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General Introduction to New Energy Motors
CHCD Flat Wire Motor Development History
Mastered core design capabilities for new energy motors in electromagnetics, thermal
management, NVH, flow field, and mechanical strength, enabling customized motor design
for customers.
Established CHCD’s motor development process, built new energy motor platform
development capabilities, and adapted to diverse customer configuration requirements.
CHCD began researching flat wire motors in 2013, and has accumulated 12 years of
experience in flat wire motor development and manufacturing to date.
New Energy Motor Platform
Based on market demand, CHCD has planned a total of 4 motor platforms. The construction
of the φ180, φ220, and φ270 platforms has been initially completed, while the φ160 platform
is currently under development. All platforms adopt 4-10 layer flat wire hairpin technology,
compatible with multiple winding methods.
| Platform | Power range |
|---|---|
| φ160 | 20~85kW |
| φ180 platform | 50~120kW |
| φ220 platform | 100~320kW |
| φ270 platform | 40~135kW |
Range Extender Motor
Range Extender Motor
EV Motor
EV Motor
P4 Motor
EV Motor
EV Motor
Motor Design
- Electromagnetic Design
- Thermal Design
- NVH Design
Flat Wire Capability
The hairpin-based flat wire motor process route features core equipment independently developed and
manufactured in-house. We hold multiple invention patents, with industry-leading technologies including
unique high-speed forming technology, multi-layer flexible twisting technology, and head-free direct
welding technology.
Core processes such as winding forming, expanding, twisting, and welding are all independently developed
and manufactured, with a production cycle of 100 seconds per unit. We have mastered the core processes
of flat wire manufacturing as well as equipment development and production capabilities, resulting in low
process and manufacturing costs.
- Expanding: Adopts a unique wire-drawing process, suitable for 4–10 layer flat wire stators. Features flexible and fast parameter setting, smooth expanding action, and excellent consistency.
- Wire twisting: Adopts a layered twisting process, enabling higher precision, greater flexibility and more stable process control. The height difference at the welding end after twisting is controlled within 0.2 mm, allowing direct welding without end trimming.
- Vision inspection: Using high-definition photography and ViDi deep learning, OK and NG solder joint data are classified to establish a database. During production, the equipment takes 100% online photos, which are compared, screened and judged against the database, preventing products with defective solder joints from entering the next process.
Mini-pin Winding Process
- The length of paint removal is approximately 4 mm, with no ablation or damage to the insulation film. The welding end length is 6–8 mm shorter than that of Hairpin products.
- TIG welding is adopted. Compared with laser welding commonly used in the industry, it has advantages in welding fusion area and pull-out force.
- Laser welding: fusion area ≤ 80%, pull-out force ≤ 400 N
- TIG welding: fusion area ≥ 100%, pull-out force ≥ 600 N, providing better joint performance at welding spots.
Our Advantages and Commitments
-
Integrated Development Capability
Deep integration of design, process, testing and manufacturing for shorter development cycles -
Core Technology
High-efficiency motor performance, high-precision simulation platform and advanced manufacturing capabilities -
Quality Assurance
Full-process testing and verification to meet automotive-grade standards
