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As a drive motor manufacturer with years of experience in motor cooling system design, I often get asked: how do electric vehicles manage the enormous heat generated by high-performance motors? Whether it’s a pure electric car or a hybrid, e-drive systems deliver impressive acceleration and power—but they also bring significant cooling challenges. So how are these heat issues solved?
If you’re sourcing motors for demanding environments — where heat, humidity, and vibration are constant challenges — then the quality of your stator insulation isn’t just important, it’s critical. That’s why more and more customers are turning to Vacuum Pressure Impregnation (VPI). Unlike traditional dipping methods, VPI delivers deep, uniform insulation that dramatically improves reliability, extends motor life, and reduces maintenance costs. But what exactly happens during the VPI process — and why is it considered the gold standard for stator windings?
Motor overheating and low efficiency—what’s the real problem? If you work in motor design or deal with motors regularly, you may have noticed that sometimes, even when the winding and control system are perfectly fine, the motor still gets hot and its efficiency doesn’t improve. The problem often lies in one critical area—excessive core loss in the stator.
How does the stacking method of stator and rotor cores affect the performance of a new energy vehicle motor? As a core lamination designer with years of experience, I often encounter this question. In fact, the stacking method directly influences the efficiency, reliability, noise level, and cost of EV motors. Choosing the right method is critical—especially for high-performance permanent magnet synchronous motors (PMSM) used in electric vehicles.
When it comes to buzzwords in new energy vehicle technology, what comes to your mind?
800V platform? SiC power devices? Or hub motors? Among the hottest trends, the hairpin motor (flat wire motor) is certainly leading the pack. Ever since Tesla adopted this technology, discussions surrounding hairpin motors have only intensified. We’ve previously published several technical articles on hairpin motor technology—such as flat wire techniques used in NEV drive motors. Feel free to check them out if you’re interested.
Are you wondering why winding methods are critical in axial flux motor design? As an experienced motor designer, I’ve spent years optimizing winding structures to improve performance, reduce loss, and simplify manufacturing. In this blog, I’ll guide you through the most common and advanced winding techniques used in axial flux motors.
Have you ever wondered what drives the heart of drones, robot vacuums, or electric vehicles? These high-tech machines all rely on BLDC motors, and inside these motors, there’s a fascinating difference in stator winding methods—some follow the “concentrated” camp. In contrast, others belong to the “distributed” side. Don’t underestimate these winding styles—they affect everything from motor efficiency and noise to cost and performance. Behind them are countless engineers’ clever design decisions.
In recent years, many automakers have talked about applying axial flux motors in new energy vehicles. But due to manufacturing difficulties and high costs, most companies were still waiting and watching. However, at this year’s Shanghai Auto Show, several companies showcased their axial motor products. Let’s take a look together. Personally, I see great potential for axial flux motors as range extenders.
Many luxury car brands see the axial flux motor as the best solution for electrification. But do you know which car models are already using it? The axial flux motor is known for its high power density, compact size, and fast response. Compared to traditional radial flux motors, it has shorter magnetic paths, higher torque output, and better cooling performance.