English
Views: 22 Author: Site Editor Publish Time: 2025-09-15 Origin: Site
New energy vehicle drive motors are the core components of electric vehicles, and the performance of their stator wires directly affects the efficiency, reliability and life of the motors. As a key component for transmitting electrical energy and generating magnetic fields in motors, stator wires (i.e., wires of stator windings) must comply with strict industry standards for their manufacture and application. This article will popularize the relevant industry standards for stator wires of new energy vehicle drive motors to help readers quickly understand their technical requirements and significance.
The stator wire is an insulated wire wound in the slots of the stator core of the motor. It is usually made of enameled copper wire or aluminum wire. It generates a rotating magnetic field through current to drive the rotor to operate. The material, insulation performance and manufacturing process of the stator wire directly determine the power density, thermal stability and service life of the motor. In the field of new energy vehicles, the demand for high efficiency and lightweight makes the design and production standards of stator wires particularly stringent.
The industry standards for stator wires of new energy vehicle drive motors are mainly formulated by the International Electrotechnical Commission (IEC), the International Organization for Standardization (ISO) and national standards (such as China's GB standards), covering materials, performance, testing and manufacturing. Here are a few key standard highlights:
Wire materials and specifications Stator wires usually use high-conductivity enameled copper wires, and some lightweight designs use aluminum wires. Standards require that the resistivity, tensile strength, and elongation of the wires meet specific ranges. For example, the IEC 60317 series of standards has detailed provisions for the electrical and mechanical properties of enameled wires. The cross-sectional shape of the wire (such as round, rectangular) needs to be optimized according to the motor design to improve the slot fill rate and heat dissipation efficiency.
Insulation performance The insulation layer of the stator wire needs to withstand high temperature, high voltage, and frequent electrical pulse shocks. Standards (such as IEC 60851) specify the heat resistance level (usually 180°C to 220°C), voltage breakdown strength, and chemical corrosion resistance of the insulating varnish. New energy vehicles often use polyimide or polyester composite insulation materials to cope with the harsh working conditions of high-power density motors.
Manufacturing process The winding and insertion process of the stator wire must meet the requirements of ISO 26262 (automotive functional safety standard) to ensure consistency and reliability. The standard has clear specifications for the arrangement of windings, the insertion of insulating paper and the end treatment to prevent short circuits or insulation failure. In addition, the accuracy of automated production equipment (such as paper inserters and winding machines) must also meet industry specifications.
Performance testing and certification Stator wires must pass multiple tests, including insulation resistance tests, heat aging tests and vibration durability tests. For example, the IEC 60034 standard specifies the electrical performance test methods for motor windings to ensure the stability of stator wires under extreme working conditions. New energy vehicle motors must also meet the special requirements of ISO 21498 on the safety of high-voltage components.
These standards provide a unified technical framework for the design, production and application of stator wires to ensure the efficiency, safety and durability of new energy vehicle drive motors. Specifically, standardized stator wires can improve the energy conversion efficiency of motors and reduce energy consumption; enhance insulation reliability and reduce the risk of failure; promote the commonality of parts and reduce production costs. At the same time, stator wires that meet international standards help companies remain competitive in the global market.
