Introduction of Flat Wire Dual U-Pin High Efficiency Drive Motor

As the power source of new energy vehicles, the process technology of drive motors is one of the core technologies of many R&D and manufacturing companies.

Yida Electric Drive has been deeply engaged in flat wire drive motors for many years. Based on a complete R&D system and independent equipment manufacturing, it has upgraded the traditional U-Pin process to a double U-Pin process to explore new energy drive motor solutions that are more in line with the trend of lightweight and high efficiency.

As one of the three cores of the power system of new energy vehicles, the heat dissipation problem and winding eddy current loss of flat wire drive motors have a significant impact on the efficiency, power and safety of new energy vehicles.

With the continuous improvement of new energy vehicle motor technology, the number of flat wire stator layers has gradually increased from 2 layers to 4 layers, 6 layers, 8 layers or more.

Under the same current density, the more conductor layers a 4-wire winding or an 8-wire winding has, the lower the AC loss. At the same time, the loss difference gradually increases with the increase in speed. Increasing the number of flat wire winding conductor layers has a significant effect on reducing AC loss.

Yida Electric's drive technology has evolved. Compared with the common 4-layer motor, the 8-layer winding motor has increased the winding surface area, which is more conducive to heat dissipation and has a significant effect on controlling temperature rise. The AC resistance is reduced, and the winding loss is reduced. At the same time, the platform design is more convenient.

Among the factors that restrict the rapid increase in the penetration rate of new energy vehicles, the cruising range and recharging time are the key reasons.

At present, Yida Electric Drive's 8-wire winding motor can meet the rated voltage of 600Vdc and 800Vdc, which is in line with the trend of high voltage.

Yida Electric Drive effectively improves the system voltage and power by increasing the number of motor winding layers, and the vehicle weight and electronic control losses are expected to be reduced, and the vehicle cruising range will be improved; at the same time, high voltage can also improve charging efficiency, speed up charging speed and solve the pain point of recharging time.

In terms of production technology, Yida Electric Drive's 8-wire winding motor adopts U-Pin double-row technology. The winding end structure is compact, and there is a very small air gap between the conductors to facilitate heat dissipation. Compared with the common flat wire U-Pin process, the height of the winding end and the size of the motor are further reduced. However, the U-Pin double-row technology has high process requirements and is difficult to manufacture, requiring strong production equipment and R&D technical support.

Nowadays, the penetration rate of flat wire motors is increasing rapidly, and the improvement of motor performance and efficiency is particularly important for the power and energy conservation of the whole vehicle. Yida Electric Drive has been deeply involved in the new energy motor and system application industry related to the low-carbon economy industry for many years, and has been developing in the main direction of high voltage, high power, high speed and diversified cooling forms of motors. With the corporate mission of "actively promoting the innovative development of the electric drive industry and helping to achieve the goals of carbon peak and carbon neutrality", Yida will continue to provide the market and customers with more advantageous flat wire motor solutions in the future.