The development of new energy vehicles, especially the arrival of 800V electrical architecture is calling for improved performance and safety of drive motors, which results in higher requirements for the manufacturing process.

Trickling and coating are essential steps during the production of the stator which is the core structure of the drive motor. The stator winding is solidified into a whole using insulation paint, providing an unobstructed heat dissipation channel, improving the stator's seismic resistance, insulation, moisture resistance, and corrosion resistance, achieving the improvement of the mechanical strength and the electrical performance of the motor, delaying motor aging, and also helping to improve the NVH characteristics of the entire vehicle.

Technical requirements background

Due to the fact that the advanced trickling equipment in the industry is controlled by European and American enterprises, and the cost is high. However, in China, many enterprises are transformed from traditional motor equipment manufacturers, lacking theoretical guidance on the trickling process of new energy products. Process control is often based on experience, making it difficult to provide customers with fast and professional after-sales service. In order to make up for technical deficiencies, provide customers with cost-effective trickling equipment, and improve service quality, Haosen has launched a special research and development on trickling technology.

Regardless of the technical route, the filling rate of trickling is always an important indicator to determine the maturity of the trickling process. Haosen's research and development focus in this field is also on improving the filling rate. Currently, Haosen has successfully developed fully automatic mass production trickling equipment with different technical routes such as chain furnace, induction heating and electric heating, with a filling rate of up to 99.8%.

Model research + Experimental exploration

Comprehensive upgrade of trickling filling effect

Temperature control, fluid control, and process parameters (rotation speed, inclination angle, and trickling volume) are the three key factors in trickling technology. Based on this, Haosen started with several mainstream heating forms in the industry, such as electric furnaces, induction heating, and electric heating, and conducted theoretical analysis one by one. Haosen constructed a research model that is suitable for the actual application scenarios of stator trickling to analyze the impact of different variables on heating effect as well as insulation paint changes on fluid processes, breaking away from the common empiricism in China and building a solid theoretical foundation for the research and development of trickling technology.

 Temperature variation curve of stator heated by electric furnace

Electric heating winding R-T curve

Induction heating electromagnetic induction intensity curve

In the Haosen special laboratory for trickling, hundreds of experiments obtain hundreds of thousands of data, which have ultimately formed a precise intelligent solution for stator trickling. This solution can realize accurate control of stator preheating, trickling, jellification and curing temperature, flexible matching of stator rotation angle and rotation speed with product changes, as well as accurate control of nozzle position and flow, ensuring uniform trickling, full trickling and no overflow.

After testing, the first piece filling rate of multiple models of stator has reached over 99.5%, with a maximum of 99.8%. No matter for the new generation X-pin products or 800V electrical architecture stator products, the most suitable trickling process parameters can be quickly obtained through this solution, so as to guide the accurate planning, rapid commissioning and excellent effect of insulation process equipment.

Considering the customer's needs for product changes, capacity expansion, and cycle time improvement, Based on strong mechanical design foundation and modular design architecture, Haosen has completed fully automatic mass production equipment such as induction heating modular trickling equipment, electric heating modular trickling equipment, and chain furnace trickling equipment, with complete functions, exquisite structure, good compatibility, reasonable control, and easy maintenance.

Haosen is committed to developing efficient, reliable, and cost-effective one-stop intelligent manufacturing solutions for drive motors, integrating the entire chain from stator, rotor, final assembly, testing to electric drive systems. Haosen conducts in-depth research on key process technologies, continues to break through industry technology bottlenecks, meet customer needs, and promotes industry development.

1. Trickling filling rate 99.8%

2. Theoretical research+test data, authority empowering

3. Modular design, precise structure, excellent effect

4. Customizable solution, short supply cycle, fast service response