Flat Wire Motor Stator Rotor Process And Automation Equipment

Flat wire motor stator rotor process and automation equipment

 

The general trend of new energy vehicle motor route is urgent for automated assembly production lines.

 

Permanent magnet synchronous motor is the main technical route of new energy vehicle drive motor. At present, the most widely used type of 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, machine base, end cover and other auxiliary standard parts, wherein the stator assembly contains stator core, copper wire winding, lead wire and insulation material, which is generally fixed with the motor housing.The rotor assembly contains rotor core, permanent magnet, shaft, bearing and other components, which are connected to the output shaft and drive the gear to drive the vehicle.

        Flat wire motor structure model

 

In permanent magnet motors, flat wire motors have obvious technical performance advantages over traditional round wire motors.

(1) Small size and high power.

(2) Reduce motor copper consumption and improve motor efficiency.

(3) The temperature performance is better.

(4) Low mechanical noise and electromagnetic noise.

        Comparison of slot full-rate of round wire motor and flat wire motor

 

The production process of flat wire motor is complex and relies on automated equipment production

 

The stator assembly is the core of the flat wire motor design, the production is difficult, with customized characteristics, after the design is finalized, any point of the wire type and size changes, need to re-customize expensive tooling mold, low compatibility.The complete flat wire motor stator assembly manufacturing process includes paper insertion, coil forming, pre-insertion, integral insertion, flaring, twisting, leveling, welding, coating and dipping, copper nose welding, a variety of processes and complex, the degree of dependence on equipment is higher than that of round wire motor, especially coil forming and welding process precision requirements, difficult, need to use professional high-end equipment, overseas enterprises in this field of deep accumulation, equipment first-mover advantage obvious.

       Flat wire motor stator assembly manufacturing process

There are three major process links of flat wire motor assembly

Among them, the rotor line and the assembly line are relatively simple, the stator transfer line has a number of complex processes such as non-destructive bending, insertion, twisting, laser welding, dipping paint, etc., there are great technical difficulties, there is no standard flat wire motor stator assembly process, and each company is exploring the process scheme. At present, only a few foreign equipment companies with experience in delivering flat wire motor stator assembly lines are Comau, BorgWarner, Fisomat and so on.By learning from the past technical experience in the field of fuel vehicle gearbox, the company has successfully mastered the assembly process of the stator of the flat wire motor, and has the technical ability of the overall solution of the three major process links of the stator, rotor and assembly of the flat wire motor. At present, there are only a few companies in China that have the ability to undertake the stator assembly line of flat wire motors, such as Haosen Co., Ltd. and Kelai Electromechanical.

   The main process flow of the stator production line of flat wire motor

 

     Key and core equipment of flat wire motor stator production line

 

For the key processes in the stator production line of flat wire motor, including coil forming, plugging, twisting and welding, which are difficult and highly dependent on automation, the company has equipped with wire forming machines, automatic plugging machines, twisting machines and welding machines, corresponding to average production cycles of 4/360/50/3s respectively, to achieve high automatic operation of the stator production line.

            Flat wire motor rotor production line

The process flow of rotor production line is: iron core insertion magnet - iron core injection molding - heating and curing - rotor stacking - rotor dynamic balance - rotor magnetization - table magnetic detection - rotor pressing - laser marking. The entire production line is complex and requires high automation, among which the key processes include: iron core magnetism, iron core injection molding, rotor stacking and rotor magnetization. The company gives full play to its technical advantages and has mastered the mature flat wire motor rotor production line and assembly line.

 

 

The key and core equipment of the flat wire motor rotor production line