New Energy Vehicle Solutions
For 800V high-voltage drive systems, we offer a high-performance enameled flat wire solution that addresses the industry’s challenges in PDIV and corona resistance.
Core Requirement 1: Enamelled flat wire for 800V drives requires a higher PDIV.
Partial Discharge Inception Voltage - Partial Discharge Inception Voltage
Requirements Specification
The Importance of High PDIV Values
As the insulation approaches the end of its service life (i.e., the design life of the vehicle), the PDIV (partial discharge inception voltage) of the insulation shall exceed the overvoltage experienced during motor operation, thereby ensuring that partial discharge does not lead to insulation degradation.
Process Challenges
Technical Challenges
The insulation varnish has a narrow margin for adjusting the curing temperature, requiring precise control, and its coating exhibits poor wear resistance.
The Issuer’s Technical Proposal
Improve the paint film material by selecting an insulating material with a lower dielectric constant.
Increase the number of painting passes to thicken the paint film.
Ensure paint film eccentricity through mold optimization.
Control baking temperature, coating line speed, and paint viscosity to enhance coating film cure.
Core Requirement 2: Enamelled flat wire for 800V drives must exhibit excellent corona resistance.
Corona Resistance - Corona Resistance
Requirements Specification
The Necessity of Corona Resistance
If an 800 V drive motor is not subjected to corona-prevention treatment, the electric field can induce ionization and discharge in the air surrounding the windings, leading to corona formation. This results in localized temperature rise, which in turn accelerates insulation aging.
Process Challenges
Technical Challenges
The paint film exhibits poor flexibility, necessitating thinner insulation layers per coat and stringent control over mold precision as well as the amount of coating applied in each pass. Moreover, curing temperature and line speed must be tightly regulated.
The Issuer’s Technical Proposal
Enhancing the corona resistance life of the coating by incorporating nano-sized SiO₂ particles.
Control the match between the bare-wire mold and the painting mold to ensure uniform paint application.
Employ multiple coating passes, applying each coat thinly, to enhance the curing degree of the paint film.
Control baking temperature, coating line speed, and the temperature and viscosity of the paint.
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No. 12, Shenxi Third East Road, Shenyang Economic and Technological Development Zone, Shenyang, China
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