The general trend of new energy vehicle motor route, the demand for automated assembly production line is urgent.
Permanent magnet synchronous motor is the main technical route for new energy vehicle drive motor. At present, the most widely used type in new energy vehicles is permanent magnet synchronous motor, which has the advantages of high power density, low energy consumption, small size and light weight. The structure of permanent magnet synchronous motor includes stator assembly, rotor assembly, base, end cover and other auxiliary standard parts. The stator assembly includes stator core, copper wire winding, lead wire and insulation material, which is generally fixed to the motor housing. The rotor assembly includes rotor core, permanent magnet, shaft, bearing and other components, which are connected to the output shaft to drive the gear to drive the vehicle.
Hairpin permanent magnet motor have obvious technical and performance advantages over traditional round-wire motor.
(1) Small size and high power.
(2) Reduce motor copper loss and improve motor efficiency.
(3) Better temperature performance.
(4) Low mechanical and electromagnetic noise.
The manufacturing process of the hairpin motor is complex and relies on automated equipment for production.
The stator assembly is the core of the hairpin motor design. It is difficult to produce and has customized characteristics. After the design is finalized, any change in the wire type and size of the wire requires the customization of expensive tooling and molds, and the compatibility is low. The complete manufacturing process of the flat wire motor stator assembly includes paper insertion, coil forming, pre-insertion, overall insertion, flaring, twisting, cutting, welding, coating and dipping, and copper nose welding. The process is numerous and complex, and the degree of dependence on equipment is higher than that of round wire motors, especially the coil forming and welding processes have high precision requirements and are difficult, requiring the use of professional high-end equipment. Overseas companies have a deep accumulation in this field and have obvious first-mover advantages in equipment.
Three major process of hairpin motor assembly.
Among them, the rotor line and assembly line are relatively simple, and the stator transfer line has many complex processes such as flat wire lossless bending, insertion, twisting, laser welding, and varnishing, which are technically difficult. There is no standard hairpin motor stator assembly process, and each company is exploring process solutions. At present, there are only a few equipment companies, such as BorgWarner and Felsomat, that have experience in delivering hairpin motor stator assembly lines abroad. At present, the company in China that can undertake hairpin motor stator assembly lines is HONEST Automation. By drawing on the past technical experience in winding and assembling stators and rotors of fuel vehicle motors, the company has successfully mastered the assembly process of hairpin motor stator lines and has the technical ability to provide overall solutions for the three major processes of hairpin motor stators, rotors, and assembly.
For the key processes in the hairpin stator assembly line, including coil forming, wire insertion, head twisting and welding, which are relatively difficult and highly dependent on automation, the company has equipped wire forming machines, automatic wire insertion machines, head twisting machines and welding machines to achieve highly automated operation of the stator production line.
The process flow of the rotor production line is: iron core loading, iron core magnetic steel insertion, rotor dynamic balancing, magnetization and magnetic flux detection, rotor laser coding, etc. The entire production line has complex procedures and high automation requirements. HONEST Automation has taken advantage of its technology and has mastered mature hairpin motor rotor production lines and assembly lines.
HONEST Automation has successfully delivered multiple hairpin motor stator assembly line and drive motor rotor assembly lines. The equipment has been upgraded to the 4th generation, with the advantages of simpler structure, more compact footprint and more convenient operation, which significantly reduces customers' procurement investment and factory operating costs. Our experienced technical team has customized and efficiently solved various technical problems of motor assembly for many well-known domestic and foreign automotive multinational groups and leading companies in the motor industry.
If you are looking for efficient, stable and cost-effective motor automation assembly solutions, please consult our technical experts online to obtain exclusive customized solutions to help you improve production efficiency and product competitiveness.
