Flat wire stator hairpin wire forming technology for new energy vehicles

In the field of new energy vehicles, flat wire motors have become the preferred solution for drive systems due to their high efficiency, high power density and low loss. Among them, the manufacturing process of the stator is particularly important and is directly related to the performance and durability of the motor. The complete manufacturing process of the flat wire motor stator assembly includes paper inserts, coil forming, pre-insertion, integral inserts, flaring, twisting, flattening, welding, painting and dipping, copper nose welding, etc.

PIN coils need to go through a series of processes such as straightening, paint removal, cutting, and forming.

01. Servo wire feeding mechanism

Through the high-precision servo wire feeding mechanism, the precise control of the hairpin wire length is ensured, human errors are reduced, and the consistency and efficiency of processing are improved.

02. Laser paint removal technology

The four-head laser paint removal equipment is used to complete the paint removal of the hairpin in a very short time, ensuring the precise control of the paint removal depth and the cleanliness of the paint surface.

03. 2D servo bending technology

The 2D servo bending mechanism realizes the precise forming of complex curves or angles, ensuring the accuracy of the hairpin in the 2D spatial form, and is suitable for diversified design needs.

04. Stamping and cutting technology

The high-precision mold stamping and cutting technology is used to ensure that the hairpin is cut quickly and the edge is flat and burr-free after cutting.

05. 3D stamping forming technology

Through the 3D stamping forming mechanism, the hairpin can be formed into a specific 3D shape through the upper and lower dies, ensuring the consistency and accuracy of the three-dimensional structure and meeting the design requirements of the product.

06. Automatic material separation mechanism

The automatic material separation mechanism can automatically adapt to the production of various types of hairpins, reduce the time of manual material separation, improve production flexibility and efficiency, and reduce the burden on operators.

With the continuous maturity and innovation of technology, flat wire stator wire forming equipment has become a powerful engine for the intelligent and efficient transformation of the new energy vehicle industry.

Ningbo NIDE Tech Co., Ltd, adhering to the customer-centric concept, focuses on the stator, rotor and complete assembly of various motors, and provides customers with one-stop solutions for highly automated, intelligent and flexible production.

We have provided flat wire hairpin motor manufacturing production lines for many well-known new energy vehicle manufacturers, aiming to create efficient and customized motor manufacturing solutions for customers, empower the new energy vehicle industry chain, and work with customers to welcome the new era of green and intelligent vehicles.