheme, in-phase windings are alternately arranged in the slots of higher-order and lower-order windings. However, by properly arranging the end windings so that all end windings are close to the stator core and by ensuring proper wiring to guarantee that the current direction of the end windings is consistent with the excitation direction of the windings in the slots, a unified positive superposition and enhanced excitation magnetic field can be formed. This transforms the function of the end windings into effective windings; that is, the end windings not only serve as connecting wires but also function as excitation windings along with the windings in the slots, thus improving motor efficiency.

[0056] Note: Figure 25 The positions X1, X2, and X3 in the diagram represent the same winding, which is a planar unfolded diagram of the overall ring winding, i.e.: a planar unfolded analytical diagram of the wiring of the three-phase winding of a second-order three-phase winding motor.

[0057] In addition, Figure 28 This diagram illustrates the series connection of in-phase ultra-flat wire windings. The curved area represents a U-shaped bend jumper. In actual connection, parallel, perpendicular, or angled connections can be used. Alternatively, they can be wound in parallel or partially in parallel (or wound in parallel on the same layer to increase the capacity to conduct large currents). This helps reduce iron losses, improve efficiency, and reduce size and weight. Note: This scheme is also applicable to motor architecture design methods based on three-wire four-phase waves, allowing different phase windings to be arranged in high-order and low-order slots. A dragon-shaped winding can be used for wiring; see prior application.

[0058] Meanwhile, this patent discloses a highly efficient internal cooling heat exchange and heat dissipation scheme, which directly introduces coolant into the hottest winding core area, realizing direct heat exchange from inside the core, improving the heat dissipation effect, and can make full use of this closed heat exchange channel to construct a steam generation chamber or other medium steam that can be used for the conversion of thermal energy into mechanical energy to meet the working requirements of the heat engine, realizing a heat recovery scheme for converting thermal energy into mechanical energy. This mechanical energy can be directly used to generate electricity or output, or the hot air can be introduced into other areas to meet other functions, such as car interior heating in winter or battery preheating. This patent application discloses two sets of heat dissipation system channels, an inner ring and an outer ring. The inner ring is located inside the winding, which can achieve efficient heat dissipation and protect the rotor permanent magnet well. In addition, it can optimize the slot effect of the winding. The outer ring cooling channel is located on the periphery of the winding. It is formed by combining the 26, 27, and 28 various shaped windows on the second stator core lamination and the third and fourth stator core laminations with the 25 channel on the middle stator core lamination. It can facilitate the setting of coolant channels and can also rely on the outer heat sink for air cooling. Alternatively, it can be closed to form a closed space to introduce cooling media, such as cooling water, oil, or cold air.

[0059] Alternatively, this invention provides a design and manufacturing method for a non-in-phase winding cross-slot wiring process based on physical space. This invention further improves upon prior applications and existing motors by employing a non-in-phase winding cross-slot wiring process based on physical space. This effectively solves the winding cross-slot problem, significantly simplifying the integrated wiring forming process of the entire winding, shortening the end winding size to reduce ineffective electromagnetic wire waste, and allowing the end winding to participate in effective excitation, reducing leakage flux and improving efficiency. It also allows for relative separation of different phase windings, improving the motor winding voltage withstand safety and optimizing motor heat dissipation. This is particularly suitable for motor architecture designs based on three-wire four-phase waves, as it can reduce one phase winding, further simplifying the process and improving the radial compactness of the convex and concave iron core.

[0060] Alternatively, the winding slots closest to the air gap can be moved outward to create a cooling space. This way, all windings have dedicated cooling systems, and all windings are isolated from the rotor permanent magnets by a heat dissipation system. This further reduces the temperature in the permanent magnet area, making it significantly lower than that in the winding area. Ultra-flat wires can maintain normal operation even at temperatures exceeding 260°C. Therefore, this facility, which adds a heat dissipation barrier between the windings and the permanent magnets, will further enhance the overload capacity of ultra-flat wires. For vehicle operating conditions, overload conditions are not normal operating conditions, so efficiency at this time can be disregarded. This allows us to further reduce the size of the motor. Under overload conditions, ultra-flat wire motors have superior long-term overload capacity to meet the requirements of these operating conditions.

[0061] Alternatively, to reduce leakage flux, enhance the excitation capability of the end windings, and increase the heat dissipation capacity of the end windings and the core, the areas with end windings at both ends of the convex and concave core can be designed as core areas. The core thickness is determined by the magnetic flux density generated by the end windings to ensure a reasonable magnetic flux density distribution. Alternatively, to reduce eddy currents, the core can be designed as radially laminated or other axially laminated structures to reduce eddy currents (refer to prior applications). Note: To minimize weight, the addition of cores on both sides only applies to the areas with end windings. Following the dragon-shaped winding form, where the end windings are discontinuous on both sides, the added cores at the ends are designed in the same way. Areas without end windings still follow the convex and concave core structure of the middle area to minimize core usage, reduce costs, and lighten weight. Alternatively, irregularly shaped cores can be filled between the end windings and the core to allow the magnetic field of the end windings to effectively participate in the overall excitation circuit, reducing leakage flux, improving motor efficiency and power density, and simultaneously enhancing the heat dissipation capacity of the end windings.

[0062] Appendix Figure 1 , Figure 7 A schematic diagram of a composite permanent magnet rotor core structure filled with high magnetic reluctance and high strength reinforcing material is also disclosed. The high magnetic reluctance material is used to isolate the magnetic circuit and fill and connect it to strengthen its mechanical properties; (see relevant prior applications).

[0063] A schematic diagram of a linear motor based on radially physical space non-co-phase winding shifting and slot-crossing is shown. The stator core, with its convex and concave shapes, enhances heat dissipation. Furthermore, its internal space contains channels for cooling media (water or oil, etc.), and both the channel and the corresponding cooling media are made of high magnetic reluctance materials. Two different phase windings are shifted radially in physical space to achieve non-crossing slot-crossing, significantly reducing the complexity of the winding configuration. This allows the co-phase windings to be designed as concentric circle windings, or the concentric windings can be designed with different axial dimensions corresponding to the core from the inside out, enabling the end windings to also participate in electromagnetic operations and become the motor's power output windings.

[0064] In addition, the core slots where the phase windings are located in the non-air gap adjacent region can be designed as heterogeneous slots as needed in order to eliminate or weaken the cogging torque.

[0065] Similarly, other pole numbers are also possible, such as 8 poles and 72 slots, as well as fractional slots. This scheme is particularly ingenious for distributed windings. It may increase iron loss slightly, but the cost is greatly reduced, copper loss is decreased, and it becomes an effective winding, improving efficiency. The difficulty of winding formation is greatly reduced. Moreover, as long as the core magnetic circuit is designed reasonably using finite element analysis, increasing the local core cross-section can achieve the effect of not increasing iron loss. This is because the core magnetic circuit of the recessed winding is very wide, since there is no winding in the middle, so it can be very wide. Of course, leakage flux and short circuit problems need to be considered. In short, its magnetic reluctance is smaller than that of other areas, so the magnetic reluctance of the recessed winding may not necessarily be large. Moreover, this is more conducive to arranging heat dissipation channels and eliminating cogging torque. The slot opening can be designed as an oblique shape to eliminate cogging torque.

[0066] The concentric circle wiring method can be used, and there is no crossover problem of cross-slot windings;

[0067] It can be pushed and swung to the top of the inner hole of the iron core for rotor assembly;

[0068] If adjacent windings interfere, they can be misaligned by increasing their axial dimensions. In other words, the best solution to resolve interference is to lengthen the winding axially, i.e., increase the axial dimension of the end winding. Minimize the end dimensions as much as possible, which can be achieved by radially offsetting the end windings vertically. Note the assembly sequence of the windings enclosed in the middle. The middle windings without curved bridges should be assembled in the middle process. Just pay attention to the assembly sequence.

[0069] Generally speaking: For phases AB (XY phases in the attached diagram), phase A adopts a bridge-type configuration to make room for phase B, so phase B adopts a direct planar U-shaped configuration. Alternatively, the two can be interleaved, i.e., cross-leaving, both of which involve bridge-arch type and planar type. The general principle is to achieve mutual misalignment through bridge-arch type and axial offset to complete the wiring of all windings with the minimum axial winding size. This end winding is similar to a heat sink, so it has good heat dissipation and can be appropriately narrower than the internal winding while maintaining the same conductivity. However, if space allows, it is better to make it larger to reduce end resistance and increase heat dissipation area.

[0070] If the two phases bend vertically and wrap around each other, the axial dimension can be minimized. However, the resistance will increase because the length increases. Therefore, from an efficiency point of view, it is better to design according to the principle of shortest length. Bridge arch and planar types can be used interchangeably to achieve the shortest length, the lowest resistance, the best heat dissipation, or the shortest axial end winding dimension.

[0071] All similar designs in this patent can be cross-combined to achieve optimal slot fill factor, short end windings, low skin effect, low resistance, simple wiring process, low cost, and good heat dissipation! Excellent insulation.

[0072] Depending on the electromagnetic conversion requirements and the characteristics such as speed and torque, series, parallel, or multiple series-parallel combinations can be used.

[0073] Note: The above design principles also apply to external rotor motors, dual rotor motors, and axial flux motors. For axial flux motors, different phase windings can be axially shifted and misaligned. At the same time, the space freed up by the axial shift can be designed as a heat dissipation channel to achieve the same multi-benefit effect as radial flux motors.

[0074] This specific implementation plan can be implemented for DC brushed motors, DC brushless motors, permanent magnet synchronous motors, and induction asynchronous motors. Due to the multi-disc complementary effect, the number of rotor and stator pole pairs can be equal, which can increase the density of stator-rotor interaction force points per unit space, increase the density of electromagnetic torque or magnetic reluctance torque, and use square waves instead of sinusoidal current. By using timely transient power cut-off in the square wave commutation and crossing region, negative torque can be effectively eliminated. The above comprehensive measures can greatly improve the power density of the motor.

[0075] The core innovation of this scheme lies in its use of the "physical space shifting phase splitting method," which allows the use of DC, square wave, or single-phase AC to replace three-phase AC. Furthermore, it addresses the issue of "mid-range transition" when the mechanical phase relationship of the electromagnetic force-acting elements (windings and permanent magnets) enters the "torque zero region" (where the forces of the windings and magnets enter a region of zero torque or balanced cancellation of forces on both sides). This is perfectly resolved through timely power-off and dual-disk phase complementarity. Timely power-off also completely eliminates the negative torque effect and saves energy. It ensures that the number of rotors and stators is equal, significantly increasing the power density of the interaction force points between the rotor and stator, maximizing the power potential of each electromagnetic force-acting element (windings and permanent magnets) within a unit space, and improving power density.

[0076] Note: The physical space split phase method or the disk split phase method mentioned above does not actually perform phase shifting and split phase on the current waveform. Instead, it is a complementary split phase in the torque range to obtain a stable and sustainable torque output. The split phase of the current or the commutation of the current direction or the waveform shift is achieved by capturing the rotor position with a brushed or brushless commutator to change the current direction in time for commutation, or it can also be called phase shift (e.g., phase change of a square wave), or by changing the current phase through an external controller.

[0077] The "physical space rotation angle phase splitting method," "winding slot phase current waveform condensation method," "2 times relative speed method," and "bidirectional magnetic flux method" are applicable to all types of motors, including: DC brushed motors, DC brushless motors, permanent magnet synchronous motors, induction asynchronous motors, switched reluctance motors, etc.; or, motors designed using all of the above methods and their combinations can be radial flux motors or axial flux motors; or, they can be stator-based dual-rotor motors, such as dual-rotor motors with fixed windings on both inner and outer sides, or dual inner rotors, dual outer rotors, or inner and outer rotors, or multi-rotor motors, such as: dual-rotor synchronous-asynchronous motors, squirrel-cage dual-rotor motors, counter-rotating dual-rotor motors, permanent magnet brushless dual-rotor motors, etc. The individual use or combined use of the above methods are all within the scope of this patent protection.

[0078] This motor can function as either an electric motor or a generator. When used in a generator, it can significantly increase power density.

[0079] Load speed regulation scheme description:

[0080] The aforementioned motors can be speed-regulated by load (DC brushed / brushless motors, AC induction asynchronous motors, and switched reluctance motors and rotor phase closed-loop permanent magnet synchronous motors with position feedback control via detection devices can be speed-regulated by load, while open-loop controlled permanent magnet synchronous motors are not suitable). Therefore, a multi-speed transmission can be used to change the gear ratio, thereby changing the motor load to achieve load-based speed regulation. This eliminates the need for complex motor control systems such as frequency converters. To allow the motor to adapt to a wider load-based speed regulation range, the voltage can be changed. For example, a tap-type power supply scheme can be used for the battery, and different input voltages can be obtained by switching the battery taps. For example, different voltages such as 20V, 50V, 100V, 200V, 400V, 600V, and 800V can be provided to the motor, allowing for a wider load-based speed regulation range. This ensures that the motor operates in its most efficient range while meeting the needs of all road conditions.

[0081] This dual-disc motor principle also applies to axial flux motors; counter-rotating dual-rotor motors; and internal and external dual flux types.

[0082] Axial flux motors can refer to the relevant solutions in the prior application, namely: arranging two or more relatively independent axial flux windings and permanent magnets (or non-permanent magnet current excitation windings) according to the corresponding phase difference angles, and controlling them according to the complementary waveform relationship, can achieve the same effect. Since the axial force of the axial flux motor is very large, it is basically used in the form of double disks or multiple disks to balance the axial force. Moreover, the axial flux motor has the characteristic of short axial dimension. Therefore, it is more advantageous to use the double disk or multiple disk scheme described in this patent application to design a compact high power density motor.

[0083] It can be a single-rotor or dual-rotor motor, as well as a dual-rotor motor with magnetic flux on both sides and a counter-rotating dual-rotor motor.

[0084] Its electromagnetic wires can be round or flat; the current waveform can be: square wave, square wave + composite wave, or sine wave;

[0085] Regarding the method of introducing rotor winding current from the outside for dual-rotor motors, please refer to the prior applications (202211030428.1 Dual-rotor motor current dynamic and static physical ports, 202211098410.5 Constant reluctance rotary transformer and core design and manufacturing method) and the related solutions below.

[0086] The above solution can also be used for conventional single-rotor motors, such as replacing existing brushless or brushed solutions.

[0087] Note: The above solution applies to all types of electric motors and generators, including asynchronous motors, synchronous motors, brushless motors, brushed motors, induction motors, permanent magnet motors, switched reluctance motors, etc.

[0088] The three-phase wires mentioned above can be the input / output harness terminals of a three-phase motor, a three-phase induction asynchronous motor, a brushless DC motor, or a permanent magnet synchronous motor.

[0089] Alternatively, the dynamic and static port connection method described in this article can also be a sliding brush method, or a sliding carbon brush solution that is easy to replace.

[0090] Note: The terms used for the dynamic and static physical ports in this article are relative and interchangeable in practice. The terms for inner and outer rotors are relative and have interactive mechanical properties, and they can be used interchangeably as inner and outer rotors.

[0091] Note:

[0092] The part numbering in the attached drawings uses the same numbering for common parts in different drawings, while different numbering is used for related equivalent functional parts in specific drawings. This is entirely to help the instruction manual to more clearly and accurately describe their working principles.

[0093] All design ideas, structures, methods, and theories presented in this document can be used to guide design. The technical content disclosed in its design theories, methods, implementation models, structures, schematic diagrams, structural diagrams, simplified diagrams, mechanism diagrams, and specific embodiments can be used to design and manufacture various types of engine devices. The implementation mechanisms listed in this patent are typical examples; not all specific facility schemes and mechanism types are listed here. Any cross-reorganization, mutual reference, combination, or arrangement of design theories, ideas, methods, models, mechanisms, or components disclosed in this document, as well as various application examples of this technical category, fall within the scope of this intellectual property protection. Any unauthorized use of these principles in design or application constitutes infringement. For example, the relevant design theories and methods are applicable to traditional electric motors, generators, and other similar power sources.

Claims

1. A method for designing and manufacturing a second-order three-phase end winding, including motor windings, stator, rotor, and housing, characterized by: The use of an ultra-flat wire cross-section structure with a large aspect ratio makes the flat wire as flexible as conventional round wire. It can be assembled by inserting from the stator winding slot, eliminating the complex processes such as opening welding in current flat wire manufacturing and improving the skin effect of the winding. This invention discloses a process design and manufacturing method for a second-order three-phase end winding. This invention further improves upon prior applications and existing motors, particularly the "process design and manufacturing method for an internally cooled, heat-exchange-type second-order three-phase winding motor." It unifies the "in-slot windings" (specifically referring to the traditional in-slot windings; the end windings in this application are also in the slots, but for ease of explanation, this paper still uses the traditional terminology to define end windings and in-slot windings) of the high and low order windings in the prior applications into the same radial space. That is, all "in-slot windings" are evenly distributed in the same diameter region concentric with the air gap. Only the end windings are divided into high-order and low-order end windings, further optimizing motor performance. It also possesses the advantage of the end windings participating in excitation with equivalent function to the in-slot windings, and the end windings have better heat dissipation and thermal conductivity. Furthermore, there is no crossover issue between windings of different phases, greatly improving the winding withstand voltage safety and simplifying the winding forming process. Generally speaking, the types are mainly divided into: M-type windings with low-order end windings and N-type windings with high-order end windings; in addition, they can also be divided into: N-type windings with E-type high-order end windings and N-type windings with F-type high-order end windings, which correspond to different types of E-type stator cores and F-type stator cores; consistent with the winding classification and wiring principle of the earlier application "Process Design and Manufacturing Method of Internal Cooling Heat Exchange Two-Order Three-Phase Winding Motor", each phase winding of the U, V, and W three-phase windings will be alternately located in the high and low order regions. Each phase winding of the U, V, and W three-phase windings in this application will alternately have M-type windings with low-order end windings and N-type windings with high-order end windings; see attached figures 24-27 for a detailed wiring diagram; the equivalent inductance and resistance of each phase winding can be obtained; Note: For ease of drawing and description, the bends of the windings in the accompanying drawings of this patent application are all right-angle bends. In practical applications, rounded bends can be used for a natural transition, and the depth of the hollowing-out area at the end of the iron core should be minimized to improve the magnetic flux density distribution of the iron core. In addition, the fully embedded process of the end iron core and the end winding described above can be a similar hollowing-out process. In practical applications, the iron core laminations in the end area are generally pre-designed into specific shapes and then stacked to present the corresponding concave and convex shapes that fully match and fit the shape of the end winding. Alternatively, the convex and concave irregular end iron cores corresponding to the end windings can be installed separately from the main iron core stator in a later stage. That is, they can be installed before the windings are installed, or they can be inserted after the windings are installed. In addition, in order to minimize eddy currents, the direction of the iron core laminations corresponding to the end windings should be as close as possible to the magnetic circuit axis to ensure that eddy current iron losses are minimized. In addition, for the convenience of drawing and description, the windings in the three-dimensional views in the accompanying drawings of this application are all drawn using linear array or circular array to concisely represent their overall structural form. In actual wiring, this is to realize the series and parallel relationship according to the circuit method. For specific wiring diagrams, please refer to Figures 24-28. Alternatively, the winding can also be made using a similar hairpin flat wire process (H-PIN), forming an independent, non-closed, single-sided opening. After insertion into the iron core, the other side is overlapped or welded and then treated with varnish or potting insulation. The difference is that the winding shape in this scheme is basically a standard rectangle. The end winding can be tightly fitted to the iron core to participate in excitation and become an effective winding. The non-welded side can fit perfectly with the iron core without any dead angles, fully utilizing the end winding's function of participating in excitation. The welded side can also be bent into a standard rectangle before butt welding or bent at an angle for butt welding (this can be butt welding with the end faces facing each other, or welding after staggered overlap at the ends, or using a mechanical pre-pressure contact electrical connection method after staggered overlap; or...). (This can be achieved by bending the wire at a 90-degree angle or other angles in the welding area before butt welding or by using mechanical pre-tightening to achieve electrical connection). In short, the welded side can also fit well with the iron core, allowing the end winding to participate in the excitation work. Moreover, since there is no problem of cross-slot proximity effect between different phases of the traditional winding, the same type of hairpin winding can be inserted synchronously at one time, which not only improves assembly efficiency but also reduces the risk of damage to the insulation layer caused by frequent interlocking and relative friction between adjacent windings. It can also further improve the density, increase the slot fill factor and thermal conductivity, and reduce electromagnetic noise. The voltage of adjacent windings basically decreases in a gradient, which can improve the withstand voltage safety level. Alternatively, the insulation layer thickness of the electromagnetic wire can be reduced, which is equivalent to increasing the slot fill factor. Alternatively, since this scheme does not involve the complex process of cross-wiring and misalignment of different phase windings, each phase winding is cyclically wound in its own trajectory area and arranged neatly. Therefore, the winding can also be wound back and forth two or more turns from both sides of the stator slot opening in a large looping manner before welding, so as to reduce the number of solder joints, or even the entire winding can be wound as a whole before finally entering the busbar for welding, which is equivalent to the distributed winding realizing the centralized winding process. Alternatively, the super-flat wire conductor layer and insulation layer separation and post-synthesis process disclosed in this series of applications can be adopted to use a more heat-resistant insulation layer, improve the high-temperature resistance of the winding, and at the same time, the conductor layer is bare copper, aluminum or other conductors, further reducing the cost of winding raw materials and process costs, and improving the yield rate; Note: In the current scheme, windings of different phases do not cross, and windings of the same phase are also arranged neatly and regularly. This configuration is conducive to the use of conductor layer and insulation layer separation and post-synthesis or online synthesis (online synthesis on the production line directly enters the winding for mutual shaping or further potting and curing shaping); In this scheme, the slot on the air gap side of the iron core can be made into a semi-open slot or a closed slot. In addition, to simplify the installation process, this solution can generally make open slots. All windings can be pre-wound and formed before being embedded into the slots through radial open slots. Alternatively, the open slots can be filled with closed slots or semi-open slot elements after the winding assembly is completed, or they can be synthesized by casting. See Figure 29 (for details, see prior application 202310792777.5, A Split Embedded Magnetic Circuit Optimization Design Process). Alternatively, ultra-flat wire can be used to slide into the slot (Note: When ultra-flat wire slides into the slot from the slot opening, it needs to be twisted at an angle and slid in at an angle. Therefore, the last layer or several layers of windings located at the edge of the slot opening can be inserted from the side, or it can be inserted back and forth around the slot opening from the side, or it can be cut into independent winding layers and installed and welded in a manner similar to hairpin flat wire; or, the remaining space near the slot opening can be left as a heat dissipation channel without adding windings, as can be seen in the prior application, which can also eliminate the slot opening effect problem), similar to the winding unwinding process of current round wire motors. Alternatively, the transition bend between the slot winding and the end winding of the ultra-flat wire can also be a 45-degree folding bend process. Alternatively, in order to reduce the impact of the stack thickness after folding, a staggered process with different axial dimensions can be adopted to reduce the increase in the radial dimension of the winding stack caused by folding. The windings can also adopt a parallel winding scheme to improve the high current carrying capacity. Alternatively, the series and parallel connection relationship of the windings can be changed in a timely manner to obtain different back EMFs and thus meet the high efficiency operation in different speed ranges. Alternatively, there is even a solution where the winding is inserted through openings on both sides and then soldered, such as I-PIN, H-PIN, X-PIN, W-PIN, etc. Alternatively, radial flux and axial flux motors can also use windings similar to W-PIN. Round wire, flat wire, or round wire can be pre-formed using a W-PIN winding bending process before being extruded into flat wire. This makes bending easier and avoids the difficulty of forming flat wire during vertical bending. Bending and then extruding into flat wire improves slot fill factor, enhances thermal conductivity, and reduces tip discharge. Alternatively, to prevent plastic deformation during extrusion from damaging the insulation film, bare copper can be bent and then extruded into flat wire before insulation treatment. This can be achieved using an impregnation process or an insulation film isolation process. See the previous applications in this series on "ultra-flat wire" for related content. Separating the conductor and insulator and then synthesizing them later has advantages such as reducing the space ratio of the insulation film and allowing the use of more high-temperature resistant materials for the insulation film to improve the overall temperature resistance of the motor. Note: Related text and figures in this section can be found in the relevant previous applications. Alternatively, the axial flux motor type produced by stamping can also adopt an end winding shape similar to X-PIN, which can reduce the size of the end winding. Pressure butt welding or soldering can be used without affecting its electrical connection characteristics. Alternatively, the winding mother-daughter layer scheme of the axial flux motor type can also adopt a transverse or longitudinal arrangement, i.e., transverse insertion or longitudinal insertion. If longitudinal insertion is adopted, I-PIN, H-PIN or X-PIN configurations can be preferred, and electrical connection can be achieved by immersion soldering or pressure butt welding. Note: The relevant text and figures in this paragraph can be found in the relevant prior applications. In addition, this solution is applicable to round wire motors, conventional flat wire motors, ultra-flat wire motors of this series of applications, as well as all types of external rotor radial flux motors and axial flux motors; As shown in Figure 30, if used in an axial flux motor with the winding in the middle and the rotor on both sides, the middle winding core can be divided into two halves along the vertical plane of the centering axis. In this way, the slots on the air gap side of the two halves of the stator core can be closed slots or semi-open slots. The winding can be pre-formed, and the stator can be joined from both sides. This ensures that the winding has no solder joints, similar to a continuous wave winding, and also solves the problem of open slots, becoming closed slots to improve motor performance. Note: The joined two halves of the stator core can be locked mechanically, or they can be mainly attracted by electromagnetic force. Because the direct contact at the middle joining point is equivalent to zero air gap, while the two sides are air gaps, the electromagnetic attraction force in the middle is much greater than that on the air gap side, which can stably attract and ensure safe and reliable operation. This mechanical locking method can be an auxiliary solution. Similarly, this application adopts a slot-crossing wiring process design method for non-in-phase windings in the physical space of the end windings, which effectively solves the problem of winding slot crossing. This not only greatly simplifies the integrated wiring forming process of the entire winding, shortens the size of the end windings and reduces the ineffective waste of electromagnetic wires, but also allows the end windings to participate in effective excitation, reducing leakage flux and improving efficiency. Furthermore, it allows for relative separation of different phase windings, improving the voltage withstand safety of the motor windings, and optimizing the motor's heat dissipation. Compared with prior applications, this method uses two-order (high-order, low-order, or inner and outer two-layer misalignment) to meet the slot-crossing wiring requirements of three-phase windings. Specific wiring schemes are shown in Figures 24-27 (wherein: in Figure 24, the dotted-dashed windings represent high-order windings; the dashed windings represent low-order windings; clearly, in this scheme, in-phase windings will be located in different order winding slots, but...). This does not affect cross-slot wiring; in Figures 25-27, different line types represent different phase windings, divided into three phases A, B, and C. The letters A, B, C, and C followed by numbers represent windings in different slot areas. This numbering is for the purpose of corresponding analysis and interpretation with Figure 24. In Figures 25-27, the longer end windings represent higher-order windings, and the shorter end windings represent lower-order windings. It is evident that in this scheme, the windings of the same phase are alternately arranged in the slots of higher-order and lower-order windings. However, as long as the end windings are arranged reasonably so that all end windings are close to the stator core and the wiring is properly routed to ensure that the current direction of the end windings is consistent with the excitation direction of the windings in the slot, a unified positive superposition and enhanced excitation magnetic field can be formed. This can transform the function of the end windings into effective windings. That is, the end windings are not only for connecting wires but also play the role of excitation together with the windings in the slot, thereby improving motor efficiency. Also note: It is necessary to ensure that the inductance of each phase winding is the same to eliminate circulating current; or, the end windings at both ends of the same winding can be designed with different high and low order structures, that is: the left end winding is designed with a low order structure and the right end winding is designed with a high order structure. This makes it easier to ensure the equal inductance and equal resistance characteristics of all windings. In addition, to improve the assembly efficiency of windings in series, multi-layer series windings can be first assembled in parallel as a whole, and then the ends of each layer of windings can be connected in series or welded in sequence to make their electrical connection relationship present as a series relationship. As shown in Figure 28, it is a schematic diagram of the series connection of ultra-flat wire windings of the same phase. The arc area represents the schematic diagram of U-shaped bending jumper wire. In actual connection, parallel connection, vertical connection or angled connection can be adopted. Alternatively, they can be wound in parallel or partially wound in parallel; or wound in parallel in the same layer and connected in parallel to increase the ability to conduct large currents. This is beneficial to reduce iron loss, improve efficiency and reduce volume and weight. Note: This scheme is also applicable to the design method of motor architecture based on three-wire four-phase wave, which allows different phase windings to be arranged in high-order and low-order slots respectively, and can be wired using dragon-shaped windings, see prior application. Note: For external rotor motors, it is recommended that the external rotor output power via a hole structure. This is because the structural relationship between the external rotor and the inner stator is equivalent to a hole-shaft relationship, while the conventional structural relationship between the inner rotor and the outer stator is a shaft-hole relationship. That is, the inner rotor is the shaft and the outer stator is the hole. Therefore, it is more suitable for the inner rotor to output power via a shaft, but it is more reasonable for the outer rotor to output power via a hole structure. Specific structural solutions can include a hollow shaft structure, with output power via a flange or gear / sprocket transmission relationship; or a planetary gear structure to output power flow. Alternatively: The above scheme is also applicable to axial flux motors, see attached diagram; it is also divided into concentrated winding and distributed winding schemes; all of them can be improved into ultra-flat wire winding structures using the above scheme. Its single-layer copper strip can be composed of several parallel copper strips with the smallest possible gaps, or it can be made using micro-hole drilling. The circumferential ultra-flat wire adopts an assembly scheme from the tooth groove gap, which can fill the remaining gap by inserting a rectangular flat wire or a round wire at the end. Its principle applies to most types of motors, including DC motors, AC motors such as permanent magnet motors and switched reluctance motors, as well as induction motors and hysteresis motors. The input current waveform of the motor can be: when the motor is transformed into an engine, the induced current waveform generated by driving the motor windings with stable torque at a constant speed can guide the design of its control current waveform. In other words, if the control current waveform of any motor is the same as the current waveform generated when the motor is driven to rotate with constant torque and constant angular velocity as a generator, then the output torque of the motor as a motor must be constant. This method can be called the "energy reverse measurement simulation method" and can be used as a guide for optimizing the control current waveform of a motor. It is applicable to any type of motor. The design method based on the physical space non-phase winding shifting and slot-crossing process effectively solves the winding slot-crossing problem. This not only greatly simplifies the integrated winding forming process of the entire winding, shortens the size of the end winding, reduces the ineffective waste of electromagnetic wire, but also allows the end winding to participate in effective excitation, reducing leakage flux and improving efficiency. Furthermore, it separates the windings of different phases, improving the voltage withstand safety of the motor windings, and optimizing the motor's heat dissipation. It is especially suitable for motor architecture design methods based on three-wire four-phase waves, which can reduce one phase winding, further simplify the process, and improve the radial compactness of the convex and concave iron core. The method employing a physical space-based non-in-phase winding shifting and slot-crossing wiring design effectively solves the winding slot-crossing problem. This not only significantly simplifies the integrated wiring forming process of the entire winding, shortens the size of the end windings to reduce ineffective electromagnetic wire waste, but also allows the end windings to participate in effective excitation, reducing leakage flux and improving efficiency. Furthermore, it separates different phase windings, improving the motor winding withstand voltage safety and optimizing motor heat dissipation. Compared to prior art, this method only requires two-order (high-order, low-order, or inner and outer two-layer misalignment) to meet the requirements of three-phase windings. The cross-slot winding routing is shown in Figures 14-17 for specific routing schemes (wherein, the dotted-dashed windings in Figure 14 represent higher-order windings; the dashed windings represent lower-order windings; it is evident that in this scheme, windings of the same phase will be located in different order winding slots, but this does not affect the cross-slot routing; in Figures 15-17, different line types represent different phase windings, divided into three phases A, B, and C, with the letters A, B, C, and numbers following them representing windings in different slot regions. This numbering is for the purpose of corresponding analysis and interpretation with Figure 14. Among them, the end windings in Figures 15-17 are longer). The windings represent higher-order windings, and the shorter end windings represent lower-order windings. Clearly, in this scheme, the in-phase windings are alternately arranged in the slots of higher-order and lower-order windings. However, by properly arranging the end windings so that all end windings are close to the stator core and by ensuring proper wiring to guarantee that the current direction of the end windings is consistent with the excitation direction of the windings in the slots, a unified positive superposition and enhanced excitation magnetic field can be formed. This transforms the end windings into effective windings; that is, the end windings not only serve as connecting wires but also function as excitation windings along with those in the slots, improving motor efficiency. Additionally, see Figure 18. This is a schematic diagram of the series connection of ultra-flat wire windings of the same phase. The arc area represents the schematic diagram of the U-shaped bend jumper. In actual connection, parallel connection, perpendicular connection, or angled connection can be adopted. Alternatively, they can be wound in parallel or partially in parallel; or wound in parallel on the same layer (connected in parallel to increase the ability to conduct large currents). This is beneficial to reduce iron loss, improve efficiency, and reduce volume and weight. Note: This scheme is also applicable to the motor architecture design method based on three-wire four-phase wave, which allows high-order and low-order slots to be arranged with different phase windings. Dragon-shaped windings can be used for wiring. See the prior application. Furthermore, this application also discloses a schematic diagram of a composite permanent magnet rotor core structure filled with high magnetic resistance and high strength reinforcing material. The high magnetic resistance material is used to isolate the magnetic circuit and fill and connect it to strengthen the mechanical properties.

2. The method for designing and manufacturing a second-order three-phase end winding according to claim 1, characterized in that: Figure 1-10: Explanatory diagram of M-type winding with low-order end winding, N-type winding with E-type high-order end winding, and E-type stator core assembly. Figure 11-17: Explanatory diagram of M-type winding with low-order end winding, N-type winding with F-type high-order end winding, and F-type stator core assembly. Figure 18-23: Explanatory diagram of M-type winding with low-order end winding, N-type winding with F-type high-order end winding, and lightweight F-type stator core assembly. Figure 24: Wiring diagram of a second-order three-phase winding motor Figures 25, 26, and 27: Analytical diagrams of the three-phase winding wiring plan of a second-order three-phase winding motor. Figure 28. Schematic diagram of series connection of in-phase ultra-flat wire windings (parallel winding or partial parallel winding is also possible; or parallel winding in the same layer, and parallel connection to increase the ability to conduct large currents). Figure 29. Schematic diagram of the optimized design structure of stator core slot opening. Figure 30. Schematic diagram of the combined iron core of the axial flux motor. in:

1. M-type winding with low-order end winding 2. N-type winding containing E-type higher-order end windings 3. Type E stator core 4. Schematic diagram of stator core made of thin laminations (For the sake of simplicity, the lamination structure of the core is not shown in this application).

5. N-type winding containing F-type higher-order end windings 6. Type F stator core 7. Lightweight F-type stator core (the outer core is removed, which reduces weight and increases the heat dissipation surface area) 8. Stator winding core chuck 9. Stator winding core teeth 10. Stator winding core slot section 11. Winding (flat wire winding) 12. Split-type embedded flared toothed block (Type A) 13. Split-type embedded flared toothed block, type B 14. Split-type embedded flared toothed block (C-shape) 15. Type A toothed block magnetic guide block area 16. Non-magnetic block area of ​​type A tooth block 17. Type B tooth block magnetic guide block area 18. Non-magnetic block area of ​​type B tooth block 19. C-type toothed block magnetic guide block area 20. C-type tooth block non-magnetic block area 21. Split iron core on the left side of the axial flux motor 22. Split iron core on the right side of the axial flux motor 23. Axial flux intermediate winding.

3. The method for designing and manufacturing a second-order three-phase end winding according to claim 1, characterized in that: This invention discloses a design and manufacturing method for a non-in-phase winding cross-slot wire assembly process based on physical space displacement. This invention further improves upon prior applications and existing motors by employing a design method based on a non-in-phase winding cross-slot wire assembly process in physical space. This effectively solves the problem of winding cross-slots, significantly simplifying the integrated wire assembly forming process of the entire winding, shortening the size of the end windings to reduce ineffective waste of electromagnetic wires, and allowing the end windings to participate in effective excitation, reducing leakage flux and improving efficiency. It also allows for relative separation of different phase windings, improving the voltage withstand safety of the motor windings, and optimizing the motor's heat dissipation. It is particularly suitable for motor architecture designs based on three-wire four-phase waves, reducing one phase winding and further simplifying the process, while improving the radial compactness of the convex and concave iron core. Alternatively, the winding slots closest to the air gap can be moved outward to create a cooling space. This way, all windings have dedicated cooling systems, and all windings are isolated from the rotor permanent magnets by a heat dissipation system. This further reduces the temperature in the permanent magnet area, making it significantly lower than that in the winding area. Ultra-flat wires can maintain normal operation even at temperatures exceeding 260°C. Therefore, this facility that adds a heat dissipation barrier between the windings and the permanent magnets will further enhance the overload capacity of ultra-flat wires. For vehicle operating conditions, overload conditions are not normal operating conditions, so efficiency at this time can be disregarded. This allows us to further reduce the size of the motor. Under overload conditions, ultra-flat wire motors have superior long-term overload capacity to meet the requirements of these operating conditions. Alternatively, to reduce leakage flux, enhance the excitation capability of the end windings, and increase the heat dissipation capacity of the end windings and the core, the areas with end windings at both ends of the convex and concave core can be designed as core areas. The core thickness is determined by the magnetic flux density generated by the end windings to ensure a reasonable magnetic flux density distribution. Alternatively, to reduce eddy currents, the core can be designed as radially laminated or in other axially laminated configurations (refer to prior applications). Note: To minimize weight, the addition of cores on both sides is only for the areas with end windings. Following the dragon-shaped winding configuration, where the end windings are discontinuous on both sides, the added cores at the ends are designed in the same way. Areas without end windings still follow the convex and concave core structure of the middle area to minimize core usage, reduce costs, and lighten weight. Alternatively, irregularly shaped cores can be filled between the end windings and the core to allow the magnetic field of the end windings to effectively participate in the overall excitation circuit, reducing leakage flux, improving motor efficiency and power density, and simultaneously enhancing the heat dissipation capacity of the end windings. Figures 1 and 7 simultaneously disclose a schematic diagram of a composite permanent magnet rotor core structure filled with high magnetic reluctance and high strength reinforcing material. The high magnetic reluctance material is used to isolate the magnetic circuit and fill and connect it to strengthen the mechanical properties; (see relevant prior applications); A schematic diagram of a linear motor based on radially physical space non-co-phase winding shifting and slot-crossing is shown. The stator core, with its convex and concave shapes, enhances heat dissipation. Furthermore, its internal space contains channels for cooling media (water or oil, etc.), and both the channel and the corresponding cooling media are made of high magnetic reluctance materials. Two different phase windings are shifted radially in physical space to achieve non-crossing slot-crossing, significantly reducing the complexity of the winding configuration. This allows the co-phase windings to be designed as concentric circle windings, or the concentric windings can be designed with different axial dimensions corresponding to the core from the inside out, allowing the end windings to also participate in electromagnetic operations and become the motor's power output windings. In addition, the core slots where the phase windings are located in the non-air gap adjacent region can be designed as heterogeneous slots as needed in order to eliminate or weaken the cogging torque. Similarly, other pole numbers are also possible, such as 8 poles and 72 slots, as well as fractional slots. This scheme is particularly useful for distributed windings. It may increase iron loss slightly, but the cost is greatly reduced, copper loss is decreased, and it becomes an effective winding, improving efficiency. The difficulty of winding formation is greatly reduced. Moreover, as long as the core magnetic circuit is designed reasonably using finite element analysis and the local core cross-section is increased, the effect of not increasing iron loss can be achieved. This is because the core magnetic circuit of the recessed winding is very wide, since there is no winding in the middle, so it can be very wide. Of course, leakage flux and short circuit problems need to be considered. In short, its magnetic reluctance is smaller than that of other areas, so the magnetic reluctance of the recessed winding may not necessarily be large. Moreover, this is more conducive to arranging heat dissipation channels and eliminating cogging torque. The slot opening can be designed as an oblique shape to eliminate cogging torque. The concentric circle wiring method can be used, and there is no crossover problem of cross-slot windings; It can be pushed and swung to the top of the inner hole of the iron core for rotor assembly; If adjacent windings interfere, they can be misaligned by increasing their axial dimensions. In other words, the best solution to resolve interference is to lengthen the winding axially, i.e., increase the axial dimension of the end winding. Minimize the end dimensions as much as possible, which can be achieved by radially offsetting the end windings vertically. Note the assembly sequence of the windings enclosed in the middle. The middle windings without curved bridges should be assembled in the middle process. Just pay attention to the assembly sequence. Generally speaking: For phases AB (XY phases in the attached diagram), phase A adopts a bridge-type configuration to make room for phase B, so phase B adopts a direct planar U-shaped configuration. Alternatively, the two can be interleaved, i.e., cross-leaving, both of which involve bridge-arch type and planar type. The general principle is to achieve mutual misalignment through bridge-arch type and axial offset to complete the wiring of all windings with the minimum axial winding size. This end winding is similar to a heat sink, so it has good heat dissipation and can be appropriately narrower than the internal winding while maintaining the same conductivity. However, if space allows, it is better to make it larger to reduce end resistance and increase heat dissipation area. If the two phases bend vertically and wrap around each other, the axial dimension can be minimized. However, the resistance will increase because the length increases. Therefore, from an efficiency point of view, it is better to design according to the principle of shortest length. Bridge arch and planar types can be used interchangeably to achieve the shortest length, the lowest resistance, the best heat dissipation, or the shortest axial end winding dimension. All similar designs in this patent can be cross-combined to achieve optimal slot fill factor, short end windings, low skin effect, low resistance, simple wiring process, low cost, and good heat dissipation! Excellent insulation. Depending on the electromagnetic conversion requirements and the characteristics such as speed and torque, series, parallel, or multiple series-parallel combinations can be used. Note: The above design principles also apply to external rotor motors, dual rotor motors, and axial flux motors. For axial flux motors, different phase windings can be axially shifted and misaligned. At the same time, the space freed up by the axial shift can be designed as a heat dissipation channel to achieve the same multi-benefit effect as radial flux motors.

4. The method for designing and manufacturing a second-order three-phase end winding according to claim 1, characterized in that: The slot can be a conventional centering type or an offset type; or, a split iron core can be used, separating the toothed area of ​​the iron core from the yoke area, and making the split toothed area and the yoke area form a convex-concave interlocking structure, so that after the winding is combined with the split toothed area, the split toothed area is then inserted into the iron core yoke area as a whole; because this method allows for a tighter contact between the winding and the toothed area after the insertion assembly, after the assembly is completed, the winding and the toothed area form an interdependent relationship, which will further increase the integrated strength and rigidity of the winding toothed area. Therefore, the toothed area width can be further expanded, the size space of the filling winding can be increased, the power density can be increased, and the electromagnetic noise can be reduced; Alternatively, when using a split core design, the winding can be unfolded into a plane during assembly. The split slots and teeth can be combined with the winding, then bent and wound together to form a 360° overall circle before being inserted into the stator yoke to form an integrated stator winding. Alternatively, when the slot density is very high, the slot opening size of the integrated stator can be enlarged so that the slot opening size is the same as the slot width. In this way, there is no need to design the iron core separately, and the flat wire or ultra-flat wire winding can be inserted into the slot opening all at once. Its ultra-flat wire winding can be laid in two ways: concentric and lapped. Alternatively, it can be an external rotor structure, in which case the stator core opening faces outward, making wiring more convenient; Alternatively, by adopting the previously applied three-wire four-phase wave scheme, the number of phases in the winding will be reduced from three to two, which can further reduce wiring complexity and reduce end size; Alternatively, using existing flat wire windings can eliminate a series of complex processes such as hairpin forming, insertion, and welding. The above scheme is also applicable to the centralized winding scheme. The centralized winding scheme can change the round wire to the ultra-flat wire, which can also increase the slot fill factor and adopt the conductor and insulator separation scheme to improve the winding temperature resistance. In addition, since the ultra-flat wire has a large specific surface area and a large contact area, its heat conduction and heat dissipation efficiency is also better.

5. The method for designing and manufacturing a second-order three-phase end winding according to claim 1, characterized in that: Alternatively, the winding slot closest to the air gap can be moved outward to create a cooling space. This way, all windings have a dedicated cooling system, and all windings are isolated from the rotor permanent magnet by a heat dissipation system. This further reduces the temperature in the permanent magnet area, making it significantly lower than that in the winding area. Ultra-flat wires can maintain normal operation even at temperatures exceeding 260°C. Therefore, this facility that adds a heat dissipation barrier between the windings and the permanent magnet will further improve the overload capacity of ultra-flat wires. For vehicle operating conditions, overload conditions are not normal operating conditions, so efficiency at this time can be disregarded. This allows us to further reduce the size of the motor. Under overload conditions, ultra-flat wire motors have superior long-term overload capacity to meet the requirements of these operating conditions. Alternatively, to reduce leakage flux, enhance the excitation capability of the end windings, and increase the heat dissipation capacity of the end windings and the core, the areas with end windings at both ends of the convex and concave core can be designed as core areas. The core thickness is determined by the magnetic flux density generated by the end windings to ensure a reasonable magnetic flux density distribution. Alternatively, to reduce eddy currents, the core can be designed as radially laminated or in other axially laminated configurations (refer to prior applications). Note: To minimize weight, the addition of cores on both sides is only for the areas with end windings. Following the dragon-shaped winding configuration, where the end windings are discontinuous on both sides, the added cores at the ends are designed in the same way. Areas without end windings still follow the convex and concave core structure of the middle area to minimize core usage, reduce costs, and lighten weight. Alternatively, irregularly shaped cores can be filled between the end windings and the core to allow the magnetic field of the end windings to effectively participate in the overall excitation circuit, reducing leakage flux, improving motor efficiency and power density, and simultaneously enhancing the heat dissipation capacity of the end windings. A schematic diagram of a composite permanent magnet rotor core structure filled with high magnetic reluctance and high strength reinforcing material is shown. The high magnetic reluctance material is used to isolate the magnetic circuit and fill and secure it, thereby strengthening its mechanical properties. (See relevant prior applications for details.) A schematic diagram of a linear motor based on radially physical space non-co-phase winding shifting and slot-crossing is shown. The stator core, with its convex and concave shapes, enhances heat dissipation. Furthermore, its internal space contains channels for cooling media (water or oil, etc.), and both the channel and the corresponding cooling media are made of high magnetic reluctance materials. Two different phase windings are shifted radially in physical space to achieve non-crossing slot-crossing, significantly reducing the complexity of the winding configuration. This allows the co-phase windings to be designed as concentric circle windings, or the concentric windings can be designed with different axial dimensions corresponding to the core from the inside out, allowing the end windings to also participate in electromagnetic operations and become the motor's power output windings. In addition, the core slots where the phase windings are located in the non-air gap adjacent region can be designed as heterogeneous slots as needed in order to eliminate or weaken the cogging torque. Similarly, other pole numbers are also possible, such as 8 poles and 72 slots, as well as fractional slots. This scheme is particularly useful for distributed windings. It may increase iron loss slightly, but the cost is greatly reduced, copper loss is decreased, and it becomes an effective winding, improving efficiency. The difficulty of winding formation is greatly reduced. Moreover, as long as the core magnetic circuit is designed reasonably using finite element analysis and the local core cross-section is increased, the effect of not increasing iron loss can be achieved. This is because the core magnetic circuit of the recessed winding is very wide, since there is no winding in the middle, so it can be very wide. Of course, leakage flux and short circuit problems need to be considered. In short, its magnetic reluctance is smaller than that of other areas, so the magnetic reluctance of the recessed winding may not necessarily be large. Moreover, this is more conducive to arranging heat dissipation channels and eliminating cogging torque. The slot opening can be designed as an oblique shape to eliminate cogging torque. The concentric circle wiring method can be used, and there is no crossover problem of cross-slot windings; It can be pushed and swung to the top of the inner hole of the iron core for rotor assembly; If adjacent windings interfere, they can be misaligned by increasing their axial dimensions. In other words, the best solution to resolve interference is to lengthen the winding axially, i.e., increase the axial dimension of the end winding. Minimize the end dimensions as much as possible, which can be achieved by radially offsetting the end windings vertically. Note the assembly sequence of the windings enclosed in the middle. The middle windings without curved bridges should be assembled in the middle process. Just pay attention to the assembly sequence. Generally speaking: For phases AB (XY phases in the attached diagram), phase A adopts a bridge-type configuration to make room for phase B, so phase B adopts a direct planar U-shaped configuration. Alternatively, the two can be interleaved, i.e., cross-leaving, both of which involve bridge-arch type and planar type. The general principle is to achieve mutual misalignment through bridge-arch type and axial offset to complete the wiring of all windings with the minimum axial winding size. This end winding is similar to a heat sink, so it has good heat dissipation and can be appropriately narrower than the internal winding while maintaining the same conductivity. However, if space allows, it is better to make it larger to reduce end resistance and increase heat dissipation area. If the two phases bend vertically and wrap around each other, the axial dimension can be minimized. However, the resistance will increase because the length increases. Therefore, from an efficiency point of view, it is better to design according to the principle of shortest length. Bridge arch and planar types can be used interchangeably to achieve the shortest length, the lowest resistance, the best heat dissipation, or the shortest axial end winding dimension. All similar designs in this patent can be cross-combined to achieve optimal slot fill factor, short end windings, low skin effect, low resistance, simple wiring process, low cost, and good heat dissipation! Excellent insulation. Depending on the electromagnetic conversion requirements and the characteristics such as speed and torque, series, parallel, or multiple series-parallel combinations can be used.

6. The method for designing and manufacturing a second-order three-phase end winding according to claim 1, characterized in that: Figure 1. Analytical diagram of the structure of a second-order three-phase winding motor with internal cooling heat exchange. Figure 2-3. Exploded view of the stator of a second-order three-phase winding motor with internal cooling heat exchange (Figure 3 is a panoramic view, and Figure 2 is a partial enlarged view). Figure 4. Design and installation instructions for the guide plate installed in the heat dissipation channel on the radial inner side of the high-order winding slot of the internal cooling heat exchanger. Figure 5-6 shows the design scheme of the manifolds at both ends of the cooling channel from two perspectives (so that the cooling channel in the winding area can form a serpentine circulation channel). Figure 7. Plan view of the internally cooled heat exchanged second-order three-phase winding motor Figure 8-13: Plan view of stator core laminations of type 6 Figure 14: Wiring diagram of a second-order three-phase winding motor Figures 15, 16, and 17: Analytical diagram of the three-phase winding wiring plan of a second-order three-phase winding motor Figure 18. Schematic diagram of series connection of in-phase ultra-flat wire windings (parallel winding or partial parallel winding is also possible; or parallel winding in the same layer, and parallel connection to increase the ability to conduct large currents). Figure 19. Enlarged view of the design and installation instructions for the guide plate installed in the heat dissipation channel on the radial inner side of the high-order winding slot of the internal cooling heat exchanger. in:

1. Motor rotor shaft (the illustration uses an 8-pole permanent magnet rotor as an example) 2. Silicon steel core laminations (or other materials with high magnetic permeability) 3. Permanent magnet 4. High-resistivity magnetic material rotor center matrix (high strength, high temperature resistance, non-magnetic) 5. High-resistivity magnetic auxiliary reinforcement material (high temperature resistant, non-magnetic) 6. Left side of the inner ring cooling channel manifold end cap (the coolant inlet and outlet are usually designed on this side; see the two inlet and outlet pipes on the outer end face of the end cap) 7. First stator core lamination (numbered in order of the stator core from the outside to the inside) 8. Second stator core lamination 9. Third stator core lamination 10. Fourth stator core lamination 11. Intermediate stator core laminations 12-13. Coolant inlet and outlet of the outer ring cooling channel 14. Right side of the inner ring cooling channel manifold end cap (serves to connect and seal the entire inner ring cooling channel to form a serpentine cooling channel).

15. The third stator core lamination (the difference from 9 is that it is installed with the front and back reversed so as to connect and close the overall outer ring cooling channel to form a serpentine cooling channel).

16. Guide plate (Because the radial dimension of the heat dissipation channel on the inner side of the high-order winding slot is wide, but the radial dimension of the inlet and outlet on both sides of the inner ring cooling channel is narrow, a guide plate is added to allow the coolant to circulate throughout the entire space after entering, so as to fully exchange heat and absorb the heat of the iron core.) 17. Stator core fastening bolt holes 18. Higher-order winding slots (named after the winding slots that are farther from the air gap).

19. The heat dissipation channel with a wider radial dimension on the inner side of the higher-order winding slot is referred to as the higher-order heat dissipation channel (in order to reduce the magnetic reluctance of the higher-order winding magnetic circuit, the circumferential dimension of this channel should be smaller than the width of the higher-order winding slot in order to increase the magnetic flux cross-section).

20. Raised heat sinks inside the advanced heat dissipation channel (increases surface area and improves heat exchange efficiency; see enlarged view at the bottom of Figure 7) 21. Low-order winding slots (named after the winding slots closest to the air gap).

22. The heat dissipation channel with a narrower radial dimension on the inner side of the low-order winding slot is referred to as the low-order heat dissipation channel.

23. Raised heat sinks inside the low-level heat dissipation channel (increase surface area and improve heat exchange efficiency; see enlarged view at the bottom of Figure 7) 24. The outer ring has external heat sinks (which can exchange heat with the outside air or be cooled by adding external cooling media such as air or other media; that is, this area can also be closed to form a closed space to introduce cooling media such as cooling water, oil, or cold air).

25. Outer ring cooling channel (formed by combining the various shaped windows (26, 27, 28) on the second, third, and fourth stator core laminations with channel 25 on the middle stator core lamination). 29, 30: High-level heat dissipation channel with thin-walled isolation (which can both isolate and seal the coolant, and also act as a magnetic bridge to prevent magnetic leakage).

31. Low-level heat dissipation channel with thin-walled insulation 32, 33: Thin-walled, sealed partition walls on both sides of the advanced heat dissipation channel, which uses other non-ferrous core high magnetic resistance materials to isolate and seal the coolant.

34. Thin-walled, sealed partition walls on both sides of the low-order heat dissipation channel, which uses other non-ferrous core high magnetic resistance materials to isolate and seal the coolant.

35. High-order heat dissipation channels using independently spaced high magnetic resistance materials 36. Low-order heat dissipation channels made of high magnetic resistance material with independent spacers are used.

7. The method for designing and manufacturing a second-order three-phase end winding according to claim 1, characterized in that: The above design principles also apply to external rotor motors and axial flux motors. For axial flux motors, different phase windings can be axially shifted and misaligned. At the same time, the space freed up by the axial shift can be designed as a heat dissipation channel to achieve the same multi-benefit effect as radial flux motors. The process design and manufacturing method of the internally cooled heat exchanged second-order three-phase winding motor described above is applicable to ultra-flat wire, traditional flat wire and round wire windings.

8. The method for designing and manufacturing a second-order three-phase end winding according to claim 1, characterized in that: The core innovation of this scheme is the use of the "physical space shifting phase splitting method," which allows the use of DC, square wave, or single-phase AC to replace three-phase AC. Furthermore, it addresses the issue of "mid-range interference when the mechanical phase relationship of the electromagnetic force-acting elements (windings and permanent magnets) enters the zero-torque region (the interaction force between the windings and magnets enters a region where the torque is zero or the forces on both sides are balanced and canceled out)" by timely power-off and dual-disk phase complementarity. Timely power-off also completely eliminates the negative torque effect and saves energy, allowing for an equal number of rotors and stators, significantly increasing the power density of the interaction force points between the rotor and stator, maximizing the power potential of each electromagnetic force-acting element (windings and permanent magnets) within a unit space, and improving power density. The aforementioned "physical space rotation phase splitting method," also known as the "disc splitting phase splitting method," does not substantially split the current waveform through physical space disk division. Instead, it achieves complementary phase splitting within the torque range to obtain a stable and sustainable torque output. The current phase splitting, current direction commutation, or waveform shifting is achieved by capturing the rotor position with a brushed or brushless commutator to change the current direction in a timely manner, which can also be called phase shifting (e.g., phase change of a square wave), or by changing the current phase through an external controller. However, the significance of this scheme lies in increasing the winding density design and effective work density, or converting three-phase AC to single-phase AC, square wave AC, or pulsating DC. Through disk splitting, the electromagnetic potential energy is continuously expanded, similar to a cyclotron, and converted 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, three-phase becomes single-phase, the effective output power density increases, and the energy density can be further improved using square waves. The "physical space rotation angle phase splitting method," "winding slot phase current waveform condensation method," "2 times relative speed method," and "bidirectional magnetic 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, motors designed using all of the above methods and their combinations can be radial flux motors or axial flux motors; or, they can be stator-based dual-rotor motors, such as dual-rotor motors with fixed windings on both inner and outer sides, or dual inner rotors, or dual outer rotors, or inner and outer rotors, or multi-rotor motors, such as: dual-rotor synchronous-asynchronous motors, squirrel-cage dual-rotor motors, counter-rotating dual-rotor motors, permanent magnet brushless dual-rotor motors, etc.; the individual use or cross-combination of the above methods are all within the scope of protection of this patent; The motor can function as either an electric motor or a generator; when used as a generator, it can significantly increase the power density of the generator.

9. The method for designing and manufacturing a second-order three-phase end winding according to claim 1, characterized in that: The control strategy for switched reluctance motors is as follows: In both dual-disc and multi-disc configurations, the control method must ensure that the reluctance disc moving away from the center position is de-energized during this period. Power is only supplied when the other discs pull it to a suitable position. This suitable position is the area where the magnetic pull generated when energized can produce positive torque. For electromagnetic torque schemes, a simple commutation is sufficient, but for reluctance motors, de-energization is necessary. That is, a similar commutation effect is achieved through power-on and power-off cycles. Since the magnetic pull of the reluctance motor is independent of the current direction (i.e., it has no directionality), only related to the magnitude of the reluctance, it always moves along the path of minimum reluctance. Therefore, there must be a certain spatial distance between adjacent magnetic poles to construct the positive torque magnetic pull. This is why the magnetic pole density of switched reluctance motors cannot be too high and must consist of salient poles. However, a disc-based design effectively solves this problem and simplifies the control system design.

10. The method for designing and manufacturing a second-order three-phase end winding according to claim 1, characterized in that: The motor assembly consists of four relatively independent motor module disks (or, the number of layers or disks can be 2, 3, 4, 5, 6...N layers) arranged coaxially. Each motor module disk consists of its own stator core, stator winding, and rotor core (or: it can also be an external rotor structure, that is: the stator core and stator winding are stationary inside, and the rotor core rotates outside; or, it can also be an axial flux motor, see below). The stator core of each motor module disk is fixed to the motor housing or fixedly connected to each other according to a set spacing angle to form the stator and motor housing of the motor assembly. The rotors of each motor module disk are axially aligned and fixed to each other and fixedly connected to the motor output shaft. Alternatively, the stator windings are axially aligned, and the rotors are fixed together with each other according to a set spacing angle to form a motor rotor.

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