Bidirectional magnetic flux second-order three-phase end winding process design and manufacturing method

Abstract

The invention relates to a bidirectional magnetic flux second-order three-phase end winding process design and manufacturing method, in particular to a second-order three-phase winding motor process design and manufacturing method aiming at further improvement of a previously applied and existing 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] The application belongs to the technical field of motor and new energy vehicle design and manufacturing. BACKGROUND

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

[0003] Based on the following prior applications:

[0004] 202410494805.x Non-cophase winding displacement cross-slot group wire process design and manufacturing method

[0005] 202410566893.x Inner-cooling heat-exchange second-order three-phase winding motor process design and manufacturing method 5.8

[0006] 202410619722.9 Second-order three-phase end winding process design and manufacturing method 5.17

[0007] 202410643792.8 Axial flux second-order three-phase end winding process design and manufacturing method 5.22

[0008] 202410684267.0 Bidirectional axial flux second-order three-phase end winding process design and manufacturing method 5.29

[0009] 202410796145.0 Second-order variable-order three-phase end winding process design and manufacturing method 6.19

[0010] 202410815412.4 Bidirectional flux second-order three-phase end winding process design and manufacturing method 6.21

[0011] The application discloses a bidirectional flux second-order three-phase end winding process design and manufacturing method, and further improves the prior application and an existing motor, and discloses a series of configuration schemes based on high-order and low-order end windings and high-order and low-order slot windings, which mainly include that high-order end windings can be bent and moved apart from two sides to create the best wiring space for low-order windings, as shown in Figs. Figure 1 、 2 The wiring diagram can be read in combination with Figs. 19, 20 and 23, and enlarged Figure 29 、 30 ;

[0012] The wiring principle of the application can be basically divided into two types, as shown in Figs. 19, 20 and 23, and Figs. Figure 24 represent another type, which can be read in combination with the online application.

[0013] Figs. Figure 3 、 4 are two ultra-thin bidirectional axial flux types, wherein Figure 3 is formed by misplacing two low-order winding assemblies, which can be read in combination with Figs. Figure 25 、 26 and 27; Figure 4 is formed by misplacing winding assemblies containing high-order and low-order end windings, which can be read in combination with Fig. Figure 28 ; the iron cores thereof are half-open iron core assemblies, which have the common advantages shown above.

[0014] Figs. Figures 5-18 respectively show a plurality of high-order end winding forming schemes, wherein Figure 15 、 16 can be read and analyzed in combination, and the assembly diagram of Fig. Figure 15 can be read in combination with other related large diagrams, Figure 16 and 15 are partial enlarged view and comparative analysis diagrams of the forming principle, and the forming principle shown in Fig. Figure 16 can also be used for Figure 15 corresponding various large diagram assembly structures (such as the structure shown in the related diagrams of Fig. Figures 5-18 The related diagrams of Fig. Figure 21 、 22 show radial flux winding types).

[0015] Among them:

[0016] 1-5: permanent magnet, the air gap of the motor is divided into three planes (axial flux) + two ring surfaces (radial flux), so the corresponding permanent magnets are divided into five regions, and the motor in this diagram is a bidirectional axial flux motor, so the permanent magnets are divided into left and right permanent magnets, which are respectively installed on left and right permanent magnet installation discs 14 and 15.

[0017] 6, 8: winding assembly with high-order end winding

[0018] 7: winding assembly with low-order end winding

[0019] 9-13: core air gap magnetic flux surface, the air gap of such a motor is divided into three planes (axial flux) + two ring surfaces (radial flux), so there are five types of core air gap magnetic flux surfaces. This example is a bidirectional axial flux motor, so it is divided into left and right core assemblies 16, 17. The two halves are designed separately, allowing the winding to be pre-formed first, and then the two half-core assemblies 16, 17 are combined. This design is fast and efficient, and the resulting core winding slot can be an open slot (or half-open slot or closed slot). See the prior application.

[0020] As shown in Figure 1 , this example is a three-phase 6-pole axial flux motor; the number of slots per pole per phase is 4; the number of slots per pole per phase is defined as the number of slots occupied by each phase winding per pole; the total number of slots = the number of slots per pole per phase * 3 * the number of poles = 4 * 3 * 6 = 72 slots;

[0021] Three-phase winding is defined as: A, B, C three-phase; among them: the end winding of B phase is low-order winding; the end winding of A, C phase is high-order winding, and the high-order end winding of A, C phase is curved to the left and right with B phase (or the center winding) as the center, providing low-order space for the end winding of B phase, forming a very compact and reasonable winding assembly, the end winding is very short and can participate in excitation, improving motor power density and efficiency. See the prior application for related content;

[0022] Figure 2 Different phase windings are represented by solid lines, dashed lines, and dotted lines to distinguish them (the legend is tentatively as follows: dotted lines represent A phase winding, solid lines represent B phase winding, and dashed lines represent C phase winding). Note that Figure 1 The angle of the three-dimensional graph is moderately transformed and varied, and the visual angle distribution density of each phase winding seems a bit tense. This example is only to show the structure of the high-order and low-order windings and the related assembly. The structure principle diagram uses 5 layers of flat wire, and the layout relationship and wiring diagram of each phase winding can be seen in Figure 2 .

[0023] Note: In this scheme, the lengths of the A, C phase windings and the B phase winding are not the same, which may cause the inductance of the three sets of windings to be different. To effectively prevent circulating current, the contact relationship between the end winding and the core or the winding compensation method can be adjusted to make the inductance of each phase winding equal. This design is not affected by the number of poles, and motors with any number of poles can be designed.

[0024] In addition, if a traditional double-layer winding is used, the winding pitch can be reduced, and short-pitch windings can be used to reduce the length of the end winding,

[0025] Or: with three layers of winding, the inductance of three-phase winding can be realized, each phase winding is evenly distributed in each layer, so that the distance from the slot opening to the slot bottom is average, and the high and low order windings are also evenly divided, and the pitch can be reduced as much as possible; at the same time, the winding is stacked on both sides, which further reduces the pitch; at the same time, it is not restricted by 6 poles;

[0026] Note: the axial flux type of this scheme is better;

[0027] Or: two-phase (or four-phase) motor is better, see the related content of the prior application: three-wire four-phase wave motor;

[0028] If the slot number of high and low order windings is not equal (the number of runway winding rings is not equal, it is recommended that the number of low order rings be large, which will appear the phenomenon that the same runway contains different phase windings, but it does not affect the end winding to participate in excitation, but the voltage difference of different phases-insulation level+ isolation paper needs to be considered), more schemes can be combined, such as 6-pole motor; for example: 4-phase 5-phase motor

[0029] Equal pole and common winding + inner and outer rotor structure, used for double-fed asynchronous machine, the rotor winding also uses the equal pole and common winding scheme;

[0030] Rolling brush static end + compression spring;

[0031] The scheme of the prior application is mainly used for 4, 8, 12-pole motors, which is not suitable for 6, 10-pole motors, which needs to be changed by order to meet the requirements, see the attached Figure 26 6-pole variable order motor

[0032] Mathematical formula that meets this condition: pole phase slot number m*3*pole number k (even number)=total slot number n; phase pole slot number m*4 can be divided by total slot number n; note: the quotient of the division can be an odd number;

[0033] Radial flux is the same, see the attached Figure 21 , 22 ; But the radial flux needs to consider the problem of putting the rotor in, so the end winding can only be double-bent on one side and single-bent on the other side, similar to three-order winding (see the attached Figure 21 ); Or the rotor can be put in first;

[0034] Parallel slots, directly divide the pre-formed winding and put it in;

[0035] Double-layer stacked winding; stacked winding; wave winding;

[0036] The application also discloses a bidirectional axial flux second-order three-phase end winding process design and manufacturing method, and the application further improves the prior application and existing motor, discloses a series of configuration schemes based on high-low order end windings and high-low order slot-in windings, and simultaneously includes axial flux and radial flux; the axial flux includes unidirectional and bidirectional axial flux; also includes a stator core containing a magnetic yoke and a non-magnetic yoke type, and can also be a double-rotor bidirectional flux type in which the stator also participates in rotation; the core laminations of the axial flux can be circumferential sheet laminations or radial sheet lamination structures; for the non-magnetic yoke bidirectional flux stator core, especially for the axial flux type, the cores of the windings are independent, the inner and outer ring surfaces (for the axial flux motor, refers to the inner and outer ring surfaces formed by the combination of the fan-shaped windings and the fan-shaped core) can be locked and positioned, and the torque is transmitted by relying on the convex-concave structure of the core teeth and slots to form a convex-concave inlay engagement relationship, a plurality of split arc blocks with the convex-concave structure can be first installed on the inner and outer ring surfaces, the split arc blocks form a convex-concave inlay relationship with the stator core, and after installation, the plurality of split arc blocks are combined into a closed circle, the outer side surface of the split arc blocks can be in a conical surface structure, then one or two whole rings with a conical surface are used to tightly lock the conical surfaces of the plurality of split arc blocks, a wedge-tight effect is formed to tightly connect the split cores into a whole structure, and the stator core is fixed with the motor shell base body for stabilizing the motor core and transmitting torque power; note: except for the core, other elements generally adopt high magnetic resistance materials;

[0037] In order to ensure that the core is a non-open slot, the stator core can be divided into two halves, and the winding is first preformed, and then the two half cores are closed from both sides of the winding; the axial flux winding is a planar structure, and after the whole is preformed, it is convenient to insert the core; the process is optimized to improve the production efficiency;

[0038] Non-magnetic yoke axial flux + high-low order slot-in and high-low order end winding, + conical restraint ring + inner and outer rings; the core is divided into two halves and inserted from both sides;

[0039] Bidirectional flux + non-magnetic yoke - tightly constrain silicon steel from inside and outside + step constraint, safety and torque transmission;

[0040] + high-order end winding staggered to reduce the proportion of deep grooves; see the attached drawings of the application of 5.29 Figures 8-23

[0041] Alternatively, based on the card-type winding of the prior application, the weld can be perpendicular to the axial plane or parallel to the axial plane or parallel to the plane of the chord length of the winding, or can be aligned and welded at one time, and the penetration welding, as long as there is a gap between the layers, can be avoided by removing the paint, and is also applicable to the existing motor process;

[0042] Or, in order to reduce the end size, the dispersion fold line to both sides can be taken to reduce the space occupied by the end winding as much as possible;

[0043] The core gasket goes to the high-low slot inner type, which can also be a symmetrical single magnetic flux, that is, the magnetic yoke can be added to the cooling channel area;

[0044] Axial flux can also be combined with multiple disks; such as: this patent application is a combined unit, containing bidirectional flux stator winding and two-sided rotor, which can also be a multiple of the same combined unit coaxially combined to obtain multiple power output; 1.0 can also be combined with multiple disks, taking 3n disk numbers.

[0045] And for the "inner cooling heat exchange two-order three-phase winding motor process design and manufacturing method", the "slot winding" (here specifically refers to the traditional slot winding, the end winding of the present application is also in the slot, but for the convenience of explanation, the traditional terms are still used to define the end winding and slot winding) is unified in the same radial space, that is, all "slot windings" are evenly distributed in the same diameter area concentric with the air gap, and only the end winding is divided into high-order end winding and low-order end winding, further optimizing the motor performance; Its characteristics are that the end winding participates in excitation, has the equivalent function of the slot winding, and the end winding has better heat dissipation and thermal conductivity, and there is no cross-over problem between different phase windings, which greatly improves the voltage withstand safety of the winding, and simplifies the winding forming process.

[0046] Generally, its type is mainly divided into: M-type winding containing low-order end winding, N-type winding containing high-order end winding; In addition, it can also be divided into: N-type winding containing E-type high-order end winding, N-type winding containing F-type high-order end winding, which corresponds to different types of E-type stator core and F-type stator core; In line with the winding classification and wiring principle of the prior application "inner cooling heat exchange two-order three-phase winding motor process design and manufacturing method", each phase winding of U, V, W three-phase winding will be in high-low order area, each phase winding of U, V, W three-phase winding of this application will appear M-type winding containing low-order end winding, N-type winding containing high-order end winding type; See the specific wiring connection relationship diagram in the attached Figures 24-27 ;

[0047] Note: In the drawings of the patent application, for the convenience of drawing and expression, the bending of the winding is all right-angle bending. In actual application, it can be curved naturally with a circular arc, and the depth of the hollowed-out area of the end part of the core is reduced as much as possible to improve the magnetic flux density distribution of the core. In addition, the full embedding process of the end core and the end winding described above can be similar to the hollowing-out process. In actual implementation and application, the core punching piece of the end part region is generally designed into a specific shape in advance, and then superimposed to present the corresponding concave-convex shape and the end winding shape to fully match and embed the end winding. Alternatively, the corresponding convex-concave special-shaped end core of the end winding can be installed separately from the main core stator in the later stage, that is, it can be installed before the winding is installed, or it can be inserted after the winding is installed. In addition, in order to reduce eddy current as much as possible, the core lamination corresponding to the end winding should correspond to the magnetic path axis as much as possible to ensure that the eddy current loss is minimized.

[0048] In addition, for the convenience of drawing and expression, the winding in the three-dimensional view of the drawings in this application all adopts the same shape or consistent shape through linear array or circular array drawing means to express the schematic diagram of the overall structure form in a simple manner. In actual wiring, this is realized according to the circuit mode, and the specific wiring diagram is shown in the drawings. Figures 24-28 ;

[0049] In addition, the winding can also adopt a similar hairpin flat wire process (H-PIN) to form an independent non-closed single-sided opening, which is inserted into the core and then the other side is lapped or welded and is treated with dripping paint or potting insulation. The difference is that the winding shape of this scheme is basically a standard rectangle, the end winding can be tightly attached to the core to participate in excitation and become an effective winding, the non-welding side can be well attached to the core without dead angle, fully playing the function of the end winding participating in excitation and work, and the welding side can also be bent to a standard rectangle and then butt-welded or bent by an angle for butt-welding (which can be butt-welding with the end face facing each other, or welding after lapping, or mechanical pre-stress contact type electrical connection after lapping; or welding after locally bending the welding area by 90 degrees or other angles, or mechanical pre-tightening force is adopted to realize electrical connection). In short, the welding side can also be well attached to the core to play the function of the end winding participating in excitation and work. Moreover, due to the absence of the different phase crossing and trans-slot adjacent effect of the traditional winding, the same type of hairpin winding can be inserted at one time, which not only improves the assembly efficiency but also reduces the damage risk of the insulation layer caused by the frequent insertion and friction between adjacent windings. In addition, it can further improve the density, increase the slot fill rate, improve the thermal conductivity, and reduce electromagnetic noise. The voltage of the adjacent winding basically decreases in a gradient, which can improve the voltage withstand safety level, or the thickness of the insulation layer of the electromagnetic wire can be reduced, which is equivalent to improving the slot fill rate.

[0050] Or, since this scheme has no different phase winding cross-wiring misplacement complex process, each phase winding is circularly wound in its own track area, arranged neatly, so the winding can also be inserted from both sides of the stator slot and then welded after being wound two or more turns, in order to reduce the welding points, or even the entire winding is wound as a whole and then welded into the busbar at the end, which is equivalent to the process of realizing the distributed winding of the concentrated winding;

[0051] Or, the conductor layer and the insulation layer of the super-flat wire can also be separated and then synthesized at a later stage, as disclosed in the present series of applications, in order to use more high-temperature-resistant insulation layers to improve the high-temperature resistance of the winding, while the conductor layer is made of bare copper material or aluminum material or other conductors, further reducing the cost of raw materials and the process cost of the winding, and improving the yield; Note: the current scheme does not cross the different phase windings, and the same phase windings are also arranged neatly and regularly. This configuration is conducive to the separation of the conductor layer and the insulation layer and the on-line synthesis process (directly into the winding after on-line synthesis on the production line, and then mutually shaped or further poured and solidified). The slot on the air gap side of the core can be made into a half-open slot or a closed slot.

[0052] In addition, in order to simplify the installation process, the current scheme can generally be made into an open slot, and all windings can be pre-wound into a shape and then inserted into the slot through the radial open slot, or the open slot can be made into a closed slot or a half-open slot element after the winding assembly is completed, or it can be poured and synthesized, see the attached Figure 29 (For details, see the previous application 202310792777.5, a split embedded magnetic circuit optimization design process);

[0053] Or, the super-flat wire can be slid into the slot (note: when the super-flat wire slides into the slot, it needs to be twisted at an angle and slid obliquely through the slot, so the last layer or several layers of winding located at the edge of the slot can be inserted from the side, can be inserted and wrapped from the side slot, or can be cut into independent winding layers and installed and welded in the form of a hairpin flat wire; Or, the remaining space near the slot is not equipped with windings, which can be used as a heat dissipation channel, which can be seen in the previous application, and the slot effect problem can also be eliminated), similar to the current winding offline process of round wire motors, or the transition bending of the in-slot winding and the end winding of the super-flat wire can also be a 45-degree folding type bending process, or in order to reduce the influence of the folded thickness, a staggered process with different axial dimensions can also be adopted to reduce the increase in the radial dimension of the winding caused by folding; The winding can also be parallel-wound to improve the large-current carrying capacity; Or, the series-parallel relationship of the winding can also be changed in time to obtain different back electromotive forces and thus meet the high-efficiency operation in different speed ranges.

[0054] Or, even after the insertion of the winding double-sided opening welding scheme, such as similar I-PIN, H-PIN, X-PIN, W-PIN and other programs;

[0055] In addition, this scheme is suitable for round wire motor, conventional flat wire motor, ultra-flat wire motor of this series application, and all types of outer rotor radial flux motor and axial flux motor;

[0056] As shown in the accompanying Figure 30 If it is used for winding in the middle and both sides are axial flux motors of the rotor, the winding core in the middle can be divided into two halves along the axial vertical plane of the center, so that the slot opening of the two half stator cores located on one side of the air gap area can be closed slot or half open slot, the winding can be preformed, and the stator can be closed from both sides. It is ensured that the winding has no welding point similar to continuous wave winding, and the open slot problem is solved, becoming closed slot to improve motor performance; Note: the two half stator cores of the closure can be locked mechanically, or it can also be mainly attracted by electromagnetic force, because the direct contact at the middle closure is equivalent to zero air gap, and the two sides are air gap. Therefore, the electromagnetic attraction force in the middle is much larger than that on the air gap side, which can be stably attracted and safely and reliably worked. The mechanical locking of this way can be an auxiliary scheme;

[0057] Similarly, the application adopts the physical space non-same phase winding displacement trans-slot group wire process design method for the end winding, so that the winding trans-slot problem is well solved, not only greatly simplifies the integrated winding forming process of the whole winding, shortens the size of the end winding, reduces the waste of the electromagnetic wire, and makes the end winding also participate in effective excitation, reduces the leakage magnetic field and improves the efficiency, and makes the different phase windings relatively separate, improves the safety of the motor winding voltage, and optimizes the motor heat dissipation effect. Compared with the prior application, this way adopts two-order, i.e. high-order, low-order or inner and outer two layers of misalignment to meet the trans-slot winding of three-phase winding. The specific wiring scheme is shown in the accompanying Figures 24-27 The dotted line winding in the accompanying Figure 24 represents the high-order winding; the dotted line winding represents the low-order winding. It is obvious that in this scheme, the same phase winding will be located in different order windings, but this does not affect the trans-slot wiring; in the accompanying Figures 25-27 different line types represent different phase windings, divided into A, B and C three phases, and the ABC letter suffix number represents the winding in different slot areas. The purpose of this numbering is to correspond to the analysis and interpretation of the accompanying Figure 24 Figures 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 those in the slots, improving motor efficiency. Additionally, [the following is an appendix / document / etc.] 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] 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.

[0059] 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.

[0060] 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.

[0061] 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.

[0062] 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.

[0063] 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.

[0064] 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.

[0065] 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.

[0066] Its electromagnetic wires can be round or flat; the current waveform can be: square wave, square wave + composite wave, or sine wave;

[0067] 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.

[0068] The above solution can also be used for conventional single-rotor motors, such as replacing existing brushless or brushed solutions.

[0069] 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.

[0070] 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.

[0071] 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.

[0072] 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.

[0073] Note:

[0074] 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.

[0075] 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. Attached Figure Description Figure 1 Assembly diagram of a dual-sided, high- and low-order, three-phase, 8-pole axial flux motor Figure 2 Exploded view of a dual-sided, high- and low-order, three-phase, 8-pole axial flux motor assembly Figure 3 , 4 Two types of ultra-thin bidirectional axial flux Appendix Figures 5-18 Various high-order end winding molding schemes were showcased. Figures 19, 20, and 23: Schematic diagrams of three-phase 8-pole lap winding circuits Figure 21 , 22 : Assembly diagram of high and low order windings of a three-phase 8-pole radial flux motor with lap windings Figure 24 , Three Schematic diagram of a 6-phase axial flux motor Figure 25 , 26 27: Structural diagram of axial flux type of double low-order winding assembly with misaligned combination Figure 28 : Axial flux type structural diagram of winding assembly with misaligned combination of high and low order end windings Figure 29 Disassembled diagram of stator and windings of a double-sided, high- and low-order, three-phase, 8-pole axial flux motor. Figure 30 Partially disassembled diagram of the stator and windings of a double-sided, high- and low-order, three-phase, 8-pole axial flux motor. Figure 30-a , Figure 30-b Yes Figure 30 The enlarged printout of the split-in-half image is only for the purpose of making the details clearer.

Claims

1. A method for designing and manufacturing a two-way flux second-order three-phase end winding, including motor windings, stator, rotor, and housing, characterized by: The super-thin wire section structure with a large aspect ratio is adopted, so that the softness of the flat wire is consistent with that of the conventional round wire, the flat wire can be assembled by inserting into the slot of the stator winding, the complex process such as opening welding of the flat wire is omitted, and the skin effect of the winding is improved; The application discloses a two-way magnetic flux second-order three-phase end winding process design and manufacturing method, and further improves the prior application and the existing motor, and discloses a series of configuration schemes based on high-order and low-order end windings and high-order and low-order slot windings, which mainly include that the high-order end winding can be bent and moved apart from two sides to give the low-order winding the best wiring space, as shown in FIGS. 1 and 2, and the wiring diagram can be read in combination with the accompanying drawings 19, 20 and 23, and the enlarged view 29 and 30; The wiring principle of the application can be basically divided into two types, as shown in the accompanying drawings 19, 20 and 23, and the accompanying drawing 24 represents another type; FIGS. 3 and 4 are two kinds of ultra-thin two-way axial magnetic flux types, wherein FIG. 3 shows that the two kinds of low-order winding assemblies are combined in a staggered manner, and can be read in combination with the accompanying drawings 25, 26 and 27; FIG. 4 shows that the winding assembly containing the high-order and low-order end windings is combined in a staggered manner, and can be read in combination with the accompanying drawing 28; the cores are both half-open core assemblies, and have the common advantages shown above; FIGS. 5-18 respectively show a plurality of high-order end winding forming schemes, wherein FIGS. 15 and 16 can be read and analyzed correspondingly, the assembly diagram of the accompanying drawing 15 can be seen in other related drawings, and the enlarged view of the forming principle of FIG. 16 is a comparative analysis diagram, and the forming principle shown in the accompanying drawing 16 can also be used for the corresponding various drawings of FIG. 15 (the structures shown in the related drawings of FIGS. 5-18 can be cross-recombined to design the high-order end winding in the most compact manner; it is particularly stated that the above principle is also applicable to the radial magnetic flux winding type shown in the accompanying drawings 21 and 22); Wherein: 1-5: permanent magnet, the air gap of the motor is divided into three planes (axial magnetic flux) + two ring surfaces (radial magnetic flux), so the permanent magnet is divided into five regions, and the motor is a two-way axial magnetic flux motor, so the permanent magnets are divided into left and right permanent magnet mounting plates 14 and 15; 6 and 8: winding assembly containing high-order end winding; 7: winding assembly containing low-order end winding; 9-13: core air gap magnetic flux surface, the air gap of the motor is divided into three planes (axial magnetic flux) + two ring surfaces (radial magnetic flux), so the core air gap magnetic flux surface is divided into five regions, and the motor is a two-way axial magnetic flux motor, so the core assemblies 16 and 17 are divided into left and right core assemblies; the two halves are designed to be separated, so that the winding can be pre-formed, and then the two half core assemblies 16 and 17 are combined to be mounted quickly, and the core winding slot formed by the two half core assemblies can be an open slot (or a half-open slot or a closed slot), which can be seen in the prior application; The application discloses a two-order variable-order three-phase end winding process design and manufacturing method, and further improves the prior application and an existing motor, discloses a series of configuration schemes based on high-low-order end windings and high-low-order slot-in windings, and focuses on two-order, three-order, variable-order, same-phase opposite-direction discrete winding and bidirectional high-order winding schemes, overcomes the limitations of previous schemes, and can be used for 6-pole and 10-pole motors; the same-phase opposite-direction discrete winding scheme can also be used for 2-pole motors; and the three-order winding can also be used. In order to distinguish, the "two-order three-phase end winding" scheme of the prior application is defined as "same-direction curved end winding scheme" (see Figs. 20 and 23, note: Fig. 23 is cited again for the convenience of referring to the corresponding prior application, and Figs. 24-27 of the corresponding prior application can be referred to); the new scheme is called "same-phase opposite-direction curved winding and double-sided high-order winding scheme" (see Figs. 1 and 2), and of course, the same-direction curved wiring can also be used, but in this way, the length of the end winding is increased, note: the opposite-direction curved and same-direction curved referred to herein specifically mean that the same-phase winding is curved to both sides or to the same side when the same-phase winding is transferred from the slot-in winding to the end winding, for example, Figs. 1 and 2 show the two-side opposite-direction curved, if the pole-phase slot number is even, the same-phase winding is generally evenly distributed and curved to both sides, if the pole-phase slot number is odd, the same-phase winding can only be unevenly distributed and curved to both sides, for example, if the pole-phase slot number is 3, the same-phase winding can only be distributed with 1 slot on one side and 2 slots on the other side; and as shown in Fig. 23, the same-phase winding is curved to the same side when the same-phase winding is transferred from the slot-in winding to the end winding, and in this way, the length of the end winding is increased. Comparative analysis: the "same-direction curved end winding scheme" (see Figs. 20 and 23) can plan the three-phase winding into two types of structure winding (from the electromagnetic characteristics, it is three-phase, but the structure is two types of structure) as a whole, and the winding is composed of 2-order winding, that is, the high-order end winding has only one form, but has a disadvantage: the long-pitch winding is long, and is not suitable for 6-pole and 10-pole motors, and the variable-order configuration needs to be adopted to complete, see Fig.

26. The so-called new scheme mentioned in the patent is called "same-phase opposite-direction curved winding and double-sided high-order winding scheme" (see Figs. 1 and 2), and the high-order winding is two types, although the structure looks the same, but the space is two types, for example, as shown in Fig. 1, the left and right parts of the low-order winding need to be arranged on both sides and separated, this mode is not conducive to the installation of the rotor for the radial flux motor (see Figs. 21 and 22), and generally, at least one side of the rotor needs to be wound according to the principles of Figs. 17 and 18, the rotor can be installed from this side, or the winding can be installed after the rotor is installed in the stator core, and this problem is more friendly to the axial flux motor; but the advantages of this type of scheme are that the long-pitch winding is short or only has short-pitch or equal-pitch winding without long-pitch winding, and can be suitable for all-pole motors, such as 2-pole, 4-pole, 6-pole, 8-pole and 10-pole motors. Definition: high-order winding or high-order end winding has been mentioned many times in the prior application, this paper reiterates: high-order winding means that the position of the winding in the slot and the end winding is located in the high position, and the distance from the air gap is greater than that of the ordinary low-order winding; High-order end winding refers to the winding in the slot and low-order winding, but its end winding adopts a deformed bending and other curve (straight line, inclined line or multi-segment vertical line or inclined broken line, such as the winding shown in figure 3 marked 11) form to avoid low-order end winding, its length will be greater than that of low-order winding; The drawings 1, 3, 5, 7 in this application (among them, figure 7 is axial bending in the same direction, which will cause the end winding to lengthen; It is not the same as the "back bending, bending in the same direction" mentioned above, but the principle is similar, which is to reasonably avoid each winding and reasonably arrange the space, this axial bending in the same direction is beneficial to the installation of rotor); The application discloses a two-way axial magnetic flux two-order three-phase end winding process design and manufacturing method, the application is further improved on the basis of the prior application and the existing motor, a series of configuration schemes based on high and low order end winding and high and low order slot winding are disclosed, which also includes axial magnetic flux and radial magnetic flux; The axial magnetic flux includes one-way and two-way axial magnetic flux; It also includes a stator core containing a magnetic yoke and a non-magnetic yoke type, and a double-rotor two-way magnetic flux type in which the stator also participates in rotation; The core laminations of axial magnetic flux can be circumferential sheet laminations or radial sheet laminations; For the non-magnetic yoke two-way magnetic flux stator core, especially for the axial magnetic flux type, the core of each winding embedded in each other is independent, the inner and outer ring surfaces (for axial magnetic flux motor, it refers to the inner and outer ring surfaces formed by the combination of fan-shaped winding and fan-shaped core) can be locked and positioned, and the convex-concave structure of the core tooth and slot is used to form a convex-concave embedded meshing relationship to transmit torque, a plurality of split circular blocks with convex-concave structure can be installed from the inner and outer ring surfaces, the split circular blocks form a convex-concave embedded relationship with the stator core, and after installation, the plurality of split circular blocks are combined into a closed circle, the outer side of the circular surface can be in the form of a conical surface structure, and then one or two whole circular rings with conical surfaces are used to tightly lock the conical surfaces of the plurality of split circular blocks, a wedge-tight effect is formed to tightly connect the split core into a whole structure, and the stator core is fixed with the motor shell base to stabilize the motor core and transmit torque power; Note: except for the core, other elements generally adopt high magnetic resistance materials; In order to ensure that the core is a non-open slot, the stator core can be divided into two parts, and the winding is pre-formed first, and then the two half cores are closed from both sides of the winding; The axial magnetic flux winding is a planar structure, and it is very convenient to insert the whole pre-formed winding into the core, which optimizes the process and improves the production efficiency; Non-magnetic yoke axial magnetic flux + high and low order slot winding and high and low order end winding + conical restraint ring + inner and outer rings; The core is divided into two halves and inserted from both sides; Two-way magnetic flux + non-magnetic yoke - tightly constrain silicon steel inside and outside + step constraint, safety and torque transmission; + high-order end winding staggered to reduce the proportion of deep slot scheme; Or, based on the card type winding of the prior application, the weld can also be perpendicular to the axial plane or parallel to the axial plane or parallel to the plane of the winding chord length, or it can be aligned with the one-time welding, penetration welding, and butt welding, which can be free of paint removal, and is suitable for existing motor technology; Or, to reduce the end size, the dispersion fold line method can be adopted to minimize the space occupied by the end winding; The core gasket trend, the high-low slot inner type can also be a symmetrical single magnetic flux, that is, the magnetic yoke can be added to the cooling channel area; The axial magnetic flux can also be combined with multiple disks; such as: the present application is a combined unit, which contains a bidirectional magnetic flux stator winding and two side rotors, and multiple same combined units can be coaxially combined to obtain multiple power output; 1.0 can also be combined with multiple disks, and 3n disk numbers are taken; The application also discloses a two-order three-phase end winding process design and manufacturing method. The application is further improved based on the prior application and existing motors, especially the "inner cooling and heat exchange two-order three-phase winding motor process design and manufacturing method". The "slot winding" (herein, the traditional slot winding is particularly referred to, and the end winding of the present application is also in the slot, but the traditional terms are still used to define the end winding and the slot winding for convenience) of the high-low winding of the prior application is uniformly arranged in the same radial space, that is, all the "slot windings" are uniformly distributed in the same diameter area concentric with the air gap, and only the end winding is divided into a high-order end winding and a low-order end winding, so that the motor performance is further optimized. The characteristics are that the end winding participates in excitation, has the equivalent function of the slot winding, has the advantages of the effective winding, the end winding has better heat dissipation and thermal conductivity, there is no cross-over problem of different phase windings between the windings, the winding pressure safety is greatly improved, and the winding forming process is simplified. Generally, the types mainly include an M-type winding containing a low-order end winding, an N-type winding containing a high-order end winding, an N-type winding containing an E-type high-order end winding, and an N-type winding containing an F-type high-order end winding, which correspond to different types of E-type stator cores and F-type stator cores. The winding classification and wiring principle of the prior application "inner cooling and heat exchange two-order three-phase winding motor process design and manufacturing method" are consistent. Each phase winding of the U, V and W three-phase windings is arranged in the high-low order area. Each phase winding of the U, V and W three-phase windings of the present application is arranged in the M-type winding containing a low-order end winding and the N-type winding containing a high-order end winding. The specific wiring connection relationship is shown in FIGS. 24-27. Note: In the drawings of this patent application, for the convenience of drawing and expression, the bending of the winding is all right-angle bending. In actual application, it can be curved naturally with a circular arc, and the depth of the hollowed-out area of the core end part region is reduced as much as possible to improve the magnetic flux density distribution of the core. In addition, the full embedding process of the end core and the end winding described above can be similar to the hollowing-out process. In actual implementation and application, the core lamination of the end part region is generally designed into a specific shape in advance, and then stacked to present the corresponding concave-convex shape and the end winding shape for full matching and embedding. Alternatively, the corresponding convex-concave special-shaped end core of the end winding can be installed separately from the main core stator in the later stage, that is, it can be installed before the winding is installed, or it can be inserted after the winding is installed. In addition, in order to reduce eddy current as much as possible, the core lamination corresponding to the end winding should correspond to the magnetic path axis as much as possible to ensure that the eddy current loss is minimized. In addition, for the convenience of drawing and expression, the winding in the three-dimensional view of the drawings of this application all adopts the same shape or consistent shape through linear array or circular array drawing means to express the principle diagram of the overall structure form in a simple manner. In actual wiring, this is realized according to the circuit mode, and the specific wiring diagram is shown in Figures 24-28. In addition, the winding can also adopt a similar hairpin flat wire process (H-PIN) to form an independent non-closed single-sided opening, which is inserted into the core and then the other side is lapped or welded and is treated with paint dripping or potting insulation. The difference is that the winding shape of this scheme is basically a standard rectangle, the end winding can be tightly attached to the core to participate in excitation and become an effective winding, the non-welding side can be well attached to the core without dead angle, fully playing the function of the end winding participating in excitation and work, and the welding side can also be bent to a standard rectangle and then butt-welded or bent at an angle for butt-welding (which can be butt-welding with the end face facing each other, or welding after lapping, or mechanical pre-stress contact type electrical connection after lapping; or welding after bending the welding area by 90 degrees or other angles, or mechanical pre-stress connection). In any case, the welding side can also be well attached to the core to play the function of the end winding participating in excitation and work. Moreover, due to the absence of the different phase crossing and slot crossing adjacent effect problem of traditional windings, the same type of hairpin winding can be inserted at one time, which not only improves the assembly efficiency but also reduces the damage risk of the insulation layer caused by the frequent insertion and friction between adjacent windings. In addition, it can further improve the density, increase the slot fill rate, improve the thermal conductivity, and reduce electromagnetic noise. The voltage of adjacent windings basically decreases in a gradient, which can improve the voltage withstand safety level, or the thickness of the insulation layer of the electromagnetic wire can be reduced, which is equivalent to improving the slot fill rate. Or, since this scheme has no different phase winding cross-wiring misplacement complex process, each phase winding is circularly wound in its own track area, arranged neatly, so the winding can also be inserted from both sides of the stator slot and then welded after being wound two or more turns, in order to reduce the welding points, or even the entire winding is wound as a whole and then welded into the busbar at the end, which is equivalent to the process of realizing distributed winding with concentrated winding; Or, the conductor layer and the insulating layer of the super-thin wire can also be separated and then synthesized at a later stage, so as to adopt a more high-temperature-resistant insulating layer to improve the high-temperature resistance of the winding, and the conductor layer is made of bare copper material or aluminum material or other conductors, further reducing the cost of raw materials and the process cost of the winding, and improving the yield; Note: the current scheme does not cross the different phase windings, and the same phase windings are also arranged neatly and regularly. This configuration is conducive to the separation of the conductor layer and the insulating layer and the later synthesis or online synthesis (directly into the winding after online synthesis on the production line, and then mutually shaped or further poured and solidified) process; The slot on the air gap side of the core can be made into a half-open slot or a closed slot; In addition, in order to simplify the installation process, the current scheme can generally be made into an open slot, and all windings can be pre-wound into a shape and then inserted into the slot through the radial open slot, or the open slot can be made into a closed slot or a half-open slot element after the winding assembly is completed, or it can be poured and synthesized, as shown in Figure 29 (for details, see the previous application 202310792777.5, a split embedded magnetic circuit optimization design process); Or, the super-thin wire can be slid into the slot (note: when the super-thin wire slides into the slot, it needs to be twisted at an angle and slid obliquely when passing through the slot, so the last layer or several layers of winding located at the edge of the slot can be inserted from the side, can be inserted from the side slot, or can be cut into independent winding layers and then welded after installation like hairpin thin wire); Or, the remaining space near the slot is not equipped with windings, which can be used as a heat dissipation channel, as shown in the previous application, which can also eliminate the slot effect problem), similar to the current winding offline process of round wire motor, or the transition bending of the in-slot winding and the end winding of the super-thin wire can also be a 45-degree folding type bending process, or in order to reduce the influence of the folded thickness, a staggered process with different axial dimensions can be adopted to reduce the increase of the radial dimension of the winding caused by folding; The winding can also adopt a parallel winding scheme to improve the large current carrying capacity: or, the series and parallel relationship of the winding can also be changed in time to obtain different back electromotive force and meet the high efficiency operation in different speed ranges; Or, even a double-sided open insertion and then welding scheme, such as I-PIN, H-PIN, X-PIN, W-PIN, etc. In addition, the current scheme is suitable for round wire motors, conventional flat wire motors, super-thin wire motors of the series application, and all types of external rotor radial flux motors and axial flux motors; As shown in FIG. 30, if the axial flux motor is used for the winding in the middle and the rotor on both sides, the winding core in the middle can be divided into two halves along the axial vertical plane in the middle, so that the slots on one side of the air gap area of the two half stator cores can be closed slots or half open slots, the winding can be preformed first, and then the stator is closed from both sides, which not only ensures that the winding has no welding point similar to continuous wave winding, but also solves the problem of open slot and becomes closed slot to improve the performance of the motor; Note: the two half stator cores can be locked by mechanical means, or they can be mainly attracted by electromagnetic force, because the direct contact at the middle joint is equivalent to zero air gap, and the two sides are air gaps, so the electromagnetic attraction force in the middle is much larger than that on the air gap side, which can be stably attracted and safely and reliably worked. The mechanical locking of this method can be an auxiliary scheme; Similarly, the present application adopts the physical space non-identical phase winding displacement trans-slot group wire process design method for the end winding, which can well solve the trans-slot problem of the winding, not only greatly simplify the integrated winding forming process of the whole winding, shorten the size of the end winding, reduce the waste of the electromagnetic wire, but also make the end winding participate in effective excitation, reduce the magnetic leakage and improve the efficiency, and make the different phase windings relatively separate, improve the motor winding voltage resistance safety, and optimize the motor heat dissipation effect; Compared with the prior application, this method can meet the trans-slot winding and wiring of the three-phase winding by adopting two-order, i.e. high-order, low-order or inner and outer two layers of misalignment, and the specific wiring scheme is shown in FIGS. 24-27 (in which: the dotted line winding in FIG. 24 represents the high-order winding; the dashed line winding represents the low-order winding, and it is obvious that the same phase winding is located in different order winding slots, but this does not affect the trans-slot wiring; in FIGS. 25-27, different lines represent different phase windings, which are divided into A, B and C three phases, and the ABC letter suffix number represents the winding in different slot areas, the purpose of this numbering is to correspond to FIG. 24 for analysis and interpretation, in which, the longer winding in the end winding in FIGS. 25-27 represents the high-order winding, and the shorter winding in the end winding represents the low-order winding, and it is obvious that in this scheme, the same phase winding is alternately arranged in the high-order and low-order winding slots, but as long as the end winding is arranged reasonably to make all the end windings close to the stator core and the wiring is reasonable to ensure that the current direction of the end winding is consistent with the excitation direction of the slot winding to form a unified positive superposition to strengthen the excitation magnetic field, the function of the end winding can be changed to effective winding, i.e. the end winding not only serves as a connection but also has the function of excitation with the slot winding to improve the efficiency of the motor; in addition, FIG. 28 is a schematic diagram of series connection of the same phase super-flat wire winding, in which the arc area represents a U-shaped bending jumper schematic diagram, and in actual connection, parallel connection or vertical connection or connection at an angle can be adopted, or parallel connection or partial parallel connection can also be adopted; or same layer parallel connection in parallel to increase the conduction current capacity, which is beneficial to reduce the iron loss, improve the efficiency and reduce the volume and weight; Note: this scheme is also applicable to the motor architecture design method based on three-wire four-phase wave, which can arrange different phase windings in high-order and low-order slots respectively, and can adopt dragon-shaped winding for wiring, see the prior application; Note: for the outer rotor motor, it is recommended that the outer rotor can be output with a hole structure, because the structure relationship between the outer rotor and the inner stator is equivalent to the hole shaft relationship, while the conventional inner rotor and outer stator structure relationship is the shaft hole relationship, that is, the inner rotor is the shaft, and the outer stator is the hole, so the inner rotor is more suitable for output as a shaft, but the outer rotor is more reasonable for output as a hole structure, and the specific structure scheme can be a hollow shaft structure, which can be output with a flange or gear, chain wheel transmission relationship; Or output power flow with planetary gear structure relationship; Or: the above scheme is also applicable to axial flux motors, see the attached drawings; It is also divided into concentrated winding and distributed winding schemes; Both can be improved to super-thin wire winding structure using the above scheme; Its single-layer copper belt can be composed of several parallel copper belts, with as small a gap as possible, or by punching micro-holes, The circumferential super-thin wire adopts a tooth slot gap assembly scheme, which can be inserted into a rectangular thin wire or circular wire to fill the remaining gap; Its principle is applicable to most motor types, which can be DC motors, AC motors, such as permanent magnet motors, switched reluctance motors, induction motors, and hysteresis motors; The input current waveform of the motor can be: when the motor role is changed to an engine, the inductive current waveform generated by driving the motor winding with a stable torque constant speed rotation is used to guide the design of the control current waveform, That is: the control current waveform of any motor is the same as the current waveform emitted when the motor is driven to rotate at a constant torque and constant angular speed as a generator, then the output torque of the motor as a motor is constant; This method can be called "energy reverse real-time simulation method", which can be used as a motor control current waveform optimization guide method; It is applicable to any type of motor; The use of physical space non-same-phase winding displacement cross-slot group wire process design method makes the winding cross-slot problem well solved, not only greatly simplifies the integrated winding forming process, shortens the end winding size, reduces the waste of magnet wire, and makes the end winding also participate in effective excitation, reduces the leakage magnetic field, improves the efficiency, and makes the different phase windings relatively separate, improves the motor winding voltage withstand safety, and optimizes the motor heat dissipation effect; Especially more suitable for three-wire four-phase wave-based motor architecture design method, which can reduce one phase winding and further simplify the process and improve the radial compactness of convex and concave cores; The physical space non-cophase winding displacement trans-slot group wire process design method is adopted, so that the winding trans-slot problem is well solved, not only greatly simplifies the integrated winding integrated group wire forming process, shortens the end winding size, reduces the electromagnetic wire invalid waste, and makes the end winding also participate in effective excitation, reduces the magnetic leakage, improves the efficiency, and makes the different phase windings relatively separate, improves the motor winding voltage withstand safety, and optimizes the motor heat dissipation effect; Compared with the prior application, the second order, i.e. high order, low order or inner and outer two layers of misalignment, can meet the trans-slot winding of three-phase winding, and the specific winding scheme is shown in FIGS. 14-17 (in which: the dotted line winding in FIG. 14 represents the high-order winding; the dashed line winding represents the low-order winding, and it is obvious that the same phase winding is located in different order winding slots, but this does not affect the trans-slot wiring; in FIGS. 15-17, different lines represent different phase windings, divided into A, B, and C three phases, and the ABC letter suffix number represents the winding in different slot areas, the purpose of this numbering is to correspond to FIG. 14 for analysis and interpretation, wherein the longer winding in the end winding in FIGS. 15-17 represents the high-order winding, and the shorter winding in the end winding represents the low-order winding, and it is obvious that in this scheme, the same phase winding is alternately arranged in the high-order and low-order winding slots, but as long as the end winding is arranged reasonably to make all the end windings close to the stator core and reasonably wired to ensure that the end winding current direction is consistent with the excitation direction of the slot winding to form a unified positive superposition to strengthen the excitation magnetic field, the end winding function can be changed to an effective winding, i.e. the end winding not only serves as a connection but also functions as an excitation with the slot winding to improve the motor efficiency; in addition, FIG. 18 is a schematic diagram of the series connection of the same phase super-flat wire winding, wherein the arc region represents a U-shaped bending jumper schematic diagram, and in actual connection, parallel connection or vertical connection or angle connection can be adopted, or parallel connection or partial parallel connection can also be adopted; or the same layer is connected in parallel to increase the conduction current capacity, which is beneficial to reduce the iron loss, improve the efficiency, and reduce the volume and weight; Note: this scheme is also applicable to the motor architecture design method based on three-wire four-phase wave, which can arrange different phase windings in high-order and low-order slots, and can adopt dragon-shaped windings for wiring, see the prior application; Furthermore, the application also discloses a high-magnetic-resistance high-strength reinforced material filled composite permanent magnet rotor core structure schematic diagram, which uses high-magnetic-resistance material to isolate the magnetic circuit and fill the connection and fastening to play a mechanical property strengthening role.

2. The bidirectional flux second-order three-phase end winding design and manufacturing method of claim 1, wherein: In order to ensure the same inductance, the same phase parallel winding must be consistent in high and low order, i.e. the total length of the same phase parallel winding is consistent, the high and low order is the same, and the position in the slot is also completely the same, for example: if there are 12 layers of flat wires in each slot, if you want to increase the number of turns of parallel winding to improve the large current capacity, then 12 layers can be divided into 5 layers in a group, each 6 layers are connected in series, and then connected in parallel two by two. Or, the local silicon steel external reinforcement can be carried out for the core region hollowed out due to the high-order end winding structure, so as to ensure the uniformity of the magnetic density distribution, and the increased silicon steel is also beneficial to heat dissipation, and a larger surface area heat dissipation is formed; The process of the axial flux stator core can be a winding type or a radial disc type; Note: In order to facilitate drawing, the bending part of each winding is not rounded; Or, the winding wire can also be a conventional round wire enameled wire, which can be wound on line, that is, without pre-winding the wire package on the winding machine, similar to the winding mode of the concentrated winding; the length of the end winding can be greatly reduced, the winding density can be improved, the slot fill factor and heat conduction and heat dissipation can be improved compared with the traditional mode, the electromagnetic noise can be reduced, and the automation rate can be further improved; Brief Description of Drawings: If there are multiple drawings, the drawings are all overall explanatory diagrams or assembly diagrams or exploded views of the same system associated components.

3. The bidirectional flux second-order three-phase end winding design and manufacturing method of claim 1, wherein: A physical space non-cophase winding displacement trans-slot grouping process design and manufacturing method, the present application further improves the prior application and existing motor, adopts a physical space non-cophase winding displacement trans-slot grouping process design method, so that the winding trans-slot problem is well solved, not only greatly simplifies the integrated winding integrated grouping forming process, shortens the end winding size, reduces the electromagnetic wire waste, and makes the end winding also participate in effective excitation, reduces the magnetic leakage and improves the efficiency, and makes the different phase windings relatively separate, improves the motor winding voltage withstand safety, and optimizes the motor heat dissipation effect; especially more suitable for a three-wire four-phase wave motor architecture design method, which can further simplify the process and improve the radial compactness of the convex-concave core; The above design principles are also applicable to external rotor motors and axial flux motors. For the axial flux motor, the different phase windings can be axially displaced and misaligned, and the space left by the axial displacement can be designed as a heat dissipation channel, so as to obtain the same effect as the radial flux motor.

4. The bidirectional flux second-order three-phase end- winding design and manufacturing method of claim 1, wherein: The slot It can be a conventional centering type or a biased type; or, a split core is adopted, the tooth and slot region of the core is separated from the choke region, and the split slot teeth and the choke region form a convex-concave inlay structure, so that after the winding and the split slot teeth are combined, the split slot teeth and the core choke region are inserted into one body; since this way can make the winding and the tooth and slot contact more closely after the insertion assembly is completed, the winding and the tooth and slot form a mutual dependent relationship after the assembly, which can further increase the integrated strength and stiffness of the winding and the tooth and slot, so that the tooth and slot width can be further expanded, the size space of the filled winding can be increased, the power density can be increased, and the electromagnetic noise can be reduced; Or, the split core scheme can be adopted during assembly, the winding can be unfolded into a plane, the split slot teeth and the winding are combined, and then the winding is bent and wound to form a 360 whole circle, and then the split slot teeth are inserted into the stator choke to form an integrated stator winding. Or, when the slot density is large, the size of the tooth slot of the integrated stator can also be increased, so that the slot size is the same as the slot width size, and the core does not need to be designed in a split manner, allowing the flat wire or super-flat wire winding to be inserted into the slot opening in one whole time; The wiring form of the super-flat wire winding can be concentric and stacked; Or, it can also be an outer rotor structure, and the opening of the stator core is outward, which is more convenient for wiring; Or, the three-wire four-phase wave scheme of the prior application is adopted, so that the number of phases of the winding changes from three to two, which can further reduce the wiring complexity and reduce the end size; Or, the existing flat wire winding can be used to save a series of complex processes such as hairpin forming, insertion, and welding; The above scheme is also applicable to the concentrated winding scheme. The concentrated winding scheme uses super-flat wire instead of round wire, which can increase the slot fill rate and use the conductor and insulation separation scheme to improve the winding temperature resistance. In addition, the super-flat wire has a large specific surface area and a large contact area, so its heat dissipation efficiency is better.

5. The bidirectional flux second-order three-phase end- winding design and manufacturing method of claim 1, wherein: The winding slot closest to the air gap can also be shifted outward to form a cooling space. In this way, all windings have a dedicated cooling system, and all windings are isolated from the rotor permanent magnet by a heat dissipation system, which further reduces the temperature of the permanent magnet area, which is significantly lower than the winding area. The super-flat wire can operate normally at a temperature of more than 260°C, so increasing the heat dissipation barrier between the winding and the permanent magnet will help improve the overload capacity of the super-flat wire. For vehicle working conditions, overload conditions are not normal conditions and can not be considered at this time. In this way, we can further reduce the size of the motor, and the super-flat wire motor has excellent long-term overload capacity to meet these working condition requirements. All similar schemes in this patent can be combined to obtain the best slot fill rate, short end winding, small skin effect, small resistance, simple group wire process, low cost, good heat dissipation, and good insulation. According to the electromagnetic conversion requirements and speed torque characteristics, the series, parallel, or multiple series and parallel combination methods can be used.

6. The bidirectional flux second-order three-phase end- winding design and manufacturing method of claim 1, wherein: The above design principles are also applicable to external rotor motors and axial flux motors. For axial flux motors, different phase windings can be axially shifted and displaced, and the space left by the axial shift can be designed as a heat dissipation channel to achieve the same effect as the radial flux motor. The above-mentioned internal cooling and heat exchange two-order three-phase winding motor process design and manufacturing method is applicable to super-flat wire, traditional flat wire, and round wire windings.

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