How WISEDRV Enabled Link Tour's Revolutionary 'Alumi' Vehicle

Integrated with the all-aluminum body

The application of the flat-wire motor can effectively enhance the overall efficiency and power performance of the vehicle. However, the deep integration of the flat-wire motor with the all-aluminum body presents several technical challenges in terms of thermal management and space layout.

Thermal management coordination issue

Under high power density conditions, the internal heat of the flat-wire motor is more concentrated. The all-aluminum body has excellent heat conductivity, which not only enhances the overall heat dissipation potential but also makes it easier for the heat from the motor to be transferred to the chassis and the surrounding cabin, thus placing higher demands on the precise control of cabin thermal comfort. Therefore, a more efficient oil-cooling system needs to be developed to achieve precise management of the motor's heat, which also poses higher technical requirements for the integrated design of the cooling system.

Space layout integration issue

The high power density design helps to reduce the size of the motor, creating conditions for optimizing the interior space. To achieve the lightweighting goal, the chassis and body structure of all-aluminum vehicles generally adopt a compact layout. Under this premise, although the volume of the flat-wire motor has an advantage, its installation and layout still need to be precisely matched with key components such as the suspension geometry and collision energy absorption structure, which constitutes an important technical issue in multi-system collaborative design. 

Synergistic improvement of lightweighting and NVH performance

During the development of all-aluminum body structures, the simultaneous optimization of lightweighting goals and NVH performance is an important technical issue in engineering implementation.

The density of aluminum alloy is approximately one-third that of steel, which brings significant lightweighting advantages. However, the vibration damping characteristics of the material itself differ from those of steel. During vehicle operation, the high-frequency electromagnetic vibration of the flat-wire motor and the subtle vibrations caused by road excitation are more prominent in the aluminum body structure. This poses a corresponding technical issue for controlling the interior quietness.

To achieve better NVH performance, adjustments can be made through the arrangement of sound insulation and vibration reduction materials, optimization of damping structures, and active noise reduction technologies. These solutions can effectively improve the driving and passenger comfort, but they also place higher matching requirements on the lightweight design margin, material selection, and assembly process. 

The manufacturing and services behind the premium driving experience

The combination of all-aluminum body and high-performance electric drive system provides support for high-quality driving experience, and also brings higher standard technical issues in the vehicle manufacturing and after-sales service processes.

After-sales maintenance system issue

To ensure the structural strength and overall performance of the body, most all-aluminum body components adopt high-integration and high-precision designs. After a vehicle collision, some body coverings and structural components need to be repaired by component replacement, which puts forward corresponding requirements for maintenance technical standards, component precision and service system construction.

Vehicle manufacturing process issue

To achieve reliable matching of all-aluminum body and high-performance components, special connection processes such as self-piercing rivets, flow-drilling screws and structural adhesives need to be adopted. These processes have strict specifications for production equipment, environmental control and assembly accuracy, and put forward corresponding technical requirements for production line investment, process control and large-scale production.

Our Solution: Precision Engineering Meets Smart Automation

As a leading electromechanical manufacturer, wise provided a tailored suite of advanced equipment to support the Alumi project lifecycle:

 

Flat Wire Motor Technology Upgrade

By replacing traditional round wire windings with flat wire technology, we utilize rectangular cross-section copper wires to achieve a significantly higher slot fill factor, directly boosting power density and heat dissipation efficiency. Our advanced X-PIN winding process further minimizes the end-winding height, reducing copper and thermal losses. This results in a 30% reduction in motor volume and an 11% decrease in weight. Empirical testing confirms that the flat wire motor's temperature rise is 12°C lower than that of round wire motors, with an average efficiency exceeding 96.5% under NEDC conditions.

 

Lightweight & High Power Density Optimization

Leveraging the flat wire motor's high slot fill rate (exceeding 75%) combined with oil cooling technology, we have achieved a breakthrough power density of 6.2 kW/kg. Our integrated e-drive design consolidates the motor, controller, and reducer into a single "3-in-1" unit, significantly reducing the weight of connectors and harnesses. Furthermore, by optimizing the magnetic circuit with a dual-V permanent magnet rotor design, we have increased torque output capability by 18% while reducing the overall e-drive system weight by 15%.

 

NVH Performance Enhancement

We have optimized the magnetic circuit structure to reduce electromagnetic noise by 5 dB, while a dual-mode oil immersion cooling system effectively eliminates high-frequency whine. To shield against electromagnetic interference, we have installed hydraulic bushings on motor mounts and wrapped high-voltage harnesses in metal braided mesh. Additionally, active suspension technology monitors and adjusts vibration in real-time, achieving vibration reduction of over 10 dB (up to 22 dB), effectively resolving high noise-vibration-harshness (NVH) issues often found in hybrid vehicles.

 

Ultimate Driving Experience Optimization

We have developed active sound enhancement control technology based on real-world vehicle conditions, establishing a subjective-objective correlation model for exhaust acceleration sound quality. By optimizing the exhaust structure and intelligently controlling the opening of the electromagnetic acoustic valve, we have successfully eliminated booming and abnormal noises during acceleration. Furthermore, our integrated thermal management system ensures zero performance degradation after 10 consecutive launch controls, lowering peak motor temperature by 35°C and improving overall heat dissipation efficiency by 55%.

 

Impact & Results: Setting a New Benchmark

This technological upgrade, leveraging flat wire motor technology and the advanced X-PIN winding process, has successfully achieved a 30% reduction in motor volume, an 11% weight reduction, and a breakthrough NEDC efficiency exceeding 96.5%. By integrating a "3-in-1" design with dual-V magnetic circuit optimization, we have elevated power density to 6.2 kW/kg and boosted torque output by 18%, while simultaneously reducing the overall e-drive system weight by 15%. In terms of NVH, the synergistic application of magnetic circuit optimization, hydraulic bushings, and active suspension technology has effectively eliminated high-frequency whine and reduced vibration by up to 22 dB. Furthermore, the implementation of intelligent active sound control and a high-efficiency thermal management system ensures zero performance degradation even after 10 consecutive launch controls, ultimately delivering an electric drive system that redefines the benchmark for high-performance driving with its exceptional lightweighting, robust power response, library-level quietness, and superior thermal stability.

 

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