The rise of new energy vehicles (NEVs) has transformed not only how we drive but also how we recycle. With global electric vehicle adoption projected to exceed 230 million units by 2030, the question of how to efficiently recycle and recover valuable materials from electric motors is becoming urgent.
At the heart of every NEV lies its motor stator, which contains flat copper wire windings—a key source of recyclable copper. But here’s the critical question:
Can a motor stator dismantling machine effectively recycle the flat copper wire of new energy vehicle motors?
Understanding the Structure of New Energy Vehicle Motors
Before answering, it’s vital to understand the unique design of NEV motors. Unlike traditional internal combustion engine motors that use round enameled copper wires, most new energy vehicle stators are designed with flat (rectangular) copper wires.
motor stator dismantling machine
These flat copper wires are favored because they:
Increase slot fill rate by 10–15%, enhancing efficiency
Improve heat dissipation and reduce energy loss
Strengthen the motor’s torque performance
However, this innovative design also introduces new challenges for recycling. The flat copper wire is often tightly bonded with high-temperature-resistant insulating epoxy or varnish, making manual dismantling extremely difficult.
That’s where motor stator dismantling machines step in.
How a Motor Stator Dismantling Machine Works
A motor stator dismantling machine is designed to separate copper wire from the stator core through an efficient mechanical process.
Here’s how it typically works:
- Positioning & Clamping: The stator is fixed securely within the dismantling chamber.
- Cutting Stage: Precision blades or hydraulic cutters slice open the stator lamination.
- Pressing or Pulling: The copper windings are pushed or pulled out cleanly using hydraulic force or rotating claws.
- Copper Recovery: Extracted copper wire is collected for refining and reuse.
For flat copper wire stators, advanced machines use programmable hydraulic pressure and adaptive cutting heads to prevent deformation or damage to the valuable copper.
So, Can It Recycle Flat Copper Wire from NEV Motors?
Yes — absolutely.
Modern multi-functional motor stator dismantling machines are specifically engineered to recycle the flat copper wire used in new energy vehicle motors.
However, not all machines can handle it effectively. Let’s look at what makes the difference.
✅ Key Capabilities Required:
- Adjustable Clamping System: To fit larger, heavier NEV stators.
- High-Pressure Hydraulic System: To overcome strong bonding between copper and resin.
- Precision Cutting Blades: Designed to prevent copper wire breakage.
- Smart Control Interface: For automatic adjustment according to motor size and copper type.
Frequently Asked Questions
1. Will the dismantling process damage the copper wire?
If done manually or with improper equipment — yes. But modern hydraulic and servo-controlled dismantling machines ensure clean separation, preserving copper wire quality and resale value.
2. Is the machine compatible with different motor types?
Yes. Multi-purpose dismantling machines can handle EV motors, air conditioner motors, washing machine stators, and industrial stators by switching molds or adjusting parameters.
3. What’s the recovery rate compared to manual dismantling?
Manual dismantling typically recovers 70–80% of copper due to cutting loss. In contrast, automated dismantling machines achieve 98–99% recovery, saving time and labor costs.
4. How does it benefit recycling companies?
Using such machines reduces labor by up to 80%, increases output by 5 times, and provides stable quality control, which helps meet environmental regulations and market demand for pure recycled copper.
5. Is the investment worthwhile?
Absolutely. With copper prices exceeding $9,000 per ton, even a 5% increase in recovery efficiency can translate to significant annual gains.
The future of copper recycling lies in automation — and motor stator dismantling machines are at the forefront of this transformation.
Yes, they can and do recycle flat copper wire from new energy vehicle motors efficiently, cleanly, and sustainably.
For recyclers, this means greater recovery rates, higher profits, and a meaningful contribution to the green economy.
For the planet, it means less waste, fewer emissions, and a step closer to circular energy production.