This equipment constitutes a critical station within a flat-wire stator production line. Its function is to flare and shape the hairpin ends of flat-wire windings after they have been inserted into the stator core, ensuring that the resulting opening angles meet the mold-entry requirements for the subsequent twisting process. The equipment features a rapid changeover structure utilizing a circular-arc guide rail system, rendering it compatible with 48-, 72-, 96-, and 108-slot stators. The flaring mechanism is capable of executing single-layer, double-layer, and multi-layer flaring operations; it supports both "upward flaring" and "downward flaring" modes and incorporates an integrated stator-flipping function. Post-flaring, the system employs position detection and pressure data feedback mechanisms—augmented by an automatic deviation correction function—to ensure that the flaring angle of every individual flat wire remains consistent and precise.
This equipment is specifically designed for the end-flaring and shaping of flat-wire stators for new energy vehicle drive motors, performed after the wire insertion process but prior to the wire twisting process. Flaring modes include single-layer, double-layer, and multi-layer configurations, as well as upward and downward flaring options. Within the production line workflow, this station is positioned immediately following the wire insertion machine and preceding the wire twisting machine. The product is compatible with stators featuring 48, 72, 96, or 108 slots; stator outer diameters ranging from 100 to 500 mm; flat-wire widths between 2 and 6 mm; and flat-wire thicknesses between 1 and 3 mm.
Automatically clamps and positions the stator; allows for the selection of flaring layers and direction; the flaring mechanism executes shaping operations according to pre-set angles; position detection verifies the spatial coordinates of the flat-wire ends post-flaring; pressure feedback provides real-time monitoring of flaring force; a deviation correction function automatically compensates for positional discrepancies; a flipping function enables double-sided flaring; and a circular-arc guide rail system facilitates rapid changeovers.
Core Features
1. Rapid Changeover & High Compatibility: Features a circular-arc guide rail design compatible with 48-, 72-, 96-, and 108-slot stators, allowing for changeovers in ≤10 minutes. 2. Multi-Layer Flaring Capability: Supports single-layer, double-layer, and multi-layer configurations (up to 12 layers), ensuring precise angle accuracy at every individual layer. 3. Flexible Flaring Direction: Supports both upward and downward flaring modes; combined with the flipping function, it adapts seamlessly to various production line layouts. 4. Precision Closed-Loop Control: Integrates position detection, pressure feedback, and deviation correction functions to achieve a flaring angle accuracy of ±0.5°. 5. High-Rigidity Structure: Ensures stable force distribution during multi-layer flaring. 6. Safety Standards: CE Certified.
Equipment Dimensions (L × W × H): 2.5 m × 2.0 m × 2.4 m
Equipment Structure: Arc-Track Rapid Changeover System
Compatible Slot Count: 48 / 72 / 96 / 108 Slots
Compatible Stator Outer Diameter Range: 100 mm ~ 500 mm
Flaring Layers: Single-Layer / Double-Layer / Multi-Layer
Flaring Direction: Upward Flaring / Downward Flaring (Integrated flipping function available)
Flaring Angle Accuracy: ±0.1 mm
Flaring Cycle Time: ≤ 6 s / Slot
Position Detection: Equipped with Vision System
Pressure Feedback: Equipped; Real-time monitoring of flaring force
Correction Function: Included; Automatic position compensation
Flipping Function: Equipped; Enables double-sided flaring
Changeover Time: ≤ 10 minutes
Power Supply: 380V / 50Hz
Air Supply: 0.5 ~ 0.7 MPa
