Matrix flat wire winding process design and manufacturing method

Abstract

This invention relates to a matrix flat wire winding process design and manufacturing method, which further improves upon prior applications and existing motors. It utilizes finely subdivided enameled flat wires pre-assembled into a coarser array of flat wires. Specifically, each large-section flat wire is subdivided into many small-section micro-flat wire micro-units. These micro-units are densely and compactly arranged to improve slot fill factor. After neat arrangement, they form a coarse flat wire group. Within the same coarse flat wire group, the micro-units are essentially connected in parallel, similar to the principle of fine enameled wire winding in a round wire motor, thus reducing the skin effect. The voltage difference between them is small or even zero, allowing for thin insulating varnish or film to isolate the sub-wire layers, which improves copper fill factor and enhances thermal conductivity and heat dissipation.

Description

Technical Field

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

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

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

[0004] 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] Regarding the aforementioned prior applications, particularly 202410619722.9, 202410643792.8, 202410684267.0, or "202510633801x, 2025106651254, 2025106995740", the structures described in those applications are also applicable to split winding designs, such as... Figure 1-3 As shown, where, Figure 1 This represents a single-sided separation, similar to a hairpin flat wire, which is inserted from one side and then joined to the other side; Figure 2 This indicates separation on both sides, meaning the winding in the middle slot is independent, and the windings at both ends are also separate. See: 202410930855.8 Forming Process and Design Method for Independent End Windings in Slots of Axial Flux Motors.

[0015] 202410938850.X Motor slot winding end winding independent forming process,

[0016] 202410947555.0 Molding process and design method for motor with separate windings;

[0017] Various welding methods or pressure butt contact electrical connections can be used, or a bare copper plus insulation material solution can be used to improve temperature resistance.

[0018] Regarding the aforementioned prior application, a method can be adopted where finely subdivided enameled flat wires are pre-assembled into a coarser array of flat wires. This involves subdividing each large-section flat wire into numerous small-section micro-flat wire micro-units. After assembly, each micro-unit is densely and compactly connected to improve slot fill factor. These micro-units are then neatly arranged to form a coarse flat wire group. Within the same coarse flat wire group, the micro-units are essentially connected in parallel, similar to the principle of fine enameled wire winding in a circular wire motor, thus reducing the skin effect. The voltage difference between them is small or even zero, allowing for thin insulating varnish or film to isolate the sub-wire layers, which helps improve copper fill factor and enhances thermal conductivity and heat dissipation. This structure is simply referred to as a "matrix flat wire winding," see Appendix. Figure 4-5Among them, part numbers 1 and 3 indicate the outer contour of the matrix flat wire winding; each differential unit of matrix flat wire windings 2 and 4 is insulated from each other; Note: Figure 4 Represents radial flux motor windings. Figure 5 The windings of axial flux motors are described using low-order windings as examples, as detailed in prior applications. Furthermore, since each thick flat wire group is composed of flat wire micro-units, the overall outer contour of the thick flat wire group can be a non-rectangular cross-section. Therefore, the core slot shape can be designed as non-rectangular to further improve the slot fill factor, and can be similar to the core slot shape of a round wire motor, such as... Figure 12-14 As shown, see the earlier application.

[0019] The advantages of "matrix flat wire winding" include reducing the skin effect, greatly increasing the flexibility of the winding, making it easier to bend and shape, causing less damage to the wire, allowing for a larger curvature of bending, and forming a very small bending transition arc, which is conducive to further compaction; in addition, the fine flat wires within the same thick flat wire group are connected in parallel, so the voltage between them is zero, so their insulation film can be very thin, further improving the slot fill factor;

[0020] Alternatively, the "ultra-flat wire combination method" mentioned multiple times in previous applications can be used; see appendix. Figure 11 Or, see appendix. Figure 10 Alternatively, a coarser flat wire can be formed by combining subdivided flat wire gauges.

[0021] It is more conducive to heat dissipation, and the cooling channel network can be preset to fully immerse the micro-flat wire group winding in the coolant environment;

[0022] An integral potting, casting, or embedded structure can be adopted to form an integrated module with all end windings, thereby increasing the insulation safety level and mechanical safety, improving insulation and heat dissipation, and reducing electromagnetic noise. Alternatively, prior applications can be consulted.

[0023] Appendix Figure 6-9Part numbers 5, 6, 7, 8, and 9 correspond to different axial sections and functions of the motor core. They are improvements to prior applications (such as: 202410619722.9 Second-order three-phase end winding process design and manufacturing method and related prior applications mentioned above). The magnetic flux density uniformity compensation cores 5 and 8 can improve the problem of uneven magnetic flux density distribution caused by insufficient magnetic yoke space due to the high-order winding clearance slot. Part number 6 is a magnetic shielding material disc, which is a selective function and can be removed. Its purpose is to prevent the formation of spatial magnetic circuits in this area, which would lead to an increase in eddy currents. As shown in the figure, 6 points to 3 types, and any one can be selected during use. 7 is the central main core area; 9 is the filling compensation core, which fully fills the contact gap between the high-order and low-order end windings and the core, so that the magnetic field of the end windings can fully enter the closed main magnetic circuit to participate in excitation, thereby improving the power density and efficiency of the motor. Figure 8 for Figure 7 The corresponding overall assembly drawing can also correspond to the corresponding drawing in the prior application. A detailed interpretation of this drawing is available, but will be omitted here (see prior application "202410619722.9 Second-order three-phase end winding process design and manufacturing method").

[0024] Appendix Figure 10 , 11 The description refers to further subdividing the winding cross-section to reduce the skin effect; 36 is the subdivided conductor; 37 is the outer conductor, and 37 represents the conductive substrate of the same layer, i.e., the flat wire group concept of this application; or, metal 3D printing, printed circuit, photolithography chip forming and other processes can be adopted, and 35, 38 and 39 are integral conductor blocks, which can realize parallel electrical connection of all conductors in the 36 and 37 regions, where 38 and 39 are integral, which means that the electrical connection cross-sectional area can be bent or expanded, which can increase the electrical connection cross-sectional area, or, the docking space of the end winding can be shifted and dispersed, see the prior application.

[0025] Figure 11 Similar to the previous ultra-flat wire structure, see the prior application; 40, overall outer contour of the ultra-flat wire group; 41, conductor region of the ultra-flat wire; 42, insulation region.

[0026] Figure 14 The structure is designed to further subdivide the winding cross-section to reduce the skin effect; 45 each pointing region represents different layers or different flat wire groups, and the basic requirement is that different layers have equal resistance characteristics; 46 each pointing region represents different conductors in the same layer, which are connected in parallel and can have different resistance values.

[0027] Note: This paragraph and its corresponding illustrations are borrowed from the illustrations in the previous patent application, and this design can be used in this application.

[0028] Note: The earlier application "202410947555.0 Motor Separate Winding Forming Process and Design Method" is attached. Figure 14-19 All of these are optimized designs to enhance conductivity; among them, part number 33 with a narrow gap is to reduce the skin effect by subdividing the end winding into several parallel copper plates connected in parallel (Note: the appendix in this paragraph...). Figure 14-19 The serial number and part number identifier 33 both refer to the serial number in the original text 202410947555.0.

[0029] The above scheme is applicable to radial flux and axial flux motors.

[0030] The present invention will now be described in detail with reference to the accompanying drawings and embodiments: Figure 1 Low-order single-sided split winding design scheme Figure 2 Low-order dual-sided split winding design scheme Figure 3 Advanced single-sided split winding design scheme Figure 4 Matrix flat wire radial flux motor winding Figure 5 : The flat lines in the matrix represent the axial flux motor windings. Figure 6-9 Schematic diagram of a combined iron core structure for high and low order winding slots Figure 11-12 Schematic diagram of matrix ultra-flat line combination structure Figure 12-14 Schematic diagram of a non-rectangular cross-section thick flat wire group structure Figure 15-16 Diagram illustrating the split-type open-ended non-crossing distributed winding and its electrical connection method. Figure 17-19 Enlarged views of the space helical winding (both individual and split-up) Figure 20-21 Diagram of series connection of a single branch of a space helical winding Figure 22 : Diagram showing the parallel connection of two branches in a space helical winding Combined with appendix Figure 1-3 The prior application has a configuration in which the in-slot winding and the end winding are separately and independently formed. The implementation scheme also includes: the end windings are all thin copper strips bent into shape, which can be interwoven to realize cross-slot wiring of different phases. 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] Including the hairpin winding end winding separation mentioned in the previous application "202410938850.X Motor Slot Winding End Winding Independent Forming Process", the existing hairpin winding end winding can also be pre-formed or independently formed, manufacturing all hairpin type end windings into an integrated end winding flat cylindrical module, which is installed and mated to the stator core like installing motor end caps, ensuring that the end windings in the end caps correspond one-to-one with the slot windings and ensuring a good electrical connection relationship, and ensuring reliable insulation characteristics between them. The electrical connection method can be pressure mating and pressing contact, or welding method, such as high current resistance welding, laser welding, electron beam welding, plasma welding, etc.

[0033] Alternatively, all winding modules can be encapsulated into a single cylindrical ingot; alternatively, a heat dissipation and cooling labyrinth channel can be pre-designed inside; or insulating ceramic material can be installed on the surface of the copper tile, which can be distributed in a mesh, rod, or granular form. In short, it can isolate and insulate adjacent copper tiles while allowing coolant to enter the gaps between the copper tiles. The copper tile has a large surface area and excellent heat dissipation.

[0034] The side of the integrated end winding module that connects with the slot winding can be precision machined to form a precise flat surface or other curved surface that matches the slot winding, such as a layout annular conical surface, etc. (as shown in the figure). In short, the mating surfaces of the integrated end winding and the slot winding are precision machined, or even paired and precision machined, so that the two can be precisely and accurately mated to achieve good conductivity. They can be mated by pressure contact to conduct electricity, or by welding processes, such as high-current resistance welding, laser welding, electron beam welding, plasma welding, etc.

[0035] Clearly, in this series of solutions, both the end windings and the slot windings can be pre-formed and manufactured. The slot windings can be pre-formed into a single unit before being inserted into the iron core, which can protect the windings and achieve high interlayer density, improving slot fill factor and thermal conductivity. Furthermore, the structure in this application simplifies the slot windings to straight copper rods (commonly known as "copper pillars"), and the end windings to be bent copper plates (commonly known as "copper tiles"). This is no longer a traditional winding made of enameled wire. Similar to the previously applied ultra-flat wire series motors, it allows for the separate design and later synthesis of the conductor layer and insulation layer. This enables the insulation layer to be made of various high-temperature resistant materials, or even air isolation, greatly improving the winding's heat resistance, increasing slot fill factor and winding yield, while reducing process difficulty and cost. See previous applications;

[0036] Ensure that the inductance of each phase is identical to eliminate circulating current.

[0037] The above design method applies to relevant prior applications, especially to patent application schemes 202410619722.9; 202410643792.8; 202410684267.0; 202410796145.0; and 202410815412.4.

[0038] Regarding the previously disclosed "flat busbar" structure and design method, the optimal design principle for the busbar is as follows: In order to reduce the proportion of the outer insulation layer of the busbar and increase the copper fill factor, the number of busbar layers should be reduced as much as possible. The optimal design principle for the busbar is: the busbar has no parallel branches, only series connections. Parallel branches that increase the current carrying capacity are all achieved by increasing the number of sub-busbar layers and the number of parallel branches. Since there is zero voltage between sub-busbar layers, the insulation film can be very thin. The fewer the number of busbar layers, the lower the difficulty of forming, twisting, turning, flaring, welding and other processes. It can be simplified to the extreme to only 1 layer (if there is 1 layer in the slot, there will be crossover at the end) or 2 layers of busbar (the end windings may also have some crossover). The forming process is greatly simplified and the safety is increased.

[0039] Alternatively, in order to improve the overall bending performance of the busbar, the rectangular aspect ratio of the cross-sectional shape of the sub-layer flat wires contained within it does not need to be too large. It can be close to a square or close to the cross-sectional ratio of the busbar. In this way, when the flat wires are bent, the difficulty of vertical bending and horizontal bending is the same, which is conducive to improving the overall bending performance, reducing the process difficulty, and increasing the yield.

[0040] like Figure 15The diagram shown is an illustration of the scheme of the prior application "Non-Synchronous End-Crossing Distributed Winding Formation and Process Design Method". For more details, please refer to the relevant attached figures of the application. Its structure has many advantages: different magnetic circuits in the same winding, or in other words, the same winding forms two magnetic circuits that cross the inner and outer air gaps, forming a dual-rotor motor structure. It has the problem of very short end windings and no need for cross-slot crossing of different phases, which simplifies the process, shortens the length of the end winding, and reduces costs. In other words, regardless of the number of pole pairs, the length of its end winding is almost consistent. This scheme is more advantageous in motors with fewer poles, which can significantly save end winding wires, reduce volume, and reduce costs.

[0041] like Figure 15-16 The "non-in-phase end non-crossing distributed winding" shown can also be a split-open structure similar to H-PIN, such as... Figure 16 As shown, the split windings are inserted into the iron core and then butt-welded. They can be butt-welded at an angle, laser-welded, or other types of welding; or, the paint can be removed without removing the paint. Among them: 10, winding; 11 and 13 are the conductive lap joint areas at the open ends of the windings; 12, the terminals of the windings of the same phase in the same slot; 14, insulating isolation plate (a high-temperature resistant isolation plate can be inserted here during welding, which can be a metal or non-metal material that has no affinity with the solder).

[0042] Wherein: the welding process can be the "low-temperature brazing composite welding" disclosed in this application, firstly, the parts to be welded (such as...) Figure 16 Parts 11 and 13 are pre-tin-plated on their surfaces. After being overlapped, they are heated to allow the tin-plated solder to melt and complete the welding. The melting process of the solder can be achieved using methods similar to resistance welding, induction welding, arc welding, flame welding, gas welding, or by using molten solder for pouring, spraying, or natural pouring waterfall welding. The tin-plated parts are heated to a temperature higher than the melting point of the solder, thus it is a low-temperature welding process. The resistance welding current does not need to be too high, just enough to melt the solder. This method has a low melting point, is safe, and allows for the simultaneous welding of multiple layers. An insulating layer can be used with a melting point higher than the solder (e.g., a heat spreader). Figure 16 Part number 14 shown is used to ensure that it does not melt during brazing. After welding is completed, the separator can be removed. For easy separation, a coating with no affinity for solder can be added to the surface of the separator for easy peeling. This welding method overcomes the shortcomings of "fusion dip welding" because it does not require immersion in molten solder, making it more suitable for various complex space applications, such as: Figure 16 The multi-layer lap weld shown;

[0043] Alternatively, the end winding welding of traditional flat wire motors no longer requires removing the enamel from all four sides; only the enamel on one side of the welding joint is needed. However, the other sides may be burned in the high-temperature laser welding environment, forming impurities that are detrimental to insulation safety. Therefore, an additional quality inspection process should be added to remove the burnt enamel residue.

[0044] like Figure 15 The diagram shown is an illustration of the scheme for the prior application "Method for Forming and Process Design of Non-in-phase End-non-crossing Distributed Windings". For more details, please refer to the relevant attached diagrams of that application. The winding and core structure can also be a spatial spiral winding scheme, and its forming structure and process design are as follows: Figure 17-22 As shown, the corresponding attached figure in the prior application "Ultra-flat wire common winding motor and design method 202411087416.1" can be referenced, and its core can also be designed as a spiral toothed groove.

[0045] See details Figure 17-22 The spatial helical winding scheme is as follows: (Attached) Figure 20 , 21 It's the same picture, attached. Figure 21 For clarity, the appendix will be included. Figure 20 The middle section of the lines is hidden; Figure 20 , 21 It is a single-branch series relationship. Figure 22 It is a two-branch parallel connection; Figure 17-19 A separate enlarged view or a split enlarged view of the spatial spiral winding;

[0046] This series of illustrations shows a 3-phase motor type with 6 layers and 3 slots per pole per phase (number of poles and phases = 3). It can be installed without welding, without end windings, and all windings participate in electromagnetic interaction.

[0047] The iron core and copper ultra-flat wire are wound in a single composite process. The winding materials include ultra-flat wire + insulation layer + silicon steel, which are wound in one piece. The structure is a spatial spiral-tire type. After the silicon steel is wound, there is an integral protrusion. With the addition of a central integrated potting, a rigid stator with a skeleton can be formed. The rotor is an open hollow tire-shaped annular permanent magnet, which is equivalent to a magnetic flux motor with up, down, left, and right sides. It has no end windings and no solder joints. The cross-section can also be rectangular instead of circular; the skeleton design is very important. Alternatively: a double-helix motor, figuratively speaking: a space tire-type winding, its cross-sectional diagram is attached. Figures 17-22 (Among them: Appendix) Figure 19-22 The diagrams are split or staggered to visually show the spatial relationship between different phase windings. Alternatively, the cross-section can be square, rectangular, triangular, polygonal, circular, elliptical, etc. The windings and the core are integrally wound and formed, or the windings are pure windings without a core structure. It represents different wiring schemes, which can be different relationships of the number of phase winding groups, or different numbers of phases, or two-phase, three-phase or multi-phase, or different numbers of slots in the same phase, etc.

[0051] The tire-type winding motor can design the corresponding air gap areas of the dual rotors on both sides into a concave semi-tire shape, which matches the tire-type winding core to form a spatial tire-type air gap, maximizing the air gap space and outputting greater power. This design has no solder joints in the windings, and except for the inner and outer ring areas of the tire-type core's cross-section which provide positioning support, the remaining areas are all air gaps. The windings are also almost entirely effective windings, which can greatly improve power density. Note: The forming process of this type of tire-type winding can adopt similar principles to the flat wire inductor forming process and the production process of helical springs or irregular springs. A specific extrusion and spinning device can be set at the straight flat wire's advancing position to automatically bend it into a specific spiral shape and a spatial tire-type spiral shape, naturally and cleverly interlocking and embedding it into the spatial tire-type core slots. To reduce weight, without affecting the magnetic flux density distribution, the central annular area of ​​the spatial tire-type core can be removed or a weight-reducing hollow design can be adopted.

[0052] Alternatively, the tire-type winding can be axially flattened into a disc shape to form an axial bidirectional flux dual rotor motor; or the tire-type winding can be radially flattened into a cylindrical shape to form a radial bidirectional flux dual rotor motor. Note: The bidirectional flux in these two schemes corresponds to different side windings after flattening, so there is a yoke in the middle area.

[0053] As shown in the figure, the pink winding can be first wound in concentric circles, then stretched and deformed into a spiral shape. During stretching, a rolling roller can be used to perform micro-plastic deformation while ensuring effective and safe insulation of the insulation layer and uniform voltage drop between layers. Then, the nine independently pre-wound concentric circle windings shown in the figure are stretched into a spiral winding and then spirally interwoven to form a nine-spiral structure (similar to a multi-head worm gear).

[0054] Reanalysis: It should be wound according to the spiral skeleton, which is a space tire-type spiral skeleton. After winding, it should be flattened; or -- during winding, it should be wound according to the flattened space tire-type spiral skeleton. This method is similar to W-PIN, but has advantages over its features.

[0055] Alternatively, refer to the W-PIN method for winding; complete each layer of ultra-flat wire using the W-PIN method before inserting them together.

[0056] Alternatively, it can be implemented according to the patent scheme of 2023.3.13;

[0057] This flattening and bending process is similar to W-PIN, but with a key difference: it allows for the creation of an ultra-flat wire structure (this is the core of the invention; the ultra-flat wire can be wound in a spiral shape, then flattened and bent into a ring before being placed in the iron core – or the iron core can be split – for example, 4-6 half-fan-shaped iron cores can be combined. This method is similar to the ancient wisdom of arched bridge structures, with excellent mechanical properties and greatly improved assembly convenience. The winding can even be directly wound in a flattened spiral shape. The key point of this method is that the conductor and insulator of the ultra-flat wire can be separately assembled; it causes minimal damage to the winding, requires no pre-bending, can be ultra-flat, and ultra-flat wire has good flexibility, making this method more convenient. It also has the advantage of uniform voltage drop across layers and significantly improved voltage resistance). Furthermore, the end windings seem to be utilized as much as possible, becoming effective windings; however, even if this isn't possible, the size of the end windings can at least be reduced. Due to the X-PIN and the absence of solder joints, this advantage alone is significant.

[0058] Problems or phenomena may occur with the end windings when they are flattened:

[0059] This can result in a large proportion of end windings with a large outer ring radius and a small proportion of end windings with a small inner bending radius.

[0060] Because ultra-flat wire is very thin, it is easier to plastically deform. Therefore, during the spiral winding and end flattening process, it will undergo timely and natural plastic deformation to meet the cross-slot bending requirements of the distributed windings at the ends.

[0061] Alternatively, it can be used in electromagnetic railgun design, specifically a high-performance linear electromagnetic railgun—used for military purposes or satellite launches. This allows for an extremely long ground-based acceleration time. Theoretically, if we disregard air friction and heat generation, the rocket could reach its predetermined cosmic velocity in its ground orbit, then be launched via a ground-based trajectory that curves upwards or diagonally upwards. This would allow the rocket to carry almost no fuel, relying almost entirely on the acceleration from the ground-based electromagnetic railgun to achieve cosmic velocity. Only a small amount of fuel would be needed for attitude control in space and for reentry, significantly reducing launch weight and cost. Of course, in practice, atmospheric friction must be considered, so excessively high speeds within the atmosphere are not advisable. However, this approach at least minimizes the amount of fuel carried by the rocket, allowing for a longer acceleration time in the ground orbit, thus maximizing the proportion of fuel carried and reducing rocket weight and launch costs.

[0062] In addition, it can be used to replace artillery fire in military electromagnetic railguns, enabling continuous and high-density firing, and can also be used to launch fighter jets using aircraft carrier electromagnetic catapults.

[0063] In summary, the above-mentioned motor can be a scheme with different phase windings interleaved and complementary, and permanent magnets radially aligned; or it can be a scheme with different phase permanent magnets arranged in complementary phases and different phase windings aligned, as can be found in the prior application.

[0064] Alternatively: the above motors can all be of the following types: external rotor, internal rotor, dual rotor, or counter-rotating dual rotor; or, the above motors can all be of the following types: synchronous reluctance, switched reluctance, permanent magnet synchronous, induction asynchronous, or DC.

[0065] Setting the winding side of an axial flux motor as an outer rotor is beneficial for space utilization and is also safer. If the inner rotor is the winding end, two layers of centrifugal force protection devices are required. However, the magnet side itself has protection. Therefore, this is beneficial for space utilization, reducing volume, or maximizing the electromagnetic radius of action to increase torque.

[0066] The above scheme is applicable to radial flux motors and axial flux motors; it can be an integer slot winding or a non-integer slot winding.

[0067] This principle also applies to axial flux motors; counter-rotating dual rotor motors; and internal and external dual flux types.

[0068] Axial flux motors can refer to the relevant solutions in the prior application, namely: arranging two or more relatively independent axial flux windings and permanent magnets (or non-permanent magnet current excitation windings) according to the corresponding phase difference angles, and controlling them according to the complementary waveform relationship, can achieve the same effect. Since the axial force of the axial flux motor is very large, it is basically used in the form of double disks or multiple disks to balance the axial force. Moreover, the axial flux motor has the characteristic of short axial dimension. Therefore, it is more advantageous to use the double disk or multiple disk scheme described in this patent application to design a compact high power density motor.

[0069] 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.

[0070] Its electromagnetic wires can be round or flat; the current waveform can be: square wave, square wave + composite wave, or sine wave;

[0071] 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.

[0072] The above solution can also be used for conventional single-rotor motors, such as replacing existing brushless or brushed solutions.

[0073] 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.

[0074] 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.

[0075] 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.

[0076] 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.

[0077] Note:

[0078] 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.

[0079] 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 matrix flat wire winding process design and manufacturing method, including motor windings, stator, rotor, and housing, characterized by: The ultra-flat wire cross-section structure with a large aspect ratio makes the flat wire as flexible as conventional round wire. It can be assembled by inserting into the stator winding slot, eliminating the complex processes such as opening welding in current flat wire manufacturing and improving the skin effect of the winding. The structure described in the application is also applicable to split winding designs, which can be single-sided split, similar to hairpin flat wire, inserted from one side and then joined to the other side; or, split on both sides, that is, the winding in the middle slot is independent, and the windings at both ends are separated. Various welding methods or pressure butt contact electrical connection methods can be used, or a bare copper plus insulation material solution can be used to improve temperature resistance. A coarser array of flat wires can be pre-assembled from finely subdivided enameled flat wires. That is, each flat wire with a large cross-section is subdivided into many micro-flat wire micro-units with very small cross-sections. After assembly, each flat wire micro-unit is very dense and compact to improve the slot fill factor. After being neatly arranged, they form a coarse flat wire group. The flat wire micro-units within the same coarse flat wire group are basically connected in parallel, similar to the principle of fine enameled wires being wound in parallel in a round wire motor, in order to reduce the skin effect. The voltage difference between them is small or even zero, so the sub-wire layers can be isolated with a very thin insulating varnish or insulating film, which is beneficial to improve the copper fill factor and increase thermal conductivity and heat dissipation performance; this structure is simply referred to as "matrix flat wire winding"; among them, part numbers 1 and 3 are the outer contours of matrix flat wire windings; each differential unit of matrix flat wire windings 2 and 4 is insulated from each other; Note: Figure 4 represents a radial flux motor winding, and Figure 5 represents an axial flux motor winding, both of which are described using low-order windings as examples, and can be found in the prior application; At the same time, since each thick flat wire group is composed of flat wire micro-units, the overall outer contour shape of the thick flat wire group can be a non-rectangular cross section, so the core slot shape can be designed as non-rectangular to further improve the slot fill factor, and can be similar to the core slot shape of a round wire motor; The advantages of "matrix flat wire winding" include reducing the skin effect, greatly increasing the flexibility of the winding, making it easier to bend and shape, causing less damage to the wire, allowing for a larger curvature of bending, and forming a very small bending transition arc, which is conducive to further compaction; in addition, the fine flat wires within the same thick flat wire group are connected in parallel, so the voltage between them is zero, so their insulation film can be very thin, further improving the slot fill factor; Alternatively, the "ultra-flat wire combination method" mentioned multiple times in previous applications can be used; or, finer-gauge flat wires can be combined into coarser-gauge flat wires; this is more conducive to heat dissipation, and a pre-set cooling channel network can be used to fully immerse the micro-flat wire group windings in the coolant environment; an integral potting, casting, or embedded structure can be adopted to form an integrated module for all end windings, increasing the insulation safety level and mechanical safety, improving insulation and heat dissipation, and reducing electromagnetic noise; or, reference can be made to previous applications. The attached figures 5, 6, 7, 8, and 9 correspond to different axial sections of the motor core and their functions. These figures represent improvements upon prior applications. The magnetic flux density uniformity compensation cores 5 and 8 improve the uneven magnetic flux density distribution caused by insufficient yoke space due to high-order winding clearance slots. Part number 6 is a magnetic shielding material disc; its function is optional and can be removed. Its addition is to prevent the formation of spatial magnetic circuits in this area, which could lead to increased eddy currents. As shown in the figure, 6 indicates three types; any one can be selected during use. 7 represents the central main core area. 9 represents the filling compensation core, which fully fills the contact gaps between the high-order and low-order end windings and the core, allowing the magnetic field of the end windings to fully enter the closed main magnetic circuit and participate in excitation, thus improving the motor's power density and efficiency. Figure 8 is the overall assembly drawing corresponding to Figure 7, and can also correspond to the relevant attached figures in prior applications. A detailed interpretation of these figures is available. Figures 10 and 11 illustrate further subdivision of the winding cross-section to reduce the skin effect; 36 is the subdivided conductor; 37 is the outer conductor, representing the conductive substrate of the same layer, i.e., the flat wire group concept of this application; alternatively, metal 3D printing, printed circuit, photolithography chip forming, etc., can be adopted, 35, 38, and 39 are integral conductor blocks, which can correspondingly realize parallel electrical connection of all conductors in the 36 and 37 regions, where 38 and 39 are integral, representing that the electrical connection cross-sectional area can be bent or expanded, which can increase the electrical connection cross-sectional area, or can shift and disperse the docking space of the end windings; Figure 11 and Similar to previous ultra-flat wire structures, see prior applications; 40, overall outer contour of ultra-flat wire group; 41, ultra-flat wire conductor region; 42, insulation region; The structure shown in Figure 14 is to further subdivide the winding cross-section to reduce the skin effect; 45 Each pointing region represents different layers or different flat wire groups, and the basic requirement is that different layers have equal resistance characteristics; 46 Each pointing region represents different conductors in the same layer, which are in parallel relationship and can have different resistance values; or, it is an optimized design to enhance conductivity; or, it increases narrow gaps to reduce the skin effect, subdividing the end winding into several parallel copper plates connected in parallel. The above solution is applicable to radial flux and axial flux motors; Alternatively, its configuration is a configuration in which the in-slot winding and the end winding are separately formed. The implementation scheme also includes: the end windings are all thin copper strips bent into shape, which can be interwoven to realize cross-slot wiring of different phases. 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. Alternatively, after separating the end windings of the existing hairpin windings, pre-forming and independent molding can be adopted to manufacture all the hairpin-type end windings into an integrated flat cylindrical module. This module is then installed and mated onto the stator core, just like installing a motor end cover. It is ensured 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. Reliable insulation characteristics between them can also be ensured. The electrical connection can be achieved by pressure mating and pressing, or by welding, such as high-current resistance welding, laser welding, electron beam welding, plasma welding, etc. Alternatively, all winding modules can be encapsulated into a single cylindrical ingot; alternatively, a heat dissipation and cooling labyrinth channel can be pre-designed inside; or insulating ceramic material can be installed on the surface of the copper tile, which can be distributed in a mesh, rod, or granular form. In short, it can isolate and insulate adjacent copper tiles while allowing coolant to enter the gaps between the copper tiles. The copper tile has a large surface area and excellent heat dissipation. The side of the integrated end winding module that connects with the slot winding can be precision machined to form a precise flat surface or other curved surfaces that match the slot winding, such as a layout annular conical surface. In short, the mating surfaces of the integrated end winding and the slot winding are precision machined, or even paired and precision machined, so that the two can be precisely and accurately mated to achieve good conductivity. They can be mated by pressure contact to conduct electricity, or by welding processes, such as high-current resistance welding, laser welding, electron beam welding, plasma welding, etc. Clearly, in this series of solutions, both the end windings and the slot windings can be pre-formed and manufactured in advance. The slot windings can be pre-formed into an integral unit before being inserted into the iron core, which can protect the windings and achieve high interlayer density, improving slot fill factor and thermal conductivity. Furthermore, the structure in this application simplifies the slot windings to straight copper rods (commonly known as "copper pillars") and the end windings to bent copper plates (commonly known as "copper tiles"). This is no longer a winding made of enameled wire in the traditional sense. Similar to the ultra-flat wire series motors in the prior application, it allows for the separate design and later synthesis of the conductor layer and insulation layer. This enables the insulation layer to be made of various high-temperature resistant materials, or even air isolation, which greatly improves the heat resistance of the windings, increases the slot fill factor and winding yield, and reduces the process difficulty and cost. See the prior application. Ensure that the inductance of each phase is identical to eliminate circulating current. Regarding the previously disclosed "flat busbar" structure and design method, the optimal design principle for the busbar is as follows: In order to reduce the proportion of the outer insulation layer of the busbar and increase the copper fill factor, the number of busbar layers should be reduced as much as possible. The optimal design principle for the busbar is: the busbar has no parallel branches, only series connections. Parallel branches that increase the current carrying capacity are all achieved by increasing the number of sub-busbar layers and the number of parallel branches. Since there is zero voltage between sub-busbar layers, the insulation film can be very thin. The fewer the number of busbar layers, the lower the difficulty of forming, twisting, twisting, flaring, welding and other processes. It can be simplified to the extreme to only 1 layer (if there is 1 layer in the slot, there will be crossover at the end) or 2 layers of busbar (the end windings may also have some crossover). The forming process is greatly simplified and the safety is increased. Alternatively, in order to improve the overall bending performance of the busbar, the rectangular length-to-width ratio of the cross-sectional shape of the sub-layer flat wires contained within it does not need to be too large. It can be close to a square or close to the cross-sectional ratio of the busbar. In this way, when the flat wires are bent, the difficulty of vertical bending and horizontal bending is the same, which is conducive to improving the overall bending performance, reducing the process difficulty, and increasing the yield. Figure 15 shows a schematic diagram of the scheme of the prior application "Non-Synchronous End-Crossing Distributed Winding Formation and Process Design Method". For more details, please refer to more related drawings of the application. Its structure has many advantages: different magnetic circuits in the same winding, or in other words, the same winding forms two magnetic circuits that cross the inner and outer air gaps, forming a dual-rotor motor structure. It has the problem of very short end windings and no need for cross-slot crossing of different phases, which simplifies the process, shortens the length of the end winding, and reduces costs. In other words, regardless of the number of pole pairs, the length of its end winding is almost consistent. This scheme is more advantageous in motors with fewer poles, which can save end winding wires, reduce volume, and reduce costs. As shown in Figures 15-16, the "non-phase end non-crossing distributed winding" can also be a split-open structure similar to H-PIN. As shown in Figure 16, the split winding is inserted into the iron core and then welded together. It can be a beveled joint, laser welding, or other welding methods; or, it can be done without removing the enamel. Among them: 10, winding; 11 and 13 are the conductive lap joint areas at the open ends of the winding; 12, the terminal of the same phase winding in the same slot; 14, insulating isolation plate (a high-temperature resistant isolation plate can be inserted here during welding, which can be a metal or non-metal material that has no affinity with the solder). The welding process can be the "low-temperature brazing composite welding" disclosed in this application. First, the surfaces of the parts to be welded are pre-plated with tin. Then, they are overlapped and heated to allow the tin-plated solder to melt, completing the welding bond. The melting process of the brazing solder can employ methods similar to resistance welding, induction welding, arc welding, flame welding, gas welding, or using molten brazing filler metal for pouring, spraying, or natural pouring waterfall welding. The tin-plated parts are heated to a temperature higher than the melting point of the brazing filler metal; therefore, it is a low-temperature welding process, similar to resistance welding. The current does not need to be too high, just enough to melt the solder; this method has a low melting point, is safe, and can weld multiple layers at the same time. The isolation layer can be a separator with a melting point higher than that of the solder (part number 14 as shown in Figure 16) to ensure that it does not melt during brazing. After the welding is completed, the separator can be removed. For easy separation, a coating with no affinity to the solder can be added to the surface of the separator for easy peeling; this welding method makes up for the shortcomings of "fusion dip welding", as it does not require immersion in molten solder, and is more suitable for various complex space applications, such as multi-layer lap welding as shown in Figure 16. Alternatively, the end winding welding of traditional flat wire motors does not require removing the enamel from all four sides; only the enamel on one side of the welding joint is removed. However, the other sides may be burned in the high-temperature laser welding environment, forming impurities that are detrimental to insulation safety. Therefore, an additional quality inspection process should be added to remove the burnt enamel residue. Figure 15 shows a schematic diagram of the scheme of the prior application "Method for Forming and Process Design of Non-in-phase End-non-crossing Distributed Winding". For more details, please refer to the more related drawings of the application. The structural forming scheme of its winding and core can also be a spatial spiral winding scheme. Its forming structure and process design are shown in Figures 17-22. Its core can also be designed as a spiral toothed groove. Alternatively, a spatial spiral winding scheme can be used, which can be a single-branch series connection or a double-branch parallel connection. Alternatively, it can be a 3-phase motor type with 6 layers and 3 slots per pole and phase (number of poles and phases = 3), which can be welded without end windings and all windings participate in electromagnetic action. The iron core and copper ultra-flat wire are wound in a single composite process. The winding materials include ultra-flat wire + insulation layer + silicon steel, which are wound in one piece. The structure is a spatial spiral-tire type. After the silicon steel is wound, there is an integral protrusion. With the addition of a central integrated potting, a rigid stator with a skeleton can be formed. The rotor is an open hollow tire-shaped annular permanent magnet, which is equivalent to a magnetic flux motor with up, down, left, and right sides. It has no end windings and no solder joints. The cross-section can also be rectangular instead of circular; the skeleton design is very important. Alternatively, it could be a double-helix motor, figuratively described as a space tire-type winding, with cross-sectional views shown in Figures 17-22 (where Figures 19-22 use split or misaligned diagrams to visually show the spatial relationship between different phase windings). Its cross-section could be square, rectangular, triangular, polygonal, circular, elliptical, etc.; the winding and core are integrally wound, or it could be a pure winding structure without a core. It represents different wiring schemes, which can be different relationships of the number of phase winding groups, or different numbers of phases, or two-phase, three-phase or multi-phase, or different numbers of slots in the same phase, etc. The tire-type winding motor can design the corresponding air gap areas of the dual rotors on both sides into a concave semi-tire shape, which matches the tire-type winding core to form a spatial tire-type air gap, maximizing the air gap space and outputting greater power. This design has no solder joints in the windings, and except for the inner and outer ring areas of the tire-type core's cross-section which provide positioning support, the remaining areas are all air gaps. The windings are also almost entirely effective windings, which can greatly improve power density. Note: The forming process of this type of tire-type winding can adopt similar principles to the flat wire inductor forming process and the production process of helical springs or irregular springs. A specific extrusion and spinning device can be set at the straight flat wire's advancing position to automatically bend it into a specific spiral shape and a spatial tire-type spiral shape, naturally and cleverly interlocking and embedding it into the spatial tire-type core slots. To reduce weight, without affecting the magnetic flux density distribution, the central annular area of ​​the spatial tire-type core can be removed or a weight-reducing hollow design can be adopted. Alternatively, the tire-type winding can be axially flattened into a disc shape to form an axial bidirectional flux dual rotor motor; or the tire-type winding can be radially flattened into a cylindrical shape to form a radial bidirectional flux dual rotor motor. Note: The bidirectional flux in these two schemes corresponds to different side windings after flattening, so there is a yoke in the middle area. As shown in the figure, the pink winding can be first wound concentrically, then stretched and deformed into a spiral shape. During stretching, a rolling roller can be used to perform slight plastic deformation while ensuring effective and safe insulation of the insulation layer and uniform voltage drop between layers. Then, the nine independently pre-wound concentric windings shown in the figure are stretched into a spiral winding and then spirally interwoven to form a nine-spiral structure (similar to a multi-head worm gear). Reanalysis: It should be wound according to the spiral skeleton, which is a space tire-type spiral skeleton. After winding, it should be flattened; or -- during winding, it should be wound according to the flattened space tire-type spiral skeleton. This method is similar to W-PIN, but has advantages over its features. Alternatively, refer to the W-PIN method for winding; complete each layer of ultra-flat wire using the W-PIN method before inserting them together. Alternatively, it can be implemented according to the patent scheme of 2023.3.13; This flattening and bending process is similar to W-PIN, but with a key difference: it allows for the creation of an ultra-flat wire structure (this is the core of the invention; the ultra-flat wire can be wound in a spiral shape, then flattened and bent into a ring before being placed in the iron core – or the iron core can be split – for example, 4-6 half-fan-shaped iron cores can be combined. This method is similar to the ancient wisdom of arched bridge structures, with excellent mechanical properties and greatly improved assembly convenience. The winding can even be directly wound in a flattened spiral shape. The key point of this method is that the conductor and insulator of the ultra-flat wire can be separately synthesized; it causes minimal damage to the winding, requires no pre-bending, can be ultra-flat, and ultra-flat wire has good flexibility, making this method more convenient. It also has the advantage of uniform voltage drop across layers and significantly improved voltage resistance). Furthermore, the end windings seem to be utilized as much as possible, becoming effective windings; however, even if this isn't possible, the size of the end windings can at least be reduced. Due to the X-PIN and the absence of solder joints, this advantage alone is significant. Problems or phenomena may occur with the end windings when they are flattened: This can result in a large proportion of end windings with a large outer ring radius and a small proportion of end windings with a small inner bending radius. Because ultra-flat wire is very thin, it is easier to plastically deform. Therefore, during the spiral winding and end flattening process, it will undergo timely and natural plastic deformation to meet the cross-slot bending requirements of the distributed winding of the end winding. Alternatively, it can be used in electromagnetic railgun design, specifically a high-performance linear electromagnetic railgun—used for military purposes or satellite launches. This allows for an extremely long ground-based acceleration time. Theoretically, if we disregard air friction and heat generation, the rocket could reach its predetermined cosmic velocity in its ground orbit, then be launched via a ground-based trajectory that curves upwards or diagonally upwards. This would allow the rocket to carry almost no fuel, relying almost entirely on the acceleration from the ground-based electromagnetic railgun to achieve cosmic velocity. Only a small amount of fuel would be needed for attitude control in space and for reentry, significantly reducing launch weight and cost. Of course, in practice, atmospheric friction must be considered, so excessively high speeds within the atmosphere are not advisable. However, this approach at least minimizes the amount of fuel carried by the rocket, allowing for a longer acceleration time in the ground orbit, thus maximizing the proportion of fuel carried and reducing rocket weight and launch costs. In addition, it can be used to replace artillery fire in military electromagnetic railguns, enabling continuous and high-density firing, and can also be used to launch fighter jets using aircraft carrier electromagnetic catapults. In summary: the above-mentioned motor can be a scheme with different phase windings interleaved and complementary, and permanent magnets radially aligned; or it can be a scheme with different phase permanent magnets arranged in complementary phases and different phase windings aligned, as can be found in the prior application; Alternatively: the above motors can all be of the following types: external rotor, internal rotor, dual rotor, or counter-rotating dual rotor; or, the above motors can all be of the following types: synchronous reluctance, switched reluctance, permanent magnet synchronous, induction asynchronous, or DC. Setting the winding side of an axial flux motor as an outer rotor is beneficial for space utilization and is safer. If the inner rotor is the winding end, two layers of centrifugal force protection devices are required. However, the magnet side itself has protection. Therefore, this is beneficial for space utilization, reducing volume, or maximizing the electromagnetic radius of action to increase torque. The above scheme is applicable to radial flux motors and axial flux motors; it can be an integer slot winding or a non-integer slot winding.

2. The matrix flat wire winding process design and manufacturing method according to claim 1, characterized in that: This invention discloses a design and manufacturing method for a non-in-phase winding cross-slot wire assembly process based on physical space displacement. This invention further improves upon prior applications and existing motors by employing a design method based on a non-in-phase winding cross-slot wire assembly process in physical space. This effectively solves the problem of winding cross-slots, significantly simplifying the integrated wire assembly forming process of the entire winding, shortening the size of the end windings to reduce ineffective waste of electromagnetic wires, and allowing the end windings to participate in effective excitation, reducing leakage flux and improving efficiency. It also allows for relative separation of different phase windings, improving the voltage withstand safety of the motor windings, and optimizing the motor's heat dissipation. It is particularly suitable for motor architecture designs based on three-wire four-phase waves, reducing one phase winding and further simplifying the process, while improving the radial compactness of the convex and concave iron core. Alternatively, the winding slots closest to the air gap can be moved outward to create a cooling space. This way, all windings have dedicated cooling systems, and all windings are isolated from the rotor permanent magnets by a heat dissipation system. This further reduces the temperature in the permanent magnet area, making it significantly lower than that in the winding area. Ultra-flat wires can maintain normal operation even at temperatures exceeding 260°C. Therefore, this facility, which adds a heat dissipation barrier between the windings and the permanent magnets, will further enhance the overload capacity of ultra-flat wires. For vehicle operating conditions, overload conditions are not normal operating conditions, so efficiency at this time can be disregarded. This allows us to further reduce the size of the motor. Under overload conditions, ultra-flat wire motors have superior long-term overload capacity to meet the requirements of these operating conditions.

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

4. The matrix flat wire winding process design and manufacturing method according to claim 1, characterized in that: This principle also applies to axial flux motors; counter-rotating dual-rotor motors; and internal and external dual flux types. Axial flux motors can refer to the relevant solutions in the prior application, that is: arranging two or more relatively independent axial flux windings and permanent magnets (or non-permanent magnet current excitation windings) according to the corresponding phase difference angles, and controlling them according to the complementary waveform relationship, can also achieve the same effect. Since the axial force of the axial flux motor is very large, it is basically used in the form of dual-disc or multi-disc to balance the axial force. Moreover, the axial flux motor has the characteristic of short axial dimension. Therefore, it is more advantageous to use the dual-disc or multi-disc scheme described in this patent application to design a compact high power density motor.

5. The matrix flat wire winding process design and manufacturing method according to claim 1, characterized in that: 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; its electromagnetic wires can be round wires or flat wires; the current waveform can be: square wave, square wave + composite wave, sine wave; 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, etc. 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. 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.

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