Flat wire stator coils differ from traditional round wire coils in performance parameters. Their efficiency is improved by approximately 2% to 3%. Flat wire motors have higher power and torque densities. The flat wire structure exhibits different heat dissipation characteristics, conducting heat more quickly. Compared to round wire motors, flat wire motors have a 29.5% higher slot fill factor. The flat wire structure is better suited for high-voltage platforms because its regular arrangement reduces the risk of breakdown and facilitates increased insulation thickness. Flat wire motors also show different NVH performance due to their higher winding stiffness.
Six-axis CNC insulation wrapping technology is applied to the manufacturing of stator coils for rail transit traction motors, helping to improve product quality and operational efficiency.
In-slot injection molding enhances insulation, increases mechanical strength, and enables in-slot oil cooling, serving as a technique for sustaining peak power. Foamed insulation paper technology effectively fills gaps and is suitable for solving the insulation challenges of PEEK wires in 800V and above high-voltage platforms.
