Hairpin Motor Stator Twisting Process

The hairpin motor stator wire twisting process is another key technology in manufacturing new energy EV motors. It twists each layer of copper wire axially to make the top of the copper wire flush, ensuring subsequent welding. However, its process involves manufacturing the twisting machine and the twisting tooling (twist barrel). The manufacturing precision requirements of the twist barrel are very high. The more layers of the product, the higher the requirements for the processing precision of the twist barrel. At the same time, the twist barrel has a multi-layer sleeve structure, which is relatively easy to wear when twisted, so it needs regular maintenance and replacement.

To ensure that the top of the wire is flush after twisting, the twisting process also needs to be developed and designed accordingly for different products. The twisting parameters include the radial distance from each layer of copper wire to the center of the stator circle, the height of each layer, and the angle of each layer. During the twisting process, these parameters need to be constantly adjusted and verified to ensure the quality and performance of the product.

When reviewing the twisting process, HONEST Automation identified three key concerns:

1.Ensure that the wire harness is not squeezed during the twisting process

Adopts the upper and lower wire and paper protection positioning system, configures the anti-slip baffle, and designs the exquisite twisting mechanism and standard multi-layer simultaneous twisting function to ensure the precise positioning and uniform force of the wire harness during the manufacturing process to avoid the risk of the wire harness being squeezed.

Automation's flat wire motor stator twisting machine:

2.Ensure?accurate?alignment?of?welding?points?after?twisting?wire

Advanced twisting mechanisms and the end expanding equipment ensure that the wire harness can be evenly stressed during the twisting process and twisted at a predetermined angle. At the same time, by precisely controlling the twisting angle and strength of each layer of wire harness and configuring a high-precision welding system, the consistency and uniformity of the welding points can be ensured, achieving accurate alignment of the welding points after twisting.

EV Motor Hairpin Stator Laser Welding Machine:

3. Improve production efficiency by meeting the previous two technical requirements

Use the high-precision automated production machine to precisely control the expansion and twisting process, avoid wire harness extrusion, and ensure accurate alignment of welding points. At the same time, optimize the production process, reduce manual intervention, and strengthen equipment maintenance, greatly improving production efficiency while ensuring technical quality.

Video here: Hairpin EV Motor: Efficiency & Breakthrough

Learn more here: E-Mobility Motor Hairpin Stator End Expanding Types

HONEST Automation's latest breakthrough in hairpin motor technology enables direct welding by eliminating end cutting after twisting, resulting in dramatically improved production efficiency and significant cost reductions. This innovation also ensures seamless H-pin/M-pin motor compatibility.