In the wave of technological advancement, every innovation is an exploration of the future.
Compared to traditional chain and belt conveyors, magnetic drive conveyor technology is innovative in that it uses the magnetic field generated by a coil motor to drive materials through magnetic force, enabling contactless high-speed material transfer on the conveyor line. This greatly promotes the efficiency, intelligence, and flexibility of the production process.
In magnetic drive conveyors, motor coil technology is particularly crucial, as it occupies a core position in the magnetic drive conveyor system and directly affects the overall production efficiency and safety.
As a pioneer in China's magnetic drive industry, Zongwei Technology has always been committed to promoting the innovation and development of motor and drive technologies, keeping pace with the development trend of high-efficiency industrial motors.
Zongwei Technology has broken through the original application scenarios of flat wire technology and creatively applied it, becoming the first company in China to apply flat wire technology to drive motors in the field of industrial automation .
For magnetic drive conveyor systems, a low-voltage common bus design is typically used to reduce the cost of the drive circuit. This means that, at the same power, the average current increases by 3-5 times compared to medium-high voltage (220V/380V), and the heat generation increases by 9-15 times, placing extremely high demands on heat dissipation and heat control technologies . This is why several smoke and fire accidents caused by stator high-current heat dissipation design flaws have occurred in the magnetic drive industry.
In traditional round wire motors, the slots are enclosed spaces, inevitably creating gaps between the wires. These gaps have lower thermal conductivity compared to conductors like copper and aluminum, resulting in weaker heat transfer capabilities. Furthermore, the gaps between the round wires cannot be completely filled, leading to a lower copper conductor cross-section (slot fill factor) per unit cross-section compared to flat wire motors, resulting in higher resistance for the same volume of round wire motor.
Compared to traditional round wire motors, flat wire motors use rectangular wire cross-sections with smaller gaps between the wires, allowing heat to be conducted away more quickly. The compact structure at the ends of the flat wires also facilitates heat dissipation. This makes flat wire motors better able to withstand high temperatures and suitable for low-voltage, high-current, and high-power-density applications.
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Zongwei Technology uses fine flat wire coil technology, which can increase the amount of copper filled by 20%-30% under the same cross-sectional area.
The copper wires are more tightly packed together, resulting in stronger thermal conductivity of the internal coils. This also improves slot fill factor, reduces resistance and heat generation, enhances motor performance, and increases safety margin. These advantages, combined with advanced drive and motion control technology, have ensured that Zongwei Technology has never experienced a single safety incident such as spontaneous combustion or fire .
The space inside the winding slots of the motor stator is limited and needs to be utilized to the maximum extent. The gaps between the wires in the round wire motor not only affect the heat dissipation effect, but also make it difficult to make full use of the space inside the slot, resulting in a slot fill factor of only about 45%.
In contrast, flat wire motors use rectangular wire sections, which better adapt to the shape of the slots; and its copper bars, like thick ropes, can more tightly wrap around the stator teeth, effectively reducing magnetic field leakage and magnetic resistance, and increasing the motor's magnetic flux. With the same or smaller volume and weight, flat wire windings can achieve a slot fill factor of over 70% , thereby enhancing the magnetic field strength.
This also means that, within the same volume, flat wire motors can provide stronger power output and significantly reduce energy consumption.
In addition, the flat wire technology of longitudinal reed significantly increases the thrust generated per unit length from 1.2N/mm to 3N/mm , making longitudinal reed magnetic drive products have advantages such as smaller stator size, more compact mover arrangement, and more trays per unit length for installation and use.
Therefore, the reed magnetic drive not only integrates better heat dissipation and lower heat generation, but also effectively saves space in production, achieves cost savings, and helps realize the concept of new quality productivity and green sustainable development.
In the field of fine flat wire, the insulation layer of flat wire is prone to damage at bending points, and the difficulty in fully automated production are major challenges to the implementation and promotion of the technology. To address this, the Zongwei process technology team has overcome the problem of high cracking probability in the winding of ultra-fine flat wire by jointly developing insulation materials with insulation material manufacturers and exploring processes. Furthermore, by leveraging its own motion control technology advantages, it has independently developed a fully automatic flat wire hollow coil winding machine , expanding the applicable scenarios of flat wire coils and enabling flat wire technology to continuously empower the field of industrial automation.
Only by daring to break with convention can one truly lead the industry trend. With its exceptional heat dissipation and power output, the Zongwei flat wire motor not only significantly improves production efficiency but also brings unprecedented safety and reliability to users . Zongwei Technology has also creatively applied this technology to the field of magnetic drives, representing not only technological advancement but also a revolutionary impetus to the industry.
Looking ahead, Zongwei Technology will continue to shoulder its mission as an industry pioneer, striving for even higher standards and unremitting efforts to achieve more remarkable accomplishments. We will provide highly valuable solutions to the global market, working hand-in-hand with our clients to stand out in fierce competition.
