The trickle impregnation process is a critical step in motor manufacturing, primarily used to address the issue of loose winding structures.

During the hairpin insertion and twisting processes in the hairpin motor, gaps may occur between copper wires. The trickle impregnation technique involves infiltrating these gaps with insulating varnish, curing to form a solid gel-like structure. This effectively secures the windings, enhances mechanical strength, and reduces vibration and noise.

At the same time, this process improves the insulation performance, heat dissipation efficiency, and thermal resistance of the windings, ensuring the motor operates reliably under harsh conditions. Therefore, the quality of the trickle impregnation process directly affects the motor's operational performance and its competitiveness in the market.

However, as the performance requirements for motors in new energy vehicles continue to rise, traditional trickle impregnation processes can no longer meet the demands for high performance and high efficiency in hairpin motors.

This conventional method faces challenges such as uneven heating, insufficient slot fill, and residual air bubbles, which can lead to reduced insulation performance, lower thermal dissipation efficiency, and even compromise the long-term operational stability of the motor.

In addition, traditional processes are characterized by high energy consumption and low efficiency, making them unsuitable for large-scale, automated production environments.

As a result, overcoming these process limitations through technological innovation has become one of the key focal points within the industry.

Against this backdrop, HONEST Automation has gradually developed a range of innovative technologies to address the challenges associated with the traditional trickle impregnation process for flat wire stator production. The key innovations are as follows:

(1) High-Frequency Heating Technology: This technology applies current directly to the copper wires for rapid and precise heating. It significantly improves the trickle impregnation process's efficiency and the varnish film's quality, ensuring that the insulating varnish maintains optimal fluidity throughout the process.

(2) Vacuum Trickle Impregnation Technology: By performing the trickle process in a vacuum environment, internal gaps within the motor can be more thoroughly filled, achieving a slot fill rate of 90–96%. This approach effectively eliminates air bubbles, enhances the density and adhesion of the varnish film, and consequently improves the insulation performance and overall reliability of the motor.

(3) Automated Trickle Impregnation System: This system integrates high-precision motion control and vision recognition technologies to enable a fully automated and intelligent trickle impregnation process, significantly enhancing production efficiency and product consistency.

With the continuous development of the new energy vehicle industry, innovative technologies such as vacuum trickle impregnation, high-frequency heating, and automated trickle systems have brought revolutionary breakthroughs to the trickle impregnation process for flat wire motors. These advancements not only enhance the efficiency of the trickle process and the quality of the varnish film but also significantly improve the insulation performance and reliability of the motor, providing strong technical support for the high performance of new energy vehicle motors.

Looking ahead, as the industry continues to pursue green manufacturing and intelligent production, the trickle impregnation process will continue to evolve toward higher efficiency, greater environmental friendliness, and increased intelligence.

As a provider of intelligent motor equipment solutions, HONEST Automation is dedicated to offering efficient and reliable fully automated production lines to customers worldwide. If you are facing similar challenges in the trickle impregnation process for hairpin motor stators or would like to learn more about our motor production line solutions, feel free to leave a comment or schedule a visit to our company for further discussion. We will provide the technical support you need to enhance your production efficiency and product quality.