1. Track focus: the "limit requirements" of aviation electrification for power
With the booming low-altitude economy, eVTOL (flying car) and high-end drones have put forward almost strict requirements for power systems. In order to achieve a longer range and higher load capacity, the aeromotor must burst out with incredible torque in a very small volume. With its ultra-high power density, axial flux motors have become the "star solution" in the field of aviation electrification.
However, aerospace-grade motors have specifications for winding consistency, insulation reliability, and lightweight that far exceed industrial standards. Traditional manufacturing processes are difficult to meet such stringent quality traceability requirements while ensuring high output. How to achieve the standardization and automated production of high-performance axial flux motors has become the focus of attention of leading enterprises in the industry.
2. Implementation of the plan: customized development to solve the problem of "special-shaped winding"
Recently, the automatic winding production line of axial flux motor customized and developed by our company for a well-known aviation drive system supplier has successfully passed the acceptance and completed delivery. The complete success of this project marks a new height in handling large-diameter and high-precision disc stator winding processes.
In view of the characteristics of customer products "special pole groove ratio and extremely compact winding space", our technical team carried out a three-month special research:
Customized Special-Shaped Fixture System: For the special physical structure of the stator of the aeromotor system, a precision fixture with automatic centering function has been developed to ensure that the stator displacement deviation is controlled at the micron level under high-speed winding.
Multi-layer stacking process optimization: Through the self-developed control software, the precise stacking of multi-layer enameled wires is realized, which not only eliminates the ineffective space at the end of the coil, but also improves the heat dissipation performance of the winding by about 15%.
Full life cycle data traceability: The production line integrates a digital monitoring terminal to record the tension data, winding turns, and line trajectory of each set of coils in real time. This "digital ID card" system perfectly meets the rigid demand for full traceability of parts quality in the aviation field.
3. Customer value: from "laboratory research and development" to "large-scale mass production"
The production line delivered this time not only greatly improves the customer's single machine output efficiency, but more importantly, solves the problem of poor manual winding consistency that has plagued customers for a long time.
According to the customer's on-site feedback, after adopting our automatic winding scheme:
Production cycle improvement: Compared with traditional processes, the overall production efficiency is increased by about 40%.
Reduced quality loss: The scrap rate of enameled wire due to damage has been reduced by more than 60%.
Enhanced performance of the whole machine: Due to the tighter and scientific arrangement of the windings, the overall temperature rise performance of the motor has been significantly improved.
4. Continuous evolution: Build a new cornerstone of global electric drive manufacturing
From new energy vehicles to aviation electrification, the application boundaries of axial flux technology are constantly expanding. Our company will take this production line delivery as an opportunity to continue to deepen the high-precision winding process, continuously optimize the algorithm, and improve the intelligent level of the equipment. We not only provide equipment, but also strive to become a trusted process partner for pioneering motor manufacturers worldwide.
At present, our company has launched R&D reserves for the next generation of "ultra-high power density motor" winding technology, and looks forward to witnessing the transformation of power systems with more industry pioneers.