Yueke Intelligence has secured multi‑hundred‑million‑yuan orders for electric‑drive smart production lines from clients including Volkswagen and GAC, spearheading a new generation of innovations in hairpin‑stator manufacturing technology!
At the start of the new year, Yueke Intelligent has successively secured orders from customers such as Volkswagen and GAC for intelligent production lines dedicated to flat‑wire stators for electric drives. This marks the first time Volkswagen has engaged a Chinese supplier in this segment, underscoring the strong endorsement that leading international automakers—including Volkswagen—place on Yueke’s flat‑wire stator manufacturing technology. Looking ahead, Yueke Intelligent will continue to deliver end-to-end electric‑drive solutions to an expanding roster of world‑class global clients.
The manufacturing process for flat‑wire stators is the most critical step in electric‑drive system production for new‑energy vehicles, characterized by its complexity, the highest equipment‑manufacturing difficulty, and the largest share of capital investment. In 2022, Yueke’s flat‑wire stator production lines shipped eight units, with a total of over 400 pieces of equipment, delivering a capacity of 1.5 million flat‑wire stators to customers. In 2023, the company is poised to set a new record, achieving several‑fold growth.
A Brave Heart Dares to Break the Mold
This flat-wire motor production line, built to support Volkswagen, will subsequently supply the brand’s latest all-electric passenger vehicles. With a rapid takt time and exceptionally stringent technical requirements, it currently boasts the highest overall efficiency worldwide.
In addition to its high production efficiency, this production line has achieved numerous breakthroughs in manufacturing technologies:
- Ultra-large-radius hairpin forming technology significantly enhances the manufacturability of extremely complex wire geometries.
- Ultra‑high flexibility: A single wire‑forming machine can seamlessly switch between more than 20 different wire‑forming patterns, supporting both hair‑pin and I‑pin configurations.
- Multi‑line parallel insertion technology: boosts insertion efficiency by several times, a world‑first from Yueke; it also supports the insertion of I‑pin‑type leads, ensuring that fully automated lead insertion for crown‑type terminals is no longer a bottleneck. The system can handle the insertion of more than 20 I‑pins.
Technical advantages of the flat-wire stator production line offered by Yueke:
- 56 seconds per piece represents the highest cycle time achieved by a domestically designed automated flat-wire stator production line.
- Ultra‑long‑life mechanical paint‑removal punch die;
- A single wire‑forming machine enables fully automated production of 22 wire types and automatic wire insertion.
- Fully automatic cutting, flattening, and welding; lock‑plate assembly and disassembly.
- High-efficiency laser welding, with a first-pass yield that leads the industry.
- In addition, the integration of technologies such as full-line unmanned operation, big-data software for flat‑wire manufacturing, and self‑learning AI vision also constitutes a major highlight of this production line.
Upon receiving an invitation from Volkswagen, Yueke assembled a pre-sales project team comprising senior solutions engineers, manufacturing technology experts, and a sample‑development team. The team proactively addressed Volkswagen’s stringent technical requirements and compliance with industry‑standard specifications, ultimately passing rigorous assessments and earning the automaker’s recognition through its technical excellence.
Exquisite · Ambitious
Rui Pai Power Technology Co., Ltd. was officially established through joint investment by GAC Group, GAC Aion, and GAC Passenger Cars, with GAC Aion holding a controlling stake. The company focuses on the independent research, development, and industrialization of IDU electric drive systems, achieving integrated capabilities in in-house electric‑drive R&D, prototyping, testing, and mass production. Over the next few years, it plans to invest 2.16 billion yuan to bolster its new‑energy vehicle drive business.
In recent years, GAC Aion has emerged as a shining star in the new‑energy vehicle industry. In 2022, it posted monthly sales exceeding 30,000 units for several consecutive months, clinching the title of China’s top‑selling new‑energy vehicle brand that year. The two mass‑production flat‑wire stator lines recently acquired by Yueke will be deployed to manufacture electric drive systems for three models: the Aion Y, Aion S, and Aion V. These lines have also overcome numerous technical and equipment challenges, including modular rapid tooling changes across two platforms for four different product variants; stringent cleanliness control on high‑voltage oil‑cooling platforms; and a 2‑second automated wire‑insertion process combined with dual‑robot collaborative insertion. Additionally, they feature a 1‑second high‑speed laser paint‑removal system integrating CO₂ and fiber‑optic technologies, automated assembly and disassembly of welding lock plates, and highly efficient laser welding with an unprecedented first‑pass yield. Supported by Yueke’s advanced flat‑wire stator production lines and bolstered by a strategic partnership with RuiPai Power, Aion now enjoys a stable and reliable capacity to deliver electric drive products.
At present, China has taken a commanding lead in the new‑energy vehicle sector. Yueke Intelligent will remain firmly rooted in the Chinese market while actively expanding into overseas markets, aspiring to become a global leader in intelligent equipment for flat‑wire stators. We will leverage cutting‑edge technology and unwavering quality to meet the stringent demands of customers worldwide for smart manufacturing, flexible production, and rapid responsiveness.
