We support you in the manufacture of your hairpin stator – from prototype to series production
The automotive industry is undergoing a worldwide transformation – the combustion engine seems to have reached its zenith. Today, electric vehicles are on the rise.
Hairpin technology is beginning to establish itself in electromobility. Unlike winding processes, in hairpin technology individual coil elements made of flat solid copper wire are inserted into the lamination stack and subsequently contacted with each other.
In the process chain for manufacturing a stator in hairpin technology, the core competencies of Röscher GmbH lie in the following process steps:
We create a 3D model of your stator based on the winding scheme
Lamination stack design
Optimisation of wire geometries
EMBOSSING OF HAIRPINS
Production of even demanding hairpin geometries by die stamping
Based on your hairpin, we design the appropriate tool for you
INSULATION OF STATOR SLOTS
With our devices you can score and cut the insulation paper to length and then insert it into the lamination stack.
The wire ends of the hairpins must be freed from the insulating layer to enable contacting later. This can be done with a suitable laser. With our cooperation partner, the prozessfabrik Berger, we offer interesting solutions.
PREASSEMBLY OF HAIRPINS
As a rule, hairpin stators consist of a large number of layers with, for example, 6 conductors per slot. The wire basket is often pre-assembled first – in a suitable fixture.
After pre-assembly of the wire basket, it must be inserted into the lamination stack without damaging the insulation paper. The wire basket is picked up with an iris tool and then lowered into the lamination stack.
SEPARATION / WIDENING
The wire ends of the hairpins in a slot are close together. To be able to insert them in the twisting tool, the wire ends have to be precisely bent apart. We use a gripper to grab the wires and carry out the bending process without damaging the insulation layer.
During twisting the wires of the stator are bent in opposite directions by a certain angle. They can then be welded together to form the desired electric coils.
The twisting tool must allow the complex bending without causing damage to the insulation layer.
Depending on the wire cross-section and the number of wires twisted at the same time, large forces occur that must be taken into account in the design of the system.
Stator before twisting – Stator after twisting
Please watch an animation of widening and subsequent twisting
Manual machine for twisting
Stator-specific tools for twisting
Do you want to manufacture a hairpin stator?
Then please consult us and our team to understand which of our solutions could support you.
If you need a solution individually designed to your requirements, here are examples of how we have been able to help our customers.
In different industries, we have developed creative approaches with our team and built the desired machine or device.