In today's rapidly developing new energy vehicle industry, the performance and reliability of the electric motor, as its core drive component, directly determine the vehicle's power output, range, and safety performance. However, the motor manufacturing process is complex, involving numerous metal processing and assembly steps. With even the slightest carelessness, tiny magnetic impurities such as iron filings and rust can enter key components, becoming "invisible killers" during motor operation. Against this backdrop, strong magnetic rods are quietly playing the role of "quality gatekeepers" in motor manufacturing, and their critical role cannot be ignored.

Strong magnetic rods are capable of performing critical tasks thanks to their superior technical features:

1. High-Intensity Magnetic Field: Made from rare earth permanent magnets (such as NdFeB), they deliver magnetic field strengths exceeding 8,000 gauss, effectively attracting micron-sized ferromagnetic impurities.

2. Temperature Stability: Utilizing high-performance magnetic materials with high intrinsic coercivity and high operating temperature, they maintain stable magnetic properties across a wide range of motor manufacturing environments.

3. Structural Diversity: Magnetic rods can be designed in various sizes, shapes, and magnetic strengths to meet diverse application scenarios and installation requirements, meeting the diverse requirements of motor manufacturing.

Strong magnetic rods, with their powerful iron removal capabilities, are used throughout the entire process of new energy vehicle motor manufacturing, from core processing to winding production to final assembly, silently protecting the quality and performance of the motor.

1. Motor Core Production: The "Nemesis" of Iron Filings

The production of motor cores is inseparable from silicon steel sheets. During the punching, shearing, and lamination processes, the mechanical forces of the equipment cause wear on the cutting tools and dies, leading to the generation of iron filings.

These seemingly insignificant iron filings can be extremely harmful if they enter the motor core. During motor operation, the iron filings within the core generate additional eddy current losses under the influence of the alternating magnetic field, causing severe heating of the core. This not only reduces motor efficiency but, over time, can damage the core and shorten the motor's lifespan.

High-strength magnetic rods are installed at the discharge port of silicon steel sheet processing equipment. Their powerful magnetic field acts like a keen "iron filing hunter," rapidly attracting iron filings. Made of rare earth permanent magnets with a high magnetic energy product, they can achieve magnetic field strengths exceeding 8,000 gauss, easily capturing even micron-sized iron filings.

2. Winding Production: The "Guardian" of Insulation

Enameled wire is the "blood vessels" of the motor windings, and the integrity of its insulation directly determines the safe operation of the motor. Iron impurities from worn winding dies or the raw materials themselves can enter the windings along with the enameled wire. Under the long-term effects of current heating and electromagnetic forces, iron impurities can easily pierce the insulation, causing short circuits between turns and leading to motor failure.

Inserting strong magnetic rods into the enameled wire delivery pipeline intercepts iron impurities at the source, ensuring the purity of the windings. Data shows that the use of strong magnetic rods increases motor power generation efficiency by approximately 8%, contributing to additional vehicle range. Higher power generation efficiency means that vehicles can travel farther with the same amount of power, precisely meeting consumers' demand for longer driving range.

3. Motor Assembly: The "Gatekeeper" of Purity

Strong magnetic rods also play an indispensable role in the motor assembly process. The motor casing, end caps, and internal connectors can also carry impurities such as iron filings during processing and handling.

Strong magnetic rods can be installed at key locations on assembly equipment to remove iron from components entering the assembly area, ensuring a clean environment within the motor and preventing various failures caused by iron impurities.

Finally, why do new energy vehicle motors require strong magnetic rods in particular?

New energy vehicle drive motors primarily include permanent magnet synchronous motors and induction asynchronous motors, with permanent magnet synchronous motors accounting for 94% of the domestic market.

These motors typically utilize neodymium iron boron permanent magnets, offering advantages such as high power density, high operating efficiency, high torque, and smooth operation. However, they also place higher demands on cleanliness:

1. Efficiency Requirements: New energy vehicle motors must maintain high efficiency across a wide speed range. Any excess loss caused by iron impurities will impact range.

2. Compact Design: Motors are trending towards higher speeds and smaller sizes, resulting in more sophisticated internal structures and increased sensitivity to impurities.

3. Reliability Requirements: As a core component of the vehicle, the reliability of the motor is directly related to its safety and service life.