In the Electric Mobility Era, What Are the Motors Used in Cars?
With the support of national policies and market promotion, sales of new energy vehicles continue to increase, and new energy and driverless technologies will be widely used in the future. Motors are used in many places in new energy vehicles, such as starter motor, electric oil pump motor, electric servo brake motor, cooling fan motor, electric power steering motor, etc.
The new energy vehicle market continues to expand and the demand for motors continues to increase. Traditional manual motor production line no longer meet the demand for motors on the market. The process requirements for motors are becoming more and more stringent. Choosing an automated motor assembly line can meet these needs.
Honest Automation has successfully completed the automobile motor assembly production line including water pump motor, wiper motor, ABS pump motor, starter motor, fan motor, window switch motor, and new energy vehicle hairpin motor production line. The key parts are all independently processed by precision equipment, and the standard parts are all of the world's top brands. Intelligent functions include lifespan management of key parts and components, face recognition, real-time traceability, upload, and distribution of production data, and docking with the MES system.
Honest Automation focuses on the R&D and customization of motor automation production lines. There are more than 400 complete line cases. The production line is compatible with a variety of motors. The motors produced can maintain high efficiency when applied to new energy vehicles.
The full-automatic motor production line only needs 1 or 2 people to operate, which improves product efficiency, and the yield rate has reached more than 99%, providing customers with professional motor intelligent equipment solutions.
From November 22 to 24, 2023, a motor industry event will be held at the Shanghai New International Expo Center, which is the much-anticipated "2023 China International 27th Small Motor Technology, Magnetic Materials Technical Seminar and Exhibition".
As one of the core parts of new energy vehicles, the electric drive system has an important impact on the performance of new energy vehicles, and has important significance for the power, economy, comfort, safety, reliability, and durability of new energy vehicles. In addition, in terms of industry needs, low cost, miniaturization, and intelligence are the main trends. The electric drive system of an electric vehicle is mainly composed of four parts: drive motor, transmission, power converter and controller. The drive motor is the core of the electric drive system, and its performance and efficiency directly affect the performance of electric vehicles. The size and weight of the drive motor and transmission will also affect the overall efficiency of the vehicle. Power converters and controllers can help electric vehicles operate safely and reliably.
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.