The Key Role Of Hairpin Flat Wire Motor Production Line In New Energy Vehicle Power Motor

Against the background of the rapid development of new energy vehicles, the requirements for the performance of electric drive systems continue to increase. As one of the core components, the efficiency, power density and heat dissipation performance of the power motor are directly related to the power performance and endurance of the whole vehicle. With its advantages of high efficiency, compactness and good heat dissipation, the hairpin flat wire motor is gradually replacing the traditional round wire motor and becoming the mainstream choice for new energy vehicle power motors. The key to supporting the rapid implementation of this trend is the intelligent and automated level of the hairpin flat wire motor production line.

Why choose a hairpin flat wire motor?

The hairpin motor uses a rectangular cross-section copper flat wire. Through the design of the "hairpin" winding and laser welding technology, it not only improves the coil slot full rate, but also effectively reduces copper loss and thermal resistance, so that the motor efficiency is significantly improved. At the same time, this structure is more suitable for high-speed and high-torque working requirements, and is an ideal drive solution for high-performance new energy vehicles.

Core functions of the hairpin motor production line

High-precision winding and forming

The flat wire material has high rigidity and extremely high requirements for winding and forming precision. Modern production lines use CNC molding equipment to achieve precise control of the angle, length and size of each hairpin wire, ensuring coil consistency and assembly accuracy.

Intelligent welding system

Welding is a key link in the manufacture of hairpin motors. Laser welding or resistance welding technology can ensure that the hairpin wire welds are firm and have low resistance. The automated welding system can accurately identify the wire position, automatically complete positioning, crimping and welding, improve production efficiency and reduce human errors.

Automated plugging and flaring equipment

Accurately inserting the hairpin wire into the stator slot and flaring it is the key to ensure the firm assembly of the winding. Modern plugging systems use robot vision recognition and multi-axis motion control to achieve high-speed and high-precision plugging, greatly improving production cycles.

Online detection and quality control

The entire production line can integrate multiple online detection functions, such as size detection, solder spot imaging, resistance measurement, insulation testing, etc., to ensure that each process link meets the high quality standards of new energy vehicle power motors.

Significance to the new energy vehicle industry

The higher the level of automation of the hairpin motor production line, the more it can meet the needs of new energy vehicles for large-volume, high-consistency, and high-reliability power motors. Through batch and standardized intelligent manufacturing, not only the labor cost is significantly reduced, but also the product delivery cycle is shortened. For vehicle manufacturers, this means higher production efficiency and stronger competitiveness.

Conclusion

The wide application of hairpin flat wire motors is inseparable from the support of advanced production lines. With the continuous advancement of production technology and intelligent manufacturing level, hairpin motor production lines will play a more critical role in new energy vehicle electric drive systems, helping the industry to develop with high quality and green transformation.