Development of High Voltage Wire for New Structure Motor in Full Hybrid Vehicle

Driving motors for hybrid vehicles and electric vehicles require magnet wires that can endure use at high voltages of 650 V or more. The magnet wire is a main motor component with the electromagnetic steel sheets and magnets. Conventional motors generally assure insulation by using the two parts of the magnet wire and insulate paper. But this increases the motor space factor and hinders weight reduction. A new magnet wire with high insulation performance was used by forming thermoplastic resin onto an enameled layer in order to reduce the number of insulating parts and enhance motor performance. The magnet wire (High-Voltage Wire: HVW) composed of polyetheretherketone (PEEK) resin . HVW can withstand the forming load during motor manufacture, secures durability for the automobile motor operating environment (Automatic Transmission Fluid: ATF), high temperatures) and can maintain high-voltage characteristics. The new-structure motor specification that uses this HVW enables a tightly wound circuit structure. Compared to a previous-structure motor with the same core structure, the new motor increases the maximum torque and maximum power by 2.6% and 8.9%, respectively, and reduces the volume and weight by 24% and 26%, respectively. This HVW has been applied to Honda’s new-structure (Honda Advanced Winding: HAW) motor that achieves top-in-class power and compactness. (1)Cross Reference: