Application Of Insertion Machine In New Energy Vehicle Motor Manufacturing

With the rapid development of the new energy vehicle industry, the motor is the core drive system, and its manufacturing quality and efficiency directly affect the performance and cost of the whole vehicle. In the motor production process, the insertion process of the stator winding is crucial, and the insertion machine is the key equipment to achieve efficient and accurate winding insertion. This article will introduce the specific application and advantages of the insertion machine in the manufacturing of new energy vehicle motors.

In new energy vehicles, the motor is usually a high-power, high-speed permanent magnet synchronous motor or asynchronous motor. The stator coils of this type of motor are dense and the slots are small, which requires extremely high filling rate and insulation performance of the winding. The traditional manual wire insertion method is difficult to meet this high-precision, high-consistency and high-efficiency production requirements, and the introduction of the insertion machine just solves these pain points.

1. High-precision winding insertion to improve motor performance

New energy vehicle motors require the windings to be closely arranged and the coils to be neat to reduce energy loss and improve heat dissipation efficiency. The insertion machine uses a precision control system and a mechanical guide mechanism to achieve uniform insertion of the coils in the stator slots, avoid coil crossover, damage or distortion, and ensure stable motor performance. This high-consistency insertion operation helps to improve the space utilization of the stator wire package and reduce temperature rise and noise.

2. Improve production efficiency and meet large-scale manufacturing

Facing the rapid growth of the new energy vehicle market, vehicle manufacturers and motor manufacturers need to have large-scale and high-efficiency production capabilities. Modern insertion machines use servo drive, PLC control and intelligent program adjustment to achieve continuous operations such as automatic loading, alignment, and wire insertion, significantly improving the beat efficiency. An efficient insertion machine can stably complete multiple stator wire insertion tasks per minute, greatly shortening the production cycle.

3. Intelligent production and quality traceability

New energy vehicle motor manufacturing pursues high quality and full-process data traceability. While realizing automatic wire insertion, the insertion machine is equipped with sensors and monitoring systems, which can collect parameters such as wire insertion depth, insertion force, speed, etc. in real time to achieve process control and defect warning. Combined with the MES system, enterprises can achieve visual management of the entire process from raw materials to finished products, effectively ensuring product quality.

4. Support multi-variety switching and flexible manufacturing

The new energy vehicle market has fast product updates and diversified motor specifications. Advanced insertion machines support rapid tooling replacement or automatic adaptation of different stator sizes and line types through programs to meet the needs of co-production of multiple models of products. This flexible manufacturing capability makes the company more market responsive.

In general, the insertion machine not only improves production efficiency in the manufacturing of new energy vehicle motors, but also ensures product quality and consistency. It is one of the core equipment for realizing intelligent and high-quality motor manufacturing. With the continuous advancement of technology, the insertion machine will play a greater role in more subdivided motor fields and help accelerate the development of the new energy vehicle industry.