1. Industry trends: the rise of axial flux motors and manufacturing pain points
With the acceleration of global electrification, motor design is undergoing a technological leap from traditional "radial flux" to high-performance "axial flux". In the cutting-edge tracks of new energy vehicle drive, aviation electrification and high-end industrial automation, axial flux motors (also known as disc motors) are gradually becoming the core choice for miniaturized and lightweight power systems with their excellent torque density and flat compact structure.
However, behind the advantages is an extremely high manufacturing threshold. The complex stator structure unique to axial flux motors poses severe challenges to its core manufacturing process, the stator coil winding process. Compared with radial motors, the stator groove usually presents asymmetrical and nonlinear special-shaped characteristics, and the winding space is extremely narrow. In pursuit of high performance, manufacturers often require extremely high coil fill rates (slot full rates), which means that enameled wires must be placed in near-perfect precision arrangement in a limited space. When dealing with such motors, traditional winding equipment often faces problems such as difficulty in path planning, wire drawing or damage to the insulation layer caused by violent tension fluctuations, which has become a key bottleneck restricting its large-scale mass production.
2. Technical tackling: precision control, reshaping winding standards
In response to the above industry pain points, our R&D team relied on its deep accumulation in the field of precision motion control, carried out special technical research for several months, and successfully launched a set of fully automatic high-precision winding solutions adapted to axial flux motors, achieving a major breakthrough in the core process.
First of all, it is the application of dynamic constant tension closed-loop control system. In the process of axial flux winding, due to the special stator groove shape, the wire movement path is complex, which can easily lead to violent fluctuations in the wire tension. Our solution adopts a highly responsive ultra-low inertia servo pay-off and milliN-level closed-loop feedback system, which can monitor and accurately control the tension fluctuation of the whole winding process in real time. This level of precision control effectively prevents the enameled wire from being thinned or the insulating film is damaged, ensuring that the electromagnetic performance of each turn of the coil is highly consistent and meets the stringent standards of aerospace and automotive grade components.
Secondly, it is the innovation of multi-axis linkage precision wiring algorithm. For the complex geometry of the special-shaped slots of the disk stator, we have independently developed a dedicated path planning algorithm. Through the synchronous linkage of the multi-axis servo system, the equipment can accurately control the landing point of the enameled wire in the special-shaped slot. This technology can achieve a neat and uniform arrangement like "shingles", greatly increasing the effective filling area (slot full rate) of the stator, and helping the customer's motor achieve higher power output and efficiency conversion.
3. Value empowerment: help customers build a competitive moat
We provide not only a machine, but also a set of mature production process support. Our flexible production system is equipped with a quick mold change function, which can be compatible with stator production of different diameters and different pole groove ratios, greatly shortening the customer's production line commissioning cycle. At the same time, the equipment integrates a comprehensive digital monitoring system, which can record and trace the winding process parameters in real time, providing a solid data foundation for customers to build a digital workshop.
In practical applications, this solution has helped customers significantly increase the coil filling rate in the limited stator space, significantly enhancing the peak torque and continuous power of the motor. By replacing manual labor with fully automated production, it not only improves the production cycle, but also ensures the quality consistency of products in large-scale mass production, reduces manufacturing costs, and builds core competitive barriers for customers in the high-performance electric drive market.
4. Looking forward to the future: jointly build a new ecology of efficient power
Innovation-driven, intelligent future. As an innovative enterprise deeply involved in the field of precision manufacturing, we have always believed that advanced winding processes are the key to unlocking the performance potential of axial flux motors. In the future, we will continue to increase investment in the field of high-performance electric drive manufacturing equipment, covering the whole process of stator assembly, shaping and testing, and work with global pioneering enterprises to jointly promote the innovation and upgrading of electric power systems.
At present, our technology center has opened special-shaped stator sample trial winding and technical consulting services, and sincerely invites industry colleagues to visit and exchange to discuss new cooperation bureaus.