NewBee Machinery is a professional machinery parts manufacturer providing high quality precision bearings, high-quality non-standard transmission components, and intelligent CNC equipment and more.
NewBee Machinery is a professional machinery parts manufacturer providing high quality precision bearings, high-quality non-standard transmission components, and intelligent CNC equipment and more.
With the global penetration rate of electric vehicles exceeding 18% (2024 data), electric drive systems are rapidly evolving toward "high voltage, high rotation speed, and high power density":
800V high-voltage platforms have become standard in high-end models (e.g., Porsche Taycan, XPeng G9). The increased voltage leads to an exponential growth in the risk of bearing electrical corrosion.
As motors with high rotation speeds of 18,000rpm+ become widespread, traditional grease-lubricated bearings face the challenge of uncontrolled temperature rise.
The penetration rate of oil-cooled motors exceeds 60%, highlighting the compatibility conflict between lubricating oil and insulating materials.
1. Industry Pain Points: Approximately 17% of motor failure cases are directly caused by bearing electrical corrosion. Bearing Technical Requirement Pyramid
Hierarchy of needs | Technical indicators | Limitations of current industry solutions |
Safety Red Line | Insulation performance ≥ 1000MΩ @ DC1500V | Alumina coatings are prone to peeling, with a service life of less than 20,000 kilometers. |
Efficiency Core | Temperature rise ≤ 45℃ @ 18,000rpm | Grease oil slinging at high speeds causes dry friction. |
Service Life Foundation | L10 life ≥ 3000 hours @ axial load of 8kN | Electrical erosion pitting leads to early failure |
System Compatibility | Resistance to oil coolant corrosion (ATF/gear oil) | Swelling and failure of organic insulating materials |
Cost Necessity | Single unit cost increase < 15% compared with traditional bearings | The price of imported ceramic bearings is more than three times higher |
Technical Requirements:
Matching 800V SiC platform;with limited axial space ≤ 80mm; - Withstanding a peak rotational speed of 25,000rpm; Passing 1500VDC/min insulation withstand voltage test; Operating for >5,000 hours in an oil-cooled environment.
3. Newbee Transmission's Innovative Solution:
Composite Insulated Bearing System Core Technological Breakthroughs
Gradient Insulation Architecture
Base Layer: Plasma-sprayed α-Al₂O₃ + nano-ZrO₂ composite ceramic (thickness 50±5μm);
Transition Layer: Laser-cladded metal-ceramic gradient material (matching the thermal expansion coefficient of the steel substrate);
Surface Layer: Vapor-deposited diamond-like carbon (DLC) film (friction coefficient < 0.05).
Topology-Optimized Raceway Design
Based on motor electromagnetic field simulation, the raceway curvature is optimized (λ = 0.52 → 0.508), reducing high-speed centrifugal stress by 28% and achieving 18% temperature rise suppression.
Molecular-level lubrication system
Custom polyetheretherketone (PEEK)-based solid lubrication cage
Special grease integrated with ionic liquid-modified MXene nano-additives
Performance verification data
Test Items | Industry Standards | Newbee's Solution | Improvement amplitude |
Insulation Resistance | ≥ 100MΩ | 1523MΩ | 1423% |
Electrical Corrosion Durability | 500h@500VDC | 2000h@1500VDC | 400 |
Maximum Rotational Speed | 18,000rpm | 28,000rpm | 55% |
Start-Stop Cycle | 500,000 cycles | >1.2 million times | 140% |
NVH Performance | 78dB(A) | 71dB(A) | Noise reduction9% |
Engineer's Insight
"The electrical corrosion of bearings in 800V platforms is essentially a failure caused by the multi-field coupling of electricity, heat, force, and chemistry. Newbee's solution has built a system-level solution through material gene editing (regulating ceramic phase composition), micro-interface engineering (solving the problem of coating adhesion), and lubrication molecular design (developing conductive-lubricating dual-function additives).
Particularly in the design of the DLC film, we innovatively adopted an amorphous carbon/sp² hybrid carbon quantum dot composite structure, which increases the insulation strength to 5 times that of traditional alumina coatings while reducing the friction coefficient by 60%—this is precisely the key to achieving the collaborative breakthrough of 'high rotation speed + high insulation'."
Industry Impact
Has been matched with 3 electric drive systems of 800V platforms (including a best-selling model with monthly sales of 50,000 units).
Promoted the market share of domestic insulated bearings to rise from 9% to 28%.
The technology has been extended to the field of insulated bearings for wind power main shafts (with a withstand voltage level of ≥ 3kV for offshore wind power).
WhatsApp
sales@newbeetrans.com
+8615090185276