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The Industrialization Wave of Flat Wire Motors: Reconstructing the Power Pattern of New Energy Vehicles
Flat wire motors, with their core advantages of high power density, low loss, and strong heat dissipation, have become the mainstream choice for driving motors in new energy vehicles. Their industrialization process has witnessed the "lane changing overtaking" of China's motor industry
Release time:
2025-11-19 17:15
Flat wire motors, with their core advantages of high power density, low loss, and strong heat dissipation, have become the mainstream choice for driving motors in new energy vehicles. Their industrialization process has witnessed the "lane changing overtaking" of China's motor industry. Compared with traditional circular wire motors, flat wire motors use tightly arranged rectangular cross-section wires, increasing the slot filling rate from less than 60% to 75% -80%, improving copper wire filling efficiency by more than 30%, reducing resistance by 18%, and directly driving a significant increase in vehicle range. The BYD e-platform 3.0 is equipped with a 10 layer flat wire winding motor, with a power density of 16.4kW/kg and a maximum speed of 30511rpm, enabling the vehicle's CLTC range to exceed 700km. The Xiaomi V8s motor adopts an 8-layer Hairpin flat wire winding and bidirectional full oil cooling technology, with a maximum efficiency of 98.11%, setting a new industry record.
Behind the technological breakthrough lies the collaborative innovation of the industrial chain: domestic enterprises have overcome the three core pain points of precision molding, high-voltage insulation, and welding processes. Baotou Rare Earth Research Institute has increased the domestic neodymium iron boron magnetic energy product to 55 MGOe, reducing costs by 40%; The joint electronic innovation of Ipin and twist head welding technology shortens the size of the stator end and further enhances power density. The global competitive landscape has shifted from being dominated by foreign investment to being led by Chinese enterprises. International patents for flat wire motors led by companies such as BYD and Huawei account for over 40%, supporting more than 40% of the global market share. European car companies are accelerating the introduction of Chinese flat wire solutions, promoting a 30% reduction in global electric drive system costs
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