This equipment is specifically developed for the production of flat-wire stators for new energy vehicle (NEV) drive motors, enabling the automated forming of flat copper wire from coil stock into "U-shaped hairpins."
The system integrates functions such as active decoiling, straightening, enamel stripping, 2D/3D forming, cutting, and fixed-length conveying, allowing for the stable production of flat-wire hairpins in various specifications.
The forming cycle time for a single hairpin can reach as low as 1.2 seconds, with a length accuracy of ±0.15 mm per 400 mm. With an overall equipment efficiency (OEE) of ≥85%, the system fully meets the demands of high-volume, high-consistency manufacturing.
Ideal for the manufacturing of flat-wire stators (hairpin-type windings) for NEV drive motors.
Capable of producing flat-wire hairpins in various shapes—including U-shaped, I-shaped, and X-shaped—this unit serves as the core machine within a flat-wire stator production line, supplying high-precision hairpins to downstream stations such as slot insulation insertion, flaring, twisting, and welding.
Features include automated flat-wire decoiling, tension control, and straightening; fixed-length feeding; and combined 2D stamping and 3D bending processes.
Additional functions include automated cutting and part collection/unloading. Optional features include inline visual inspection, laser distance measurement, and enamel stripping quality monitoring.
The system supports rapid changeovers and is compatible with a wide range of flat-wire dimensions and hairpin geometries.
1. High Speed & Precision: A single-piece cycle time of 1.2 seconds and a forming precision of ±0.15 mm per 400 mm ensure high-quality results for subsequent twisting and welding processes.
2. High Stability: The equipment achieves an OEE of over 85%, features a low failure rate during continuous operation, and boasts a mold lifespan of ≥2 million cycles.
3. Flexible Changeovers: Compatible with hairpin lengths ranging from 250 mm to 1000 mm, the system allows for changeovers in ≤15 minutes and supports one-touch recall of parameters for various hairpin shapes.
4. Intelligent Control: Equipped with an HMI (Human-Machine Interface) that displays real-time production output, cycle times, and fault alarms; includes a reserved MES interface for comprehensive production data traceability.
5. Safety & Reliability: Features fully enclosed sheet metal safety guards and safety light curtains, complying with CE standards; both pneumatic and servo-driven components are equipped with overload protection mechanisms.
Equipment Dimensions (L × W × H): 10.5 m × 1.7 m × 2.2 m
Single Hairpin Forming Cycle Time: ≤ 1.2 s/pin
Forming Length Compatibility Range: 250 mm ~ 1000 mm
Length Accuracy (400 mm Datum): ±0.15 mm
Overall Equipment Effectiveness (OEE): ≥ 85%
Flat Wire Width Compatibility: 2 ~ 8 mm
Flat Wire Thickness Compatibility: 1 ~ 3 mm
Power Supply: 380V / 50Hz / 3-Phase 5-Wire System; Total Power: Approx. 50 kW
Air Supply: 0.5 ~ 0.7 MPa; Air Consumption: Approx. 300 L/min
Equipment Weight: Approx. 10 tons
Mold Lifespan: ≥ 2 million cycles
Changeover Time: ≤ 15 minutes
Control System: PLC + Touchscreen (Optional Handheld Terminal)
