The Hairpin shaped winding flat motor is independently developed by the Shun Driving Force R&D team and planned to be mass-produced in mid-2022.
The SG series of flat wire forming windings are axially embedded, with high slot filling rate and short winding ends. The SG motor has higher efficiency and can adapt to more transmission systems of different powers; its raw material cost is low, and the supplier system is mature. It’s current mass production equipment is relatively mature. In particular, it has low production line investment, and high production efficiency.
SG290/55
SG270/77
CharacteristicHigher slot full rate and higher efficiency
Under the same power, it smaller size, less materials, and lower cost
Parallel slots reduce iron core saturation, reduce iron loss, and improve efficiency
Flat wire motor has better rigidity and noise suppression
Oil injection cooling at the end of the stator improves power density and torque density
Customer revenueThe torque can be expanded by changing the diameter/length
Flexible supply method, can provide complete machine or stator and rotor parts
Vibration and noise can be suppressed and optimized
Local development team, fast and flexible customer support
High product consistency
Suitable for moderate hybrid and strong hybrid vehicles
R & D strength
Core process
Manufacturing
Double/Multi-magnet layout has advantage to decrease the harmonic core losses
PIN flat wire can increase remarkably the slot factor
Multi-PIN design（6-8PIN）depress the skin and proximity effect
High flat ratio design for high efficiency at speed area
Double/Multi-magnet layout have good chance to reduce tangential / radial force fluctuation
Short pitch winding strongly decrease 6P torque ripple
V-Step skewing can efficiently reduce acoustic noise
Harmonic slot design on the surface of rotor
EMAG Genetic Algorithm Optimizer(EGAO):
Interface to FEA software
Capable for handling thousands of generations
The old population will be compared with the new population (after crossover, mutate, migrate…), the best cases will be selected
Preheating, round and hot set technology integration
The of the induction heating system
Induction heating system is precision
Roundness pressure equipment control system
Customized into a circular grinding tool
Automatic feeding system
The size of the insulation frame and tension on-line control
Insulation frame fracture prevention design
High quality, high precision control of the glue system
Vacuum potting material and good traffi
Preparation and automatic feeding system 24 hours a day
The vacuum potting process control, ensure no bubble
The data records of the all process is can be traced
The area of the first phase of production base: 16000 m²
Investment: 750 million
The stability of the production line has been verified by the German Schaeffler Electric Drive Module Project
Production line automation reaches 90%
The import rate of production line equipment reaches 80%
The production line has produced more than 10,000 products, the yield rate reached 99%, and customer complaints were 0%
capacity of phase I：
Production cycle：10.8 min
Capacity：40,000 units/year
SOP achieved
Planning capacity for the second phase：
Capacity：100,000 units/year
Expected to achieve SOP in 2021
