Core Manufacturing Process of New Energy Drive Motor
As one of the three core components of new energy vehicles, the drive motor must continuously improve power output and continuously reduce production costs, so that the sales of new energy vehicles will continue to soar.
1. Drive Motor Type & Performance
The drive motor is the power source of new energy vehicles. It is mainly composed of rotor assembly, stator assembly, motor housing, front/rear cover, gearbox, rotary transformer assembly and cooling water channel and other components.
Since the new energy vehicles were launched on the market, the used drive motors have been DC motors, asynchronous motors, permanent magnet synchronous motors and switched reluctance motors. These motors are affected by factors such as their speed range, power density, reliability, and manufacturing cost. Some of them have become the mainstream preferred components of new energy vehicles, some have been listed as new generation reserve parts, and some have been eliminated.
2. Stator Assembly and Manufacturing
The stator assembly of the permanent magnet synchronous motor of new energy vehicles involves components such as coils, cores, tooth poles and housings.
According to statistics, the stator assembly accounts for about 35% of the cost of permanent magnet motors. However, as the demand for personalized customization of automobiles increases, most models are in small and medium batches, and the permanent magnet motors equipped with them show a niche phenomenon of variable structure, wide performance, urgent orders and different stators.
Therefore, the high-cost stator assembly production cannot continue to use traditional manufacturing solutions, but adopts flat wire hairpin technology (Hair-pin), digital technology and information technology to improve the flexibility, integration and efficiency of the stator production line, thereby reducing space occupation, shortening delivery cycle and reducing production costs.
Manufacturing equipment for stator assemblies
The equipment used for stator assemblies involves industrial control cleaning machines, wire embedding machines, wire arranging machines, binding machines, etc., as well as laser cutting machines and welding machines, servo axis positioning paper inserting machines, heating machines, shaping machines and assembly machines, and flammable and explosive varnishing and drying equipment.
3. Rotor assembly and manufacturing
In recent years, almost all EVs and HEVs are equipped with built-in permanent magnet synchronous reluctance (IPMSynRM). As another core component of the new energy vehicle drive motor, the rotor is mainly composed of the rotor shaft, rotor core, permanent magnet (also known as magnetic steel) and its front and rear baffles.
The rotor shaft subtractive manufacturing includes turning and grinding of the outer circle and steps, rolling cutting of splines, milling of keyways, drilling, expansion, tapping and chamfering of bolt holes, etc. The surface magnetic test involves the detection of parameters such as the number of poles, polarity, pole peak, angle, area, width and half-width height. The manufacturing process improves the material utilization rate by optimizing the motor structure, introduces metal 3D printing to replace the production line with long process, many equipments and large fixed assets, and increases the coverage of automatic assembly and flexible cutting.
4. Stator and rotor assembly test and manufacturing process route
The stator and rotor assembly test and manufacturing are the last process of the new energy vehicle drive motor manufacturing. This process requires ensuring the precise matching and reasonable installation of each component to avoid problems such as oil leakage, noise or vibration caused by improper assembly. At the same time, cleaning and anti-fouling measures during the assembly process are also very important to ensure the cleanliness and operation stability of the motor. In addition, strict quality inspection and testing are required during the assembly process to ensure that the performance of the motor meets the design requirements.
In summary, the three core manufacturing process routes of new energy vehicle drive motors - stator assembly manufacturing, rotor assembly manufacturing, and stator and rotor assembly testing and manufacturing, together constitute the core system of new energy vehicle drive motor manufacturing. With the continuous expansion of the new energy vehicle market and the continuous advancement of technology, these manufacturing process routes will also be continuously optimized and improved, providing strong support for the development of new energy vehicles.
After years of development, NIDE has gradually accumulated a certain influence and brand effect at home and abroad. At present, the products cover the professional manufacture of new energy motor stator and rotor, hairpin motor, automatic aluminum casting rotor line, brushless motor/ BLDC motor, universal motor, wheel hub motor, etc., which are used in new energy vehicles, household appliances, industrial motors, water pump motors, servo motors, etc. Provide customers with a variety of new energy motor manufacturing solutions, including round wire motor manufacturing solutions, flat wire motor manufacturing solutions, hairpin flat wire technology solutions, flat wire hairpin stator forming machines, etc.