Centralized physical hierarchical branch number hybrid winding process and design method

Abstract

This invention relates to a centralized physical layered winding process and design method, which improves upon previously filed series of "distributed and separated winding process design and manufacturing methods" by proposing a "centralized physical layered winding process and design method for ultra-flat wires." Its key features are: the conventional number of flat wire layers is no longer constrained; to reduce the number of connection or welding points, the number of physical layers can be combined as much as possible, simplifying it to two or more layers. This significantly reduces the workload of twisting, cutting, flaring, and welding at the end windings, and improves reliability. However, multiple windings or branch windings can exist within the same physical layer, allowing for several additional sub-layers or parent layers (defined in previous applications); it also facilitates flaring the inner and outer diameters first, increasing space and increasing the conductive cross-section to reduce end winding resistance; simultaneously, the above principles can also be considered to minimize the number of high-voltage layers with line voltage.

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 requirements have been placed on indicators such as electric power density, efficiency, volume, and cost. Flat wire motors have replaced round wire motors as the mainstream in the new energy vehicle market. In order to improve performance indicators such as efficiency, most main drive motors now use distributed windings. Especially for motors with a small number of pole pairs, the slot pitch of the distributed windings is very large, which greatly increases the length of the end windings, the axial dimension is long, and the process is complicated. The same problem applies to flat wire motors, where the winding forming process is complicated and the cost increases. Summary of the Invention

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

[0004] 202410619722.9 Second-order three-phase end winding process design and manufacturing method

[0005] 202410643792.8 Design and Manufacturing Method of Second-Order Three-Phase Axial Flux End Winding

[0006] 202410684267.0 Design and Manufacturing Method of Bidirectional Axial Flux Second-Order Three-Phase End Winding

[0007] 202410796145.0 Second-order variable-order three-phase end winding process design and manufacturing method

[0008] 202410815412.4 Design and Manufacturing Method of Two-Way Flux Second-Order Three-Phase End Winding

[0009] 202410909726.0 Independent forming process and design method for end windings of motor slot windings

[0010] 202410930855.8 Independent Forming Process and Design Method for End Windings of Slot-Mounted Axial Flux Motor

[0011] 202410938850.X Motor slot winding end winding independent forming process

[0012] 202410947555.0 Separate winding forming process and design method for electric motors

[0013] 202411008099.X Matrix Flat Wire Winding Process Design and Manufacturing Method

[0014] 202411244382.2 Design and Manufacturing Method of Triangular Arc Slot-Crossing Winding

[0015] 202411319540.6 Low-loss winding process design and manufacturing method

[0016] 202411390722.2 Design and Manufacturing Method of Split Low-Loss Winding

[0017] 202411448081.1 Low-loss circuit board type end circuit process design and manufacturing method

[0018] 202411553914.0 Design and manufacturing method for mother-daughter layer circuits to reduce skin effect.

[0019] Based on the aforementioned prior applications, this invention improves upon the specific embodiments of the series of "distributed split winding process design and manufacturing methods" in the prior applications by proposing a "mother-daughter layer winding and variable wire gauge process and design method". Its features include: designing all parallel windings according to the principle of daughter-layer windings, resulting in zero voltage between daughter-layer windings, allowing for insulation using a very thin insulation process to further improve the copper fill factor, while also accommodating more layers and reducing the skin effect; similarly, the end windings can also be designed with mother-daughter layer separation as much as possible, greatly reducing the number of adjacent cross layers between different phase windings of the end windings and improving safety.

[0020] Variable gauge type: The cross-sectional dimensions of the gauge can have different shapes in different spaces, and the cross-section inside the groove is different from the cross-section at the outer end of the groove, such as: second-order type, third-order type; double short-pitch type,

[0021] It can have a structure similar to a continuous wave winding, with no solder joints on either side. Due to the ultra-flat wire's parent-child layer and combined variable gauge size structure, that is: the gauge is composed of a straight slot gauge and a continuous wave gauge superimposed. The straight slot gauge is only present in the slot area (it can slightly extend out of the slot to obtain better equal cross-sectional conductivity), while the continuous wave gauge exists both inside and outside the slot. The two overlap in the slot area, and are electrically connected only on both sides of the slot opening to form a parallel electrical connection. The middle area is insulated with an insulating film to reduce the yielding effect. To obtain an equivalent conductive cross-sectional area, the continuous wave gauge becomes very wide in the slot area, that is: its cross-sectional area is equal to The cross-sectional area of ​​the slot area is approximately equal to, greater than, or less than the design principle: if the goal is to reduce resistance and improve efficiency, the total cross-sectional area of ​​the external winding is greater than the total cross-sectional area of ​​the related parallel windings inside the slot; if the goal is to reduce cost and size, the external conductive cross-sectional area is smaller than the internal conductive cross-sectional area; generally, it is equal to or approximately equal to the design principle; different materials can also be used, see prior application) the sum of the cross-sectional areas of the slot area of ​​the straight slot wire gauge plus the continuous wave wire gauge. Note: The straight slot wire gauge plus the continuous wave wire gauge can be one or more layers combined; the thickness of the flat wire in the end winding area extending out of the slot can be very thin, allowing for cross-slot insertion between end windings of different phases (two-phase or three-phase lines);

[0022] Since this continuous wave is only a part of the thin flat wire of the combined wire gauge, its continuous wave winding flat wire is very thin and can be easily slid into the stator core slot, ensuring that the slot is still a semi-open slot, unlike the current continuous wave whose slot is an open slot. It achieves a winding process similar to that of a round wire motor, but the overall and end dimensions are significantly shorter than those of a round wire. Because the flat wire is regular and neat, its continuous wave wire gauge can be neatly arranged and slid into the slot. Its axial dimension can be precisely designed so that after winding, it is regular, neat and has a very short axial dimension, as shown in the figure.

[0023] Note: Continuous wave does not specifically refer to waveform winding; it can be either continuous wave winding or continuous lap winding.

[0024] To simplify assembly, it can be either a segmented continuous wave winding or a segmented continuous lap winding.

[0025] Alternatively, it can be a discontinuous structure, similar to the split winding mentioned in the prior applications of this series, where the end winding is separated from the slot winding. It can be a split type at both ends, or a continuous type on one side and a split type on the other. That is, similar to a hairpin flat wire, it is pre-formed, inserted from one side of the iron core, and then connected to the split end winding on the other side for electrical connection. The electrical connection can be achieved by welding or mechanical contact pressure connection.

[0026] It can be a two-order or three-order relationship; see the attached circuit diagram for details.

[0027] Alternatively, to minimize the number of adjacent interleavings between different phases in the end winding region, multiple sub-layers can be stacked and then divided into two- or three-order relationships. That is, the end windings extending out of the slot for cross-slot connections are also composed of multiple layers. For example, there are 36 layers per phase per slot, and the total number of layers of the end windings extending out of the slot for cross-slot connections is 12. The goal is to combine as many adjacent layers as possible into a parallel winding and parallel electrical connection relationship for transmission. This can reduce the number of layers that need to be insulated at the line voltage and high voltage level, that is, reduce the number of layers with line voltage between adjacent layers of the end winding, reduce the number of high voltage insulation layers, and improve safety. See the attached circuit diagram.

[0028] Meanwhile, a series of configuration schemes based on independent forming of slot windings and end windings were disclosed. The key points include: the end windings are all thin copper strips bent into shape, which can be interwoven to realize cross-slot wiring of different phases. Note: the end windings in this embodiment have the same shape and structure. For ease of description, they are named first-order, second-order, and third-order end windings, which correspond to the electrical connection of slot windings of different phases, respectively.

[0029] Among them: 1. Iron core (For the sake of simplicity in the attached drawings, only the outline of the iron core is shown. The actual structure is composed of laminated silicon steel sheets. See attached drawing for details.) Figure 7 1. Two stacked structure directions are shown respectively; 2. In-slot winding (strictly speaking: the structure in this example is no longer a winding structure but a heterogeneous conductive post); 3, 4, 5 correspond to the first, second, and third order end windings of the inner ring; 6, 7, 8 correspond to the first, second, and third order end windings of the outer ring; the principle of this structure can also be found in the previous application.

[0030] As mentioned above: the naming of first-order, second-order, and third-order is only for ease of explanation and to distinguish the definitions from the perspective of spatial termination. The attached diagram shows that each corresponds to a winding of a different phase. In this scheme with three-order spatial misalignment, the busbar thickness of the winding at the end of each phase can only be 1 / 3 or slightly less than 1 / 3 of the busbar thickness of the winding in the slot. See attached diagram. Figure 14 If it is divided into two-order spatial misalignment, then the busbar thickness of the end winding of each phase (note: also a three-phase electrical winding) can be 1 / 2 or slightly less than 1 / 2 of the busbar thickness of the winding in the slot. See Appendix. Figure 13 :

[0031] All independently separated end windings in the prior application can be pre-formed or independently formed, manufacturing all end windings (including various types such as enameled wire windings and bare copper plate bent plates) into an integrated flat cylindrical end winding module. This module is then installed and mated onto the stator core, just like installing a motor end cover. It ensures that the end windings in the end cover correspond one-to-one with the windings in the slot and that there is a good electrical connection. It also ensures that there are reliable insulation characteristics between them. The electrical connection can be achieved by pressure mating and pressing, or by welding, using processes such as high-current resistance welding, laser welding, electron beam welding, and plasma welding.

[0032] The relevant outlines for this series of applications are listed below:

[0033] On May 17, 2024, a high- and low-order scheme for the end winding was first proposed.

[0034] On July 8, 2024, a 1 / 2 thickness concentric arc copper tile scheme and a split winding scheme were first proposed; and on July 11 and 7.12, a winding scheme and related schemes for an axial flux motor based on relevant theories were proposed.

[0035] On July 15, 2024, a cross-layer oblique arc copper tile scheme was first proposed; it is a wave winding (or a lap winding, see prior application); a circuit board scheme was proposed in the interim period between the two.

[0036] On November 29, 2024, a scheme for concentric arc copper tiles with a thickness of 1 / 3 was proposed; the winding is lapped.

[0037] The new application filed on November 28, 2025, combines the above-mentioned approach and focuses on the priority application based on November 29, 2024. It is basically divided into two categories, as follows:

[0038] Category 1: A separate design for cross-layer oblique arc copper tile schemes, where the electrical connection between the slot winding and the end winding can be achieved through pressure butt welding or welding; it is a wave winding (or a lap winding, see prior application); see appendix. Figure 1-6 Appendix Figure 12-15 And Figures 21-26, with Figure 21 being an appendix. Figure 3 Enlarged view of the area corresponding to part number identifier 10, see Figures 22-26 and 24. Figure 1-6 The principle of the end winding is the same; this is to further clarify its structural and technological principles. Figure 1-6 The corresponding slot winding has 12 layers (see attached reference). Figure 12-15 Figures 22-26 show that the windings within the slots have four layers, which more clearly illustrates the structure. For details regarding Figures 22-26, please refer to the prior application (including its corresponding part number identification).

[0039] Category Two: Original Works Figures 7-11 The stator winding scheme diagram for a 48-slot, 8-pole, 3-layer motor with a 1 / 3 bidirectional short-pitch, three-stage interleaving scheme is shown. The scheme uses a 1 / 3 thickness, concentric arc-shaped copper tile in the same layer. Due to the simultaneous crossing of three-phase windings in the end winding area, the end winding thickness is designed to be less than or equal to 1 / 3 of the winding thickness within the slot, facilitating interleaving wiring at the ends. The circuit diagram is shown in attached figures 19 and 20 (focus on figure 20). It features 48 slots and 8 poles, with 2 pole-phase slots. A, B, and C correspond to different line types, representing different phase windings (A corresponds to dashed line, B to dotted line, and C to double-dotted line). This scheme... The thickness of the end winding in the case is 1 / 3 of the thickness of the in-slot winding. See Figure 28 for an explanation of this relationship. The left, middle, and right figures represent different phase windings. The thickness inside the slot is three times that outside the slot. In this example, the in-slot winding is a bus-and-sub-bus winding, with each bus layer composed of three sub-layers. The middle area is insulated from each other to improve the skin effect. The two ends are connected as a whole to ensure a parallel electrical connection, and each end is electrically connected to the end winding along the corresponding sub-layer position shown in the figure. This connection can be achieved through mechanical pressure contact or welding. The illustrated scheme is a lap winding. Therefore, the wiring relationships of the end windings at both ends are shown in the attached figures. Figure 10 , Figure 11 One end is a concentric arc copper tile structure of the same layer ( Figure 11 The other end is a multi-layer structure. Figure 10 The two ends of the structure, when combined, form a closed concentric lapped winding circuit, which can be combined with... Figure 7-9 Let's read and analyze.

[0040] The application content is illustrated with relevant case studies:

[0041] The flat busbar scheme can be divided into pre-entry welding and post-entry welding schemes. 1. Before entering the tank, the busbars at both ends are fused and welded together to form a whole. The welding process can be resistance welding. The advantage of pre-entry welding is that it can weld a large number of busbars at once. After that, the busbars with welded ends will be treated the same as the current thick flat busbars. The subsequent processes are basically the same, including: twisting, flaring, cutting flat, welding, coating, etc. The welding can be laser welding.

[0042] The advantages of welding after slotting are as follows: Before being installed in the stator slots, the busbars and sub-busbars are separate, each independent, and each sub-busbar's thickness is less than the width of the stator slot opening. This allows for a sliding-in assembly from the narrow slot opening of the stator core. Therefore, the flat wire can be pre-formed and uniformly pre-formed outside the slot according to the twist-flaring requirements, eliminating the twist-flaring process after the flat wire winding is installed in the slot. After installation, the mutual fusion welding between the busbars and sub-busbars, as well as the welding between adjacent layers of busbars (i.e., the ends of the busbars to be welded), are completed all at once, combining the welding processes. However, this method still has its limitations. While it may reduce production efficiency, from an efficiency standpoint, pre-welding might be more efficient overall, especially with this busbar design. Since the busbar has few layers and is composed of multiple thin, flat wires, it offers better flexibility during twisting. Therefore, pre-welding before placement in the slot, followed by twisting, cutting, and laser welding after placement, might be preferable. However, if dip welding (see prior application) is used, welding after placement is recommended. For most motors, the maximum temperature limit at peak power is below 200 degrees Celsius, so dip welding is acceptable. Therefore, uniform welding after placement is recommended. Furthermore, due to limitations on the bending angle of the busbar, an i-pin-like method with welding at both ends is suggested.

[0043] Analysis: The reason why flat wire motor winding structure has become mainstream is that it is indeed a very good structural solution. Therefore, the cross-bracing I-PIN solution of this application is also a good solution (see also the relevant prior applications).

[0044] Alternatively, a separate winding scheme can be adopted (see relevant prior applications). The end windings can be copper tiles or copper plates, and are electrically connected to the slot-mounted flat wire straight posts by pressure butt welding or welding. Figuratively speaking, the slot-mounted windings can be called copper posts, and the end windings can be called copper tiles, copper discs, copper fan blades, etc. In addition, the rotor can be installed first, and then the end windings can be joined and welded together. This scheme is advantageous because the end windings occupy a smaller area than the air gap, which can reduce the length of the end windings. Especially for motors with a small number of pole pairs, the length of the end windings can be significantly reduced.

[0045] Alternatively, the X-PIN approach can be further modified by changing the welding area to a horizontal butt joint or overlapping parallel butt joint before welding (see Figure 27). This can increase the overlapping area and the welding area. Another approach is the "busbar or longitudinal and transverse busbar" scheme disclosed in this related application. While ensuring that the number of busbar series turns in each phase winding meets the motor parameter requirements, the number of parallel branches should be minimized, preferably with 1 parallel branch. The skin effect can be optimized by maximizing the number of sub-layers in each busbar. The total number of stator slots can be optimized by reasonably adjusting the total number of slots. Generally speaking, after balancing manufacturability, mechanical strength, reliability, and cost, the total number of slots should be maximized to further reduce the number of busbar layers in each slot. For example, after the above optimization, the number of busbar layers in each slot can be only two, optimizing performance while simplifying the process, reducing manufacturing costs, and improving reliability.

[0046] Note: The above figures refer to the figures from the earlier application.

[0047] This application falls under Class 1. Figures 1-15 As shown, the winding in the corresponding slot has 2 layers, which is a 2-layer busbar, with 72 slots and 8 poles. The number of pole phase slots is 3, the number of winding mother layers in each slot is 2, and the winding of each phase is in a single-branch series state to minimize the number of mother layers.

[0048] In the embodiments, the end electrical connection elements are all manufactured by stamping thin conductors, and are insulated from each other in the middle section, except for the first and second ends, in order to reduce the skin effect, improve heat dissipation, and reduce processing costs.

[0049] This invention improves upon the previously filed series of "Distributed Separate Winding Process Design and Manufacturing Methods" by proposing a "Super Flat Wire Centralized Physical Layered Branch Number Hybrid Winding Process and Design Method." Its key features are: the conventional number of flat wire layers is no longer constrained; to reduce the number of connection or welding points, the number of physical layers can be merged as much as possible, simplifying it to two or more layers. This significantly reduces the workload of twisting, cutting, flaring, and welding the end windings, and improves reliability. However, multiple windings or branch windings can exist within the same physical layer, allowing for several additional sub-layers or parent layers (defined in previous applications). It also facilitates flaring the inner and outer diameters first, increasing space and increasing the conductive cross-section to reduce end winding resistance. Simultaneously, the above principles can also be considered to minimize the number of high-voltage layers with line voltage.

[0050] A design method for end winding assemblies that can reduce the skin effect is characterized by: the end winding being separate and independent from the slot winding; the end winding being composed of several thinner wires or enameled wires connected in parallel to form a large total conductive cross-sectional area to meet the requirements of large current conduction; and the electrical connection between the end winding and the slot winding can be achieved by pressure contact butt welding or welding. See the attached drawings for details and specific implementation examples.

[0051] To achieve a conductive surface pressure contact butt joint, the butt joint ends need to be machined into a neat and flat cross-section to ensure excellent conductivity of the butt joint connection. Additionally, the butt joint ends need to be designed to facilitate the application of pressure, or the entire thin, flexible wire should be cured, such as through potting, to ensure a proper butt joint and good conductivity after pressure is applied. Figure 1-3 The images show various schemes, including thin round lines and thin flat lines.

[0052] Generally, parallel thin wires or enameled wires are brazed at the ends, such as the most common soldering or tin-immersion treatment, so that the ends form a parallel electrical connection. Note: If it is an enameled wire, the insulation varnish needs to be removed from its ends.

[0053] The conductor can be enameled wire or ultra-flat wire, see relevant prior applications, and the bare copper wire (or bare aluminum wire) can be isolated and insulated with a high-temperature resistant insulation layer;

[0054] Its conductor cross-section can be round or flat, and the enameled wire can be enameled round or enameled flat;

[0055] If the fine wire has not undergone curing treatment, pressure contact is not ideal. Welding or brazing methods, such as tin soldering or silver soldering, can be used. To ensure high-temperature resistance, hard brazing can be used. The process specifications include: brazing with a filler metal melting point above 450℃ is considered hard brazing. Hard filler metals include copper-based, silver-based, and aluminum-based alloys. Common fluxes include borax, boric acid, fluorides, and chlorides. Heating methods include flame heating, salt bath heating, resistance heating, and high-frequency induction heating. Hard brazed joints have a strength up to 490MPa and are suitable for workpieces subjected to high stress and operating at high temperatures.

[0056] Soft soldering can also be used. The process specifications include: soldering with a filler metal melting point below 450℃ is considered soft soldering. Commonly used filler metals are tin-lead alloys. Commonly used fluxes include rosin and ammonium chloride solution. Commonly used methods include soldering irons and other flame heating.

[0057] Figure 1-15 The example described is a diagram illustrating the structure of a 72-slot, 8-pole, double-layer, flared-end copper tile winding. In this example, the copper tile is composed of multiple layers of thin copper material (4 layers in this case), with each layer adding an insulation layer and gaps between layers. The combined function of these elements is to reduce the skin effect and improve heat dissipation. Additionally, electrical connection blocks are installed on both sides of the straight-slot winding, made of materials with low resistivity, such as silver, which offers good conductivity and low hardness. This allows for optimal contact and conductivity when the end winding and the slot winding are fully compressed. In this example, the end winding is embedded in the motor end cover, completing the electrical connection between the end winding and the slot winding in one step during the installation of the motor end cover and the outer casing. This reduces assembly workload and facilitates disassembly and maintenance. See the attached diagram for details. Figure 1-15 ;

[0058] Figure 16 -Another structure and process description for ultra-flat wire centralized physical layered branch number mixed winding, with example examples:

[0059] A. Dedicated conductive copper pillars or terminals are pre-welded or riveted to the electrical connection mating surface area between the end winding and the slot winding. Electrical connection is then achieved through terminals, such as bolted connections, pressure fitting, interlocking, interference fit, wedge fit, etc., using mechanical stress pre-stressing processes to achieve a tight bond. Alternatively, welding methods, such as copper welding or brazing, can be used. The end winding can be a wire bundle composed of several fine-diameter conductors, enameled wires, enameled flat wires, ultra-flat wires, etc., and its material can be conductive materials such as copper and aluminum. To improve efficiency, the total length of the end winding... The conductive cross section can be larger than that of the winding in the slot. In short, the resistance of the end winding should be minimized to improve the overall efficiency. Alternatively, aluminum wire can be used instead of copper wire to save costs. Since the end winding is a separate flexible wire, the inner and outer spaces of the motor end area can be fully utilized to reduce the axial space of the overall winding and make the most of the rotor space without affecting the rotor. Since the diameter of this area is small, a shorter transmission conductive path can be obtained to reduce resistance and save materials. Alternatively, cooling water pipes, water jackets, or oil pipes can be placed in parallel in the wire harness to achieve a superior direct heat conduction and heat absorption effect.

[0060] B. Using ultra-flat wire (see prior application) to manufacture integral flat wire gauge, that is: replacing the space where the wire gauge of the traditional flat wire motor is located with ultra-flat wire, dividing a large cross-section flat wire into several small conductive cross-sections, which are insulated from each other to reduce the skin effect and improve assembly characteristics. Since the flat wire is very soft and narrow, it can slide into the slot of the stator core, similar to the assembly process of round wire windings, and can be made into a continuous wave winding without solder joints; or, it can also be electrically connected by pressure butt welding, welding or brazing soldering processes, see above;

[0061] Alternatively, the overall wire gauge of the manufactured ultra-flat wire can be used to complete the overall winding manufacturing according to H-PIN, I-PIN, X-PIN, and W-PIN processes; the width and cross-sectional angle of the flat wire can be placed horizontally (perpendicular to the diameter) or vertically (parallel to the diameter) in the slot, or the ultra-flat wire size in the slot area can be widened to reduce resistance, or the ultra-flat wire size in the slot area can be narrowed to reduce the axial dimension of the winding and reduce the volume;

[0062] Generally speaking, if a vertical arrangement is used, it is recommended to use the I-PIN process, which is free to disconnect at both ends, making assembly easy and wiring flexible. The electrical connection between the slot windings can be achieved by pressure butt welding, soldering, or brazing.

[0063] Alternatively, the bare copper material used to manufacture wire gauges can be impregnated with enamel, pre-protecting conductive connection areas, such as pressure butt joint areas or welding areas, from being immersed in the enamel, thus eliminating the need for a secondary enamel removal process.

[0064] Alternatively, the entire motor winding can be impregnated after all windings are completed. The impregnation process can be the enameled wire insulation process, or other impregnation insulation processes or potting processes, etc.

[0065] A review of new principles for the design and manufacturing process of ultra-flat wire centralized physical layered branch windings: The conventional number of flat wire layers is no longer constrained. To reduce the number of joints or welding points, the number of physical layers can be combined as much as possible, simplifying it to two or more layers. This greatly reduces the workload of twisting, cutting, flaring, and welding of the end windings, and improves reliability. However, there can be multiple windings or branch windings in the same physical layer, and there can be several more sub-layers or parent layers (defined in prior applications). It also facilitates the flaring of the inner and outer diameters, increasing space and helping to increase the conductive cross-section and reduce the resistance of the end windings. At the same time, the above principles can also be considered to minimize the number of high-voltage layers with line voltage.

[0066] The insulation layer can also be pre-wrapped on the overall wire gauge, eliminating the need for slot paper, which helps improve slot fill rate and protects the wire gauge from damage during insertion.

[0067] The above solution is also applicable to axial flux motors.

[0068] This invention improves upon the previously filed series of "winding process design and manufacturing methods" by proposing a "mother-and-child layer winding and variable wire gauge process and design method." Its key features are: all parallel windings are designed according to the principle of child layer windings, resulting in zero voltage between child layer windings. This allows for insulation using a very thin insulation process, further increasing the copper fill factor and accommodating more layers while reducing the skin effect. Similarly, the end windings can also be designed with mother-and-child layer separation as much as possible, significantly reducing the number of adjacent cross layers between different phase windings in the end windings and improving safety.

[0069] Variable gauge type: The cross-sectional dimensions of the gauge can have different shapes in different spaces, and the cross-section inside the groove is different from the cross-section at the outer end of the groove, such as: second-order type, third-order type; double short-pitch type,

[0070] This invention improves upon the previously filed series of "distributed split winding process design and manufacturing methods" by proposing a "mother-daughter layer winding and variable wire gauge process and design method". Its features include: designing all parallel windings according to the principle of daughter-daughter layer windings, resulting in zero voltage between daughter-daughter layer windings, allowing for insulation with a very thin insulation process to further improve the copper fill factor, while accommodating more layers and reducing the skin effect; similarly, the end windings can also be designed with mother-daughter layer separation as much as possible, greatly reducing the number of adjacent cross layers between different phase windings of the end windings and improving safety.

[0071] Variable gauge type: The cross-sectional dimensions of the gauge can have different shapes in different spaces, and the cross-section inside the groove is different from the cross-section at the outer end of the groove, such as: second-order type, third-order type; double short-pitch type,

[0072] It can have a structure similar to a continuous wave winding, with no solder joints on either side. Due to the ultra-flat wire's parent-child layer and combined variable gauge size structure, that is: the gauge is composed of a straight slot gauge and a continuous wave gauge superimposed. The straight slot gauge is only present in the slot area (it can slightly extend out of the slot to obtain better equal cross-sectional conductivity), while the continuous wave gauge exists both inside and outside the slot. The two overlap in the slot area, and are electrically connected only on both sides of the slot opening to form a parallel electrical connection. The middle area is insulated with an insulating film to reduce the yielding effect. To obtain an equivalent conductive cross-sectional area, the continuous wave gauge becomes very wide in the slot area, that is: its cross-sectional area is equal to The cross-sectional area of ​​the slot area is approximately equal to, greater than, or less than the design principle: if the goal is to reduce resistance and improve efficiency, the total cross-sectional area of ​​the external winding is greater than the total cross-sectional area of ​​the related parallel windings inside the slot; if the goal is to reduce cost and size, the external conductive cross-sectional area is smaller than the internal conductive cross-sectional area; generally, it is equal to or approximately equal to the design principle; different materials can also be used, see prior application) the sum of the cross-sectional areas of the slot area of ​​the straight slot wire gauge plus the continuous wave wire gauge. Note: The straight slot wire gauge plus the continuous wave wire gauge can be one or more layers combined; the thickness of the flat wire in the end winding area extending out of the slot can be very thin, allowing for cross-slot insertion between end windings of different phases (two-phase or three-phase lines);

[0073] Since this continuous wave is only a part of the thin flat wire of the combined wire gauge, its continuous wave winding flat wire is very thin and can be easily slid into the stator core slot, ensuring that the slot is still a semi-open slot, unlike the current continuous wave whose slot is an open slot. It achieves a winding process similar to that of a round wire motor, but the overall and end dimensions are significantly shorter than those of a round wire. Because the flat wire is regular and neat, its continuous wave wire gauge can be neatly arranged and slid into the slot. Its axial dimension can be precisely designed so that after winding, it is regular, neat and has a very short axial dimension, as shown in the figure.

[0074] Note: Continuous wave does not specifically refer to waveform winding; it can be either continuous wave winding or continuous lap winding.

[0075] To simplify assembly, it can be either a segmented continuous wave winding or a segmented continuous lap winding.

[0076] Alternatively, it can be a discontinuous structure, similar to the split winding mentioned in the prior applications of this series, where the end winding is separated from the slot winding. It can be a split type at both ends, or a continuous type on one side and a split type on the other. That is, similar to a hairpin flat wire, it is pre-formed, inserted from one side of the iron core, and then connected to the split end winding on the other side for electrical connection. The electrical connection can be achieved by welding or mechanical contact pressure connection.

[0077] It can be a two-order or three-order relationship; see the attached circuit diagram for details.

[0078] Alternatively, to minimize the number of adjacent interleavings between different phases in the end winding region, multiple sub-layers can be stacked and then divided into two- or three-order relationships. That is, the end windings extending out of the slot for cross-slot connections are also composed of multiple layers. For example, there are 36 layers per phase per slot, and the total number of layers of the end windings extending out of the slot for cross-slot connections is 12. The goal is to combine as many adjacent layers as possible into a parallel winding and parallel electrical connection relationship for transmission. This can reduce the number of layers that need to be insulated at the line voltage and high voltage level, that is, reduce the number of layers with line voltage between adjacent layers of the end winding, reduce the number of high voltage insulation layers, and improve safety. See the attached circuit diagram.

[0079] The above solution can also be used for conventional single-rotor motors, such as replacing existing brushless or brushed solutions.

[0080] 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, and axial flux motors, etc.

[0081] Note:

[0082] 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.

[0083] 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 centralized physical layered branch number mixed winding process and design method, including motor windings, stator, rotor, housing, etc., characterized by: The conventional number of flat wire layers is no longer constrained by this. In order to reduce the number of butt joints or welding points, the number of physical layers can be combined as much as possible, which can be simplified to two or more layers. This greatly reduces the workload of twisting, cutting, flaring, and welding of the end windings and improves reliability. However, there can be multiple windings or multiple branch windings in the same physical layer, and there can be several more sub-layers or parent layers (defined in the prior application). It is also convenient to flare the inner and outer diameters first, increase the space and help increase the conductive cross-section to reduce the resistance of the end windings. At the same time, the above principles can also be considered to minimize the number of high-voltage layers with line voltage. Based on the aforementioned prior applications, this invention improves upon the specific embodiments of the series of "distributed split winding process design and manufacturing methods" in the prior applications by proposing a "mother-daughter layer winding and variable wire gauge process and design method". Its features include: designing all parallel windings according to the principle of daughter-layer windings, resulting in zero voltage between daughter-layer windings, allowing for insulation using a very thin insulation process to further improve the copper fill factor, while accommodating more layers and reducing the skin effect; similarly, the end windings can also be designed with mother-daughter layer separation as much as possible, greatly reducing the number of adjacent cross layers between different phase windings of the end windings and improving safety. Variable gauge type: The cross-sectional dimensions of the gauge can have different shapes in different spaces, and the cross-section inside the groove is different from the cross-section at the outer end of the groove, such as: second-order type, third-order type; double short-pitch type, It can have a structure similar to a continuous wave winding, with no solder joints on either side. Due to the ultra-flat wire's parent-child layer and combined variable gauge size structure, that is: the gauge is composed of a straight slot gauge and a continuous wave gauge superimposed. The straight slot gauge is only present in the slot area (it can slightly extend out of the slot to obtain better equal cross-sectional conductivity), while the continuous wave gauge exists both inside and outside the slot. The two overlap in the slot area, and are electrically connected only on both sides of the slot opening to form a parallel electrical connection. The middle area is insulated with an insulating film to reduce the yielding effect. To obtain an equivalent conductive cross-sectional area, the continuous wave gauge becomes very wide in the slot area, that is: its cross-sectional area is equal to The cross-sectional area of ​​the slot area is approximately equal to, greater than, or less than the design principle: if the goal is to reduce resistance and improve efficiency, the total cross-sectional area of ​​the external winding is greater than the total cross-sectional area of ​​the related parallel windings inside the slot; if the goal is to reduce cost and size, the external conductive cross-sectional area is smaller than the internal conductive cross-sectional area; generally, it is equal to or approximately equal to the design principle; different materials can also be used, see prior application) the sum of the cross-sectional areas of the slot area of ​​the straight slot wire gauge plus the continuous wave wire gauge. Note: The straight slot wire gauge plus the continuous wave wire gauge can be one or more layers combined; the thickness of the flat wire in the end winding area extending out of the slot can be very thin, allowing for cross-slot insertion between end windings of different phases (two-phase or three-phase lines); Since this continuous wave is only a part of the thin flat wire of the combined wire gauge, its continuous wave winding flat wire is very thin and can be easily slid into the stator core slot, ensuring that the slot is still a semi-open slot, unlike the current continuous wave whose slot is an open slot. It achieves a winding process similar to that of a round wire motor, but the overall and end dimensions are significantly shorter than those of a round wire. Because the flat wire is regular and neat, its continuous wave wire gauge can be neatly arranged and slid into the slot. Its axial dimension can be precisely designed so that after winding, it is regular, neat and has a very short axial dimension, as shown in the figure. Note: Continuous wave does not specifically refer to waveform winding; it can be either continuous wave winding or continuous lap winding. To simplify assembly, it can be either a segmented continuous wave winding or a segmented continuous lap winding. Alternatively, it can be a discontinuous structure, similar to the split winding mentioned in the earlier applications of this series, where the end winding is separated from the slot winding. It can be a split type at both ends, or a continuous type on one side and a split type on the other. That is, similar to a hairpin flat wire, it is pre-formed, inserted from one side of the iron core, and then connected to the split end winding on the other side for electrical connection. The electrical connection can be achieved by welding or mechanical contact pressure connection. It can be a two-order or three-order relationship; see the attached circuit diagram for details. Alternatively, to minimize the number of adjacent interleavings between different phases in the end winding region, multiple sub-layers can be stacked and then divided into two- or three-order relationships. That is, the end windings extending out of the slot for cross-slot connections are also composed of multiple layers. For example, there are 36 layers per phase per slot, and the total number of layers of the end windings extending out of the slot for cross-slot connections is 12. The goal is to combine as many adjacent layers as possible into a parallel winding and parallel electrical connection relationship for stacking and transmission. This can reduce the number of layers that need to be insulated at the line voltage and high voltage level. In other words, it reduces the number of layers with line voltage between adjacent layers of the end winding, reduces the number of high voltage insulation layers, and improves safety. See the attached circuit diagram. Meanwhile, a series of configuration schemes based on independent forming of slot windings and end windings were disclosed. The key points include: the end windings are all thin copper strips bent into shape, which can be interwoven to realize cross-slot wiring of different phases. Note: the end windings in this embodiment have the same shape and structure. For ease of description, they are named first-order, second-order, and third-order end windings, which correspond to the electrical connection of slot windings of different phases, respectively. Wherein:

1. Iron core (for the sake of simplicity, only the outline of the iron core is shown in the attached diagram. The actual structure is composed of silicon steel laminations. See attached diagram 7, which shows two lamination orientations); 2. In-slot winding (strictly speaking, the structure in this example is no longer a winding structure but an anisotropic conductive post); 3, 4, and 5 correspond to the first, second, and third order end windings of the inner ring; 6, 7, and 8 correspond to the first, second, and third order end windings of the outer ring. The principle of this structure can also be found in the previous application. As mentioned above: the naming of first-order, second-order, and third-order is only for ease of explanation and to distinguish the definitions from the perspective of spatial arrangement. The attached diagram can correspond to windings of different phases respectively. In this scheme, which is divided into three-order spatial misalignment, the busbar thickness of the end winding of each phase can only be 1 / 3 or slightly less than 1 / 3 of the busbar thickness of the winding in the slot, see attached diagram 14; if it is divided into two-order spatial misalignment, the busbar thickness of the end winding of each phase (note: also a three-phase electrical winding) can be 1 / 2 or slightly less than 1 / 2 of the busbar thickness of the winding in the slot, see attached diagram 13. All independently separated end windings applied for earlier can be pre-formed or independently formed, manufacturing all end windings (including various types such as enameled wire windings, bare copper plate bending plates, etc.) into an integrated flat cylindrical end winding module, which is installed and mated onto the stator core like installing motor end covers, ensuring that the end windings in the end cover correspond one-to-one with the windings in the slot and ensuring a good electrical connection, and ensuring reliable insulation characteristics between them. The electrical connection can be achieved by pressure mating and pressing contact, or by welding, such as high current resistance welding, laser welding, electron beam welding, plasma welding, etc. The relevant outlines for this series of applications are listed below: On May 17, 2024, a high- and low-order scheme for the end winding was first proposed. On July 8, 2024, a 1 / 2 thickness concentric arc copper tile scheme and a split winding scheme were first proposed; and on July 11 and 7.12, a winding scheme and related schemes for an axial flux motor based on relevant theories were proposed. On July 15, 2024, a cross-layer oblique arc copper tile scheme was first proposed; it is a wave winding (or a lap winding, see prior application); a circuit board scheme was proposed in the interim period between the two. On November 29, 2024, a scheme for concentric arc copper tiles with a thickness of 1 / 3 was proposed; this is a lap winding scheme. The new application filed on November 28, 2025, combines the above-mentioned approach and focuses on the priority application based on November 29, 2024. It is basically divided into two categories, as follows: Category 1: A separate design for cross-layer oblique arc copper tile, where the electrical connection between the slot winding and the end winding can be achieved by pressure butt welding or welding; it is a wave winding (or a lap winding, see prior application); see Figures 1-6; Figures 12-15 and 21-26, where Figure 21 is a partial enlarged view of the area corresponding to part number 10 in Figure 3; Figures 22-26 have the same end winding principle as Figures 1-6, and are used to further clarify its structural and technological principles; Figures 1-6 correspond to 12 layers of slot winding (see Figures 12-15 for reference); Figures 22-26 correspond to 4 layers of slot winding, which can more clearly show its structure; details related to Figures 22-26 can be found in prior applications (including their corresponding part number identification descriptions). Category 2: Original, Figures 7-11: 1 / 3 bidirectional short-pitch three-stage interleaving scheme for 48-slot 8-pole 3-mother-layer motor stator windings, using a 1 / 3 thickness concentric arc copper tile scheme. The end winding area has a problem of three-phase windings simultaneously crossing each other, so the end winding thickness is less than or equal to 1 / 3 of the thickness of the winding in the slot as the design basis to facilitate interleaving wiring at the ends; see attached figures 19 and 20 for circuit diagrams (focus on Figure 20); it is 48 slots 8 poles, with 2 pole-phase slots. A, B, and C correspond to different line types, representing different phase windings (A corresponds to dashed line, B to dotted line, C to double dotted line); the thickness relationship diagram of the end winding thickness being 1 / 3 of the thickness of the winding in the slot can be seen in attached figure 28. The three figures on the left, middle, and right represent different phase windings. The thickness inside the slot is three times that outside the slot. In this example, the winding inside the slot is a bus-and-sub-bus winding. Each bus layer is composed of three sub-layers. The middle area is insulated from each other to improve the skin effect. The two ends are connected as one to ensure a parallel electrical connection. Each end is electrically connected to the end winding along the corresponding sub-layer position area shown in the figure. This can be done by mechanical pressure contact or welding. The scheme shown is a lap winding. Therefore, the wiring relationship of the end windings at both ends is shown in Figures 10 and 11. One end is a concentric arc copper tile structure in the same layer (Figure 11), and the other end is a cross-layer structure (Figure 10). The two end structures are combined to form a closed concentric lap winding circuit relationship, which can be read and analyzed in conjunction with Figures 7-9. The application content is illustrated with relevant case studies: The flat busbar scheme can be divided into pre-entry welding and post-entry welding schemes.

1. Before entering the tank, the busbars at both ends are fused and welded together to form a whole. The welding process can be resistance welding. The advantage of pre-entry welding is that it can weld a large number of busbars at once. After that, the busbars with welded ends will be treated the same as the current thick flat busbars. The subsequent processes are basically the same, including: twisting, flaring, cutting flat, welding, coating, etc. The welding can be laser welding. The advantages of welding after slotting are as follows: Since the busbars and stator windings are separate before being installed in the stator slots, each busbar is independent and its thickness is less than the width of the stator slot opening. This allows for a sliding-in assembly from the narrow slot opening of the stator core. Therefore, the flat wire can be pre-formed and uniformly pre-formed outside the slot according to the twist-flaring requirements, eliminating the twist-flaring process after the flat wire winding is installed. After installation, the mutual fusion welding between the busbars and stator windings, as well as the welding between adjacent busbar layers (i.e., the ends of the busbars to be welded), are completed all at once, combining the welding processes. However, this method may still reduce production efficiency. From a production efficiency perspective, it might be better to advance the process earlier. The welding method offers higher overall production efficiency, especially when using this busbar design. Since the busbar has fewer layers and is composed of multiple thin, flat wires, it exhibits better flexibility during twisting. Therefore, welding before placement in the slot, followed by twisting, cutting, and laser welding after placement, may be preferable. However, if dip welding (see prior application) is used, welding after placement in the slot is recommended. For most motors, the maximum temperature limit at peak power is within 200 degrees Celsius, so dip welding is feasible. Therefore, uniform welding after placement in the slot is recommended. Additionally, due to the limited bending angle of the busbar, a method similar to an i-pin is recommended, with welding at both ends. Analysis: The reason why flat wire motor winding structure has become mainstream is that it is indeed a very good structural solution. Therefore, the cross-bracing I-PIN solution of this application is also a good solution (see also the relevant prior applications). Alternatively, a separate winding scheme can be adopted (see relevant prior applications). The end windings can be copper tiles or copper plates, and are electrically connected to the slot-mounted flat wire straight posts by pressure butt welding or welding. Figuratively speaking, the slot-mounted windings can be called copper posts, and the end windings can be called copper tiles, copper discs, copper fan blades, etc. In addition, the rotor can be installed first, and then the end windings can be joined and welded together. This scheme is advantageous because the end windings occupy a smaller area than the air gap, which can reduce the length of the end windings. Especially for motors with a small number of pole pairs, the length of the end windings can be significantly reduced. Alternatively, the X-PIN approach can be further modified by changing the welding area to a horizontal butt joint or overlapping parallel butt joint before welding (see Figure 27). This can increase the overlapping area and the welding area. Another approach is the "busbar or longitudinal and transverse busbar" scheme disclosed in this related application. While ensuring that the number of busbar series turns in each phase winding meets the motor parameter requirements, the number of parallel branches should be minimized, preferably with 1 parallel branch. The skin effect can be optimized by maximizing the number of sub-layers in each busbar. The total number of stator slots can be optimized by reasonably adjusting the total number of slots. Generally speaking, after balancing manufacturability, mechanical strength, reliability, and cost, the total number of slots should be maximized to further reduce the number of busbar layers in each slot. For example, after the above optimization, the number of busbar layers in each slot can be only two, which optimizes performance, simplifies the process, reduces manufacturing costs, and improves reliability. Note: The above-mentioned figures refer to the figures from the earlier application; This application belongs to the first category as shown in Figures 1 to 15. The corresponding slot winding has 2 layers, which is a 2-layer busbar, with 72 slots and 8 poles. The number of pole phase slots is 3, the number of winding mother layers in each slot is 2, and the winding of each phase is a single branch series state to minimize the number of mother layers. In the embodiments, the end electrical connection elements are all manufactured by stamping thin conductors, and are insulated from each other in the middle section, except for the first and second ends, in order to reduce the skin effect, improve heat dissipation, and reduce processing costs.

2. The centralized physical layered branch number mixed winding process and design method according to claim 1, characterized in that: This paper proposes a "process and design method for ultra-flat wire centralized physical layered branch number hybrid winding", characterized by: the conventional number of flat wire layers is no longer constrained; to reduce the number of joints or welding points, the number of physical layers can be merged as much as possible, and it can be simplified to two or more layers. This greatly reduces the workload of twisting, cutting, flaring, and welding of the end windings, and improves reliability; however, there can be multiple windings or multiple branch windings in the same physical layer, and there can be several more sub-layers or parent layers (defined in the prior application); it is also convenient to first flare the inner and outer diameters, increase space and help increase the conductive cross-section to reduce the end winding resistance; at the same time, the above principles can also be considered to minimize the number of high-voltage layers with line voltage; A design method for end winding assemblies that can reduce the skin effect is characterized by: the end winding being separate and independent from the slot winding; the end winding being composed of several thinner wires or enameled wires connected in parallel to form a large total conductive cross-sectional area to meet the requirements of large current conduction; and the electrical connection between the end winding and the slot winding can be achieved by pressure contact butt welding or welding. See the attached drawings for details and specific implementation examples. To achieve a conductive surface pressure contact butt joint, the butt joint ends need to be machined into a neat and flat cross-section to ensure excellent conductivity of the butt joint connection. In addition, the butt joint ends need to be designed to facilitate the application of pressure, or the entire thin and soft wire needs to be cured, such as by potting and curing, so that it can be fully connected and meet good conductivity after pressure is applied; as shown in Figures 1-3, these are solutions for thin round wire, thin flat wire, etc. Generally, parallel thin wires or enameled wires are brazed at the ends, such as the most common soldering or tin-immersion treatment, so that the ends form a parallel electrical connection. Note: If it is an enameled wire, the insulation varnish needs to be removed from its ends. The conductor can be enameled wire or ultra-flat wire, see relevant prior applications, and the bare copper wire (or bare aluminum wire) can be isolated and insulated with a high-temperature resistant insulation layer; Its conductor cross-section can be round or flat, and the enameled wire can be enameled round or enameled flat; If the fine wire has not undergone curing treatment, pressure contact is not ideal. Welding or brazing methods, such as tin soldering or silver soldering, can be used instead. To ensure high-temperature resistance, hard brazing can be used. The process specifications include: brazing with a filler metal melting point above 450℃ is considered hard brazing; filler metals include copper-based, silver-based, and aluminum-based alloys; commonly used fluxes include borax, boric acid, fluorides, and chlorides; heating methods include flame heating, salt bath heating, resistance heating, and high-frequency induction heating; hard brazed joints have a strength up to 490MPa and are suitable for workpieces subjected to high stress and operating at high temperatures. Soft soldering can also be used. The process instructions include: soldering with a solder melting point below 450°C is called soft soldering; commonly used solders are tin-lead alloys; commonly used fluxes are rosin, ammonium chloride solution, etc.; commonly used soldering irons and other flame heating methods are used. Figure 1-15 illustrates the structure of a 72-slot, 8-pole, double-physical-layer, flared-end copper tile winding. In this case, the copper tile is composed of multiple layers of thin copper material, specifically four layers. Each layer adds an insulation layer, and gaps are added between layers. The combined function of these two elements is to reduce the skin effect and improve heat dissipation. Additionally, electrical connection blocks are installed on both sides of the straight-line slot winding, made of materials with low resistivity, such as silver, which has good conductivity and low hardness. This allows for optimal contact and conductivity when the end winding and the slot winding are fully compressed. In this case, the end winding is embedded in the motor end cover. The electrical connection between the end winding and the slot winding is completed in one step during the installation of the motor end cover and the outer casing, reducing assembly workload and facilitating disassembly and maintenance. See Figure 1-15 for details. Figure 16 illustrates another structure and process of ultra-flat wire centralized physical layered branch number mixed winding, with example examples: A. Dedicated conductive copper pillars or terminals are pre-welded or riveted to the electrical connection mating surface area between the end winding and the slot winding. Electrical connection is then achieved through terminals, such as bolted connections, pressure fitting, interlocking, interference fit, wedge fit, etc., using mechanical stress pre-stressing processes to achieve a tight bond. Alternatively, welding methods, such as copper welding or brazing, can be used. The end winding can be a wire bundle composed of several fine-diameter conductors, enameled wires, enameled flat wires, ultra-flat wires, etc., and its material can be conductive materials such as copper and aluminum. To improve efficiency, the total length of the end winding... The conductive cross section can be larger than that of the winding in the slot. In short, the resistance of the end winding should be minimized to improve the overall efficiency. Alternatively, aluminum wire can be used instead of copper wire to save costs. Since the end winding is a separate flexible wire, the inner and outer spaces of the motor end area can be fully utilized to reduce the axial space of the overall winding and make the most of the rotor space without affecting the rotor. Since the diameter of this area is small, a shorter transmission conductive path can be obtained to reduce resistance and save materials. Alternatively, cooling water pipes, water jackets, or oil pipes can be placed in parallel in the wire harness to achieve a superior direct heat conduction and heat absorption effect. B. Using ultra-flat wire (see prior application) to manufacture integral flat wire gauge, that is: replacing the space where the wire gauge of the traditional flat wire motor is located with ultra-flat wire, dividing a large cross-section flat wire into several small conductive cross-sections, which are insulated from each other to reduce the skin effect and improve assembly characteristics. Since the flat wire is very soft and narrow, it can slide into the slot of the stator core, similar to the assembly process of round wire windings, and can be made into a continuous wave winding without solder joints; or, it can also be electrically connected by pressure butt welding, welding or brazing soldering processes, see above; Alternatively, the overall wire gauge of the manufactured ultra-flat wire can be used to complete the overall winding manufacturing according to H-PIN, I-PIN, X-PIN, and W-PIN processes; the width and cross-sectional angle of the flat wire can be placed horizontally (perpendicular to the diameter) or vertically (parallel to the diameter) in the slot, or the ultra-flat wire size in the slot area can be widened to reduce resistance, or the ultra-flat wire size in the slot area can be narrowed to reduce the axial dimension of the winding and reduce the volume; Generally speaking, if a vertical arrangement is used, it is recommended to use the I-PIN process, which is free to disconnect at both ends, making assembly easy and wiring flexible. The electrical connection between the slot windings can be achieved by pressure butt welding, soldering, or brazing. Alternatively, the bare copper material used to manufacture wire gauges can be impregnated with enamel, pre-protecting conductive connection areas, such as pressure butt joint areas or welding areas, from being immersed in the enamel, thus eliminating the need for a secondary enamel removal process. Alternatively, the entire motor winding can be impregnated after all windings are completed. The impregnation process can be the enameled wire insulation process, or other impregnation insulation processes or potting processes, etc. A review of new principles for the design and manufacturing process of ultra-flat wire centralized physical layered branch windings: The conventional number of flat wire layers is no longer constrained. To reduce the number of joints or welding points, the number of physical layers can be combined as much as possible, simplifying it to two or more layers. This greatly reduces the workload of twisting, cutting, flaring, and welding of the end windings, and improves reliability. However, there can be multiple windings or branch windings in the same physical layer, and there can be several more sub-layers or parent layers (defined in prior applications). It also facilitates the flaring of the inner and outer diameters, increasing space and helping to increase the conductive cross-section and reduce the resistance of the end windings. At the same time, the above principles can also be considered to minimize the number of high-voltage layers with line voltage. The insulation layer can also be pre-wrapped on the overall wire gauge, eliminating the need for slot paper, which helps improve the slot fill rate and protects the wire gauge from damage during insertion. The above solution is also applicable to axial flux motors; This invention improves upon the previously filed series of "winding process design and manufacturing methods" by proposing a "mother-and-child layer winding and variable wire gauge process and design method." Its key features are: all parallel windings are designed according to the principle of child layer windings, resulting in zero voltage between child layer windings. This allows for insulation using a very thin insulation process, further increasing the copper fill factor and accommodating more layers while reducing the skin effect. Similarly, the end windings can also be designed with mother-and-child layer separation as much as possible, significantly reducing the number of adjacent cross layers between different phase windings in the end windings and improving safety. Variable gauge type: The cross-sectional dimensions of the gauge can have different shapes in different spaces, and the cross-section inside the groove is different from the cross-section at the outer end of the groove, such as: second-order type, third-order type; double short-pitch type, This invention improves upon the previously filed series of "distributed split winding process design and manufacturing methods" by proposing a "mother-daughter layer winding and variable wire gauge process and design method." Its key features are: all parallel windings are designed according to the principle of daughter-daughter layer windings, resulting in zero voltage between daughter-daughter layer windings. This allows for insulation using a very thin insulation process, further increasing the copper fill factor and accommodating more layers while reducing the skin effect. Similarly, the end windings can also be designed with mother-daughter layer separation as much as possible, significantly reducing the number of adjacent cross layers between different phase windings in the end windings and improving safety. Variable gauge type: The cross-sectional dimensions of the gauge can have different shapes in different spaces, and the cross-section inside the groove is different from the cross-section at the outer end of the groove, such as: second-order type, third-order type; double short-pitch type, It can have a structure similar to a continuous wave winding, with no solder joints on either side. Due to the ultra-flat wire's parent-child layer and combined variable gauge size structure, that is: the gauge is composed of a straight slot gauge and a continuous wave gauge superimposed. The straight slot gauge is only present in the slot area (it can slightly extend out of the slot to obtain better equal cross-sectional conductivity), while the continuous wave gauge exists both inside and outside the slot. The two overlap in the slot area, and are electrically connected only on both sides of the slot opening to form a parallel electrical connection. The middle area is insulated with an insulating film to reduce the yielding effect. To obtain an equivalent conductive cross-sectional area, the continuous wave gauge becomes very wide in the slot area, that is: its cross-sectional area is equal to The cross-sectional area of ​​the slot area is approximately equal to, greater than, or less than the design principle: if the goal is to reduce resistance and improve efficiency, the total cross-sectional area of ​​the external winding is greater than the total cross-sectional area of ​​the related parallel windings inside the slot; if the goal is to reduce cost and size, the external conductive cross-sectional area is smaller than the internal conductive cross-sectional area; generally, it is equal to or approximately equal to the design principle; different materials can also be used, see prior application) the sum of the cross-sectional areas of the slot area of ​​the straight slot wire gauge plus the continuous wave wire gauge. Note: The straight slot wire gauge plus the continuous wave wire gauge can be one or more layers combined; the thickness of the flat wire in the end winding area extending out of the slot can be very thin, allowing for cross-slot insertion between end windings of different phases (two-phase or three-phase lines); Since this continuous wave is only a part of the thin flat wire of the combined wire gauge, its continuous wave winding flat wire is very thin and can be easily slid into the stator core slot, ensuring that the slot is still a semi-open slot, unlike the current continuous wave whose slot is an open slot. It achieves a winding process similar to that of a round wire motor, but the overall and end dimensions are significantly shorter than those of a round wire. Because the flat wire is regular and neat, its continuous wave wire gauge can be neatly arranged and slid into the slot. Its axial dimension can be precisely designed so that after winding, it is regular, neat and has a very short axial dimension, as shown in the figure. Note: Continuous wave does not specifically refer to waveform winding; it can be either continuous wave winding or continuous lap winding. To simplify assembly, it can be either a segmented continuous wave winding or a segmented continuous lap winding. Alternatively, it can be a discontinuous structure, similar to the split winding mentioned in the earlier applications of this series, where the end winding is separated from the slot winding. It can be a split type at both ends, or a continuous type on one side and a split type on the other. That is, similar to a hairpin flat wire, it is pre-formed, inserted from one side of the iron core, and then connected to the split end winding on the other side for electrical connection. The electrical connection can be achieved by welding or mechanical contact pressure connection. It can be a two-order or three-order relationship; see the attached circuit diagram for details. Alternatively, to minimize the number of adjacent interleavings between different phases in the end winding region, multiple sub-layers can be stacked and then divided into two- or three-order relationships. That is, the end windings extending out of the slot for cross-slot connections are also composed of multiple layers. For example, there are 36 layers per phase per slot, and the total number of layers of the end windings extending out of the slot for cross-slot connections is 12. The goal is to combine as many adjacent layers as possible into a parallel winding and parallel electrical connection relationship for transmission. This can reduce the number of layers that need to be insulated at the line voltage and high voltage level, that is, reduce the number of layers with line voltage between adjacent layers of the end winding, reduce the number of high voltage insulation layers, and improve safety. See the attached circuit diagram.

3. The centralized physical layered branch number mixed winding process and design method according to claim 1, characterized in that: The above solution can also be used for conventional single-rotor motors, such as replacing existing brushless solutions and brushed solutions; The above solution is applicable to all types of electric motors and generators, including asynchronous motors, synchronous motors, brushless motors, brushed motors, induction motors, permanent magnet motors, switched reluctance motors, and axial flux motors, etc.

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