Automatic Hairpin Stator Forming Machine Hairpin Motor Technology Solution for Automobile Drive Motor

Hairpin Stator Forming Machine Process description

The main structure includes: wire feeding mechanism, straightening mechanism, punching and paint removal mechanism, wire release mechanism, cutting mechanism, hairpin coil forming mechanism, waste suction mechanism, wiring mechanism, etc.;

The hairpin stator forming machine is started manually, and the machine automatically completes material unloading, copper wire straightening, punching and paint removal, fixed-length feeding, 2D forming, cutting, 3D forming, waste suction, stamping and forming, and hair pin collection.

Manual loading and unloading of copper wire coils,

Automatic forming by machine,

Manual replacement of molding molds.

The hairpin stator winding process is divided into 5 steps:

•Unwinding copper wire from coil, straightening and feeding into the station

•Remove insolation from wire at certain positions

•Cutting wire pieces to certain required lengths

•Bending 2D forms

• Forming 3D shapes with one installed forming die, flexible to exchange for different forms

Quality Control of Hairpin Forming Technology

1. Servo wire feeding system, wire feeding	accuracy can meet ≤±0.2mm;
2. The deviation between the U-shaped shape size after forming and the theoretical digital model:	the straightness of the leg is ≤0.2, the crown including R and the contour 20mm below the crown is ≤1;
3. The 2D bending angle	accuracy is ≤0.5°;
4. The breakdown voltage of the U-pin line	is not less than 90% of the copper wire withstand voltage requirement (the withstand voltage value needs to be verified in practice);
5. The U-pin has no abnormal bending, deformation or interweaving;
6. There is no residue at the paint removal, and the thickness is uniform;