Research on the Development of Intelligent Automation Equipment Based on Hairpin Motor
With the continuous advancement of science and technology and the rapid development of the automobile industry, the application range of hairpin motors has continued to expand, and the productivity of hairpin motors has also increased sharply. In order to meet market demand and improve the production efficiency and quality of hairpin motors, the development of intelligent automation equipment for hairpin motors has received more and more attention. This article will introduce the development and research of intelligent automation equipment based on hairpin motors in detail.
1. Hairpin Motor and Its Advantages
Hairpin motor is a process that uses multiple copper wires pressed into the insulation layer to realize the motor manufacturing process. This motor has many advantages. First of all, its small size and compact structure can better meet the design requirements of the car space. Secondly, its light weight can reduce the weight of the whole vehicle and reduce fuel consumption. In addition, the hairpin motor has stable performance and low noise, which can provide a better driving experience. Due to the simple manufacturing process, the manufacturing cost of the hairpin motor is relatively low, which is conducive to reducing the cost of the entire vehicle. Finally, hairpin motors are easy to install and can better adapt to the needs of automotive production lines.
2. Development of Hairpin Motor Intelligent Automation Equipment
In order to improve the production efficiency and product quality of hairpin motors, intelligent automation equipment for hairpin motors has been widely used. At present, some progress has been made in intelligent automation equipment for hairpin motors, such as automated winding equipment, automated welding equipment, and automated assembly equipment. The emergence of these devices not only improves the production efficiency of hairpin motors, but also improves the quality of hairpin motors.
① Universal Wire Making Machine Equipment
Universal wire making machine equipment is mainly composed of 3 parts: wire supply assembly, paint stripping assembly and wire making assembly. The equipment is highly automated and intelligent. It adopts 2D folding + 3D mold line making, and one wire making machine completes all the wire shapes of the automatic stator. It is equipped with MES system to realize functions such as production status dynamic information display, quality traceability system and factory information management. It can also be flexibly adjusted and optimized according to different product requirements to meet the needs of different customers.
② Stator Flaring Machine
The equipment is connected with the front and rear machine heads by means of pallet transportation + conveying line, which mainly completes the automatic transfer of the stator to flaring position, the automatic paper protection of the paper protection needle, and automatic flaring. There is a press-in detection of the stator into the flared sleeve on the equipment, and real-time monitoring; Multiple sets of fixtures flare the copper wire at the same time to ensure the consistency and efficiency of flaring. There are various flaring methods such as jaws and sleeves for different products.
There is a press-in detection of the stator into the twisting wire mold on the equipment, and real-time monitoring; Through reasonable logic program design, various complex functions such as assembly and detection are completed. The servo control of the upper and lower layers of paper protection needle discs effectively protects the position accuracy of insulating paper and copper wires.The equipment is connected with the front and rear machine heads using the method of pallet transportation + conveying line, which mainly completes the automatic transfer of the stator to the twisting position, the automatic paper protection of the paper protection needle, and the automatic twisting of the wire.
3. Research Direction of Hairpin Motor Intelligent Automation Equipment
Although some progress has been made in hairpin motor intelligent automation equipment, there are still some problems and challenges. In order to better meet market demand and improve the production efficiency and quality of hairpin motors, the research direction of hairpin motor intelligent automation equipment includes the following aspects:
① Improve Production Efficiency and Product Quality
Further improving the production efficiency and product quality of hairpin motors is one of the focuses of current research. By introducing more advanced technology and equipment, the production efficiency and product quality can be better improved. For example, with more advanced control systems and sensor technologies, more precise automation control and monitoring can be achieved, thereby improving production efficiency and product quality.
② Reduce Manufacturing Costs
Reducing the manufacturing cost of hairpin motors is of great significance for improving market competitiveness. The manufacturing cost of hairpin motors can be reduced by researching cheaper and more efficient raw materials and manufacturing processes. For example, the use of new insulating materials and more efficient manufacturing processes can reduce raw material costs and manufacturing time, thereby reducing manufacturing costs.
③ Realize More Intelligent Control
Realizing more intelligent control is one of the important research directions of hairpin motor intelligent automation equipment. By introducing artificial intelligence and machine learning technology, self-learning and optimization can be carried out according to actual production data and rules, so as to achieve more intelligent control. For example, through machine learning technology, the analysis of production data can be realized, so as to predict the operating status and production efficiency of equipment, and make corresponding adjustments and optimizations.
The development of intelligent automation equipment for hairpin motors is an important research field, which is of great significance for improving the production efficiency and quality of hairpin motors. With the continuous advancement of technology and changes in market demand, the research direction of hairpin motor intelligent automation equipment will also be continuously adjusted and optimized. In the future, through multidisciplinary cooperation and technological innovation, the development of intelligent automation equipment for hairpin motors can be further promoted, and contribute to the development of the automotive industry and social progress.
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In the long term, the trend of flat wire motors is highly certain. In the first half of 2021, the penetration rate of flat wire motors among the top 15 vehicle models in terms of sales reached 28%, compared to just 14% in 2020. It is anticipated that by 2025, the proportion of flat wire motors in the drive systems of new energy vehicles will exceed 80%.
X-Pin motor technology allows for a reduction in the height of the linear segment at the end of the motor while maintaining a high slot fill factor. This results in a shorter overall motor length, saving copper wire usage and improving motor efficiency, thus achieving miniaturization.
In recent years, the market penetration of new energy passenger vehicles has continued to rise. Due to the high demand, existing cylindrical-wire motors have become insufficient in meeting the performance requirements of electric vehicle propulsion. Therefore, the substitution of flat-wire motors for cylindrical-wire motors is a highly certain trend for the future. Motor manufacturers are actively seeking high-capacity, high-quality production processes to meet market demands, with ongoing optimization and innovation in the manufacturing processes of flat-wire motor stators.
As is well known, the energy conversion efficiency of electric motors is around 90%, meaning that losses account for approximately 10%. Within the energy losses of a motor, copper loss, which is the heat generated by the current passing through the stator winding, constitutes about two-thirds of these losses.By adopting flat wire motors, the round wire windings are replaced with flat wire windings, increasing the amount of copper per unit area on the stator. This increases the copper fill factor to 20% to 30%, meaning more copper is packed into the stator slots. This effectively reduces winding resistance, and the lower the resistance of the winding, the higher the electrical efficiency. Consequently, it reduces copper losses.