Heron Intelligent Manufacturing | The "Steel Shield" for Automotive Motor Safety, Defining the Industry's Safety Standard with Technology
Over the past two years, the global new energy vehicle market has grown at an annual rate exceeding 25%. Technological innovation and policy support remain the primary drivers of this market expansion. However, as the market continues to scale, automotive enterprises are placing greater emphasis on vehicle motor systems, particularly concerning safety maintenance. For example, the increasing complexity of technology and rapid innovation cycles have created a need for technical upgrades in certain vehicle motor systems.
The reliability of the "Three-Electric System" (motor, power battery, and electronic control system) in automobiles directly impacts overall vehicle quality. Among these components, 30% of motor failures result from welding defects, causing annual direct losses of up to 5 billion RMB per year. Certain substandard welding processes are inefficient, have large heat-affected zones, and may even lead to short circuits due to paint film damage, which significantly impair motor performance. Addressing these challenges, Heron leverages over 30 years of industry experience to successfully implement its mature equipment and automated systems for large-scale automotive motor components welding, providing source support for industrial efficiency.
Heron utilizes its independently developed MFDC (Medium Frequency Direct Current) resistance welding technology to deliver comprehensive welding solutions for automotive drive motor manufacturing and related components. These solutions encompass core equipment such as stator three-phase wire welding machines, stator center line welding machines, terminal block welding machine and enameled wire welding machines. This technology enables efficient and precise welding through medium frequency inversion and direct current output, establishing a technical foundation for the performance and safety of new energy vehicle motors.
The MFDC (Medium Frequency Direct Current) process offers unparalleled advantages:
1. Precise Control and Efficient Welding: MFDC technology converts AC power into frequencies such as 1 kHz, 2 kHz, or 4 kHz through an inverter, which is then fed into a medium-frequency transformer for voltage reduction. The current is rectified again, resulting in low-voltage, high-current output with rapid response times. Additionally, the improved power factor reduces energy consumption by 40% compared to traditional welding machines.
2. Material Protection and High Applicability: During welding, energy is concentrated in the weld zone, minimizing spatter and cold welds. This meets automotive motor protection standards and is suitable for welding copper, aluminum, and coated materials. It also prevents core magnetic property degradation, ensuring motor energy efficiency.
Regarding machine selection, Heron offers a series of welding equipment for drive motors, starter motors, motor casings, and other components. These systems feature compatibility and intelligent functionality to accommodate various workpiece requirements in automotive electrical systems.
Drive Motor Series: Includes stator three-phase wire welding, stator center line welding, and terminal-to-enameled wire welding machines.
Starter Motor Series: Covers starter motor stator welding and starter motor component welding.
Generator Series: Features motor rotor welding systems.
Heron welding technology offers significant benefits and industry application value for the new energy vehicle sector:
1. Improved Electrical Connection Reliability
MFDC technology ensures balanced three-phase resistance in stator windings, preventing localized overheating or short circuits caused by cold welding. This optimization reduces motor operating temperature, thereby extending motor lifespan.
2. Enhanced Protection Performance
The welding process maintains a high protection rate for the enameled wire’s insulation layer, improving the motor’s voltage resistance. This meets high-voltage platform system safety standards and reduces leakage and fire risks.
3. Lightweight and High-Power Adaptation
Precise control over aluminum/copper composite material welding supports motor lightweighting while ensuring weld point strength. This adaptability suits the demanding conditions of medium- and high-power-density motors.
With the rapid growth in production and sales of new energy vehicles, we are confident that the efficient welding and automation compatibility of Heron's MFDC welding equipment will provide core support for the safety, energy efficiency, and market competitiveness of new energy vehicles, driving the industry toward higher standards.