This equipment serves as a critical station within a flat-wire stator production line. Its function is to twist the hairpin ends of multi-layer flat-wire windings—after they have been inserted into the stator core—to a predetermined angle in accordance with process specifications, thereby creating a uniform and precise welding interface.
The machine features a gantry-style lifting structure and incorporates proprietary algorithms developed in-house for Z-axis compensation and C-axis rotational profiling. This enables the simultaneous twisting of up to 12 layers, as well as next-generation capabilities for twisting different layers to varying angles within the same plane. The twisting head control precision is maintained within ±0.2°.
The equipment integrates post-twist angle verification and pressure feedback monitoring systems. Furthermore, it is paired with mirror-polished quick-change tooling and a dedicated tool-changing cart, allowing for rapid model changeovers while ensuring that the wire insulation remains completely undamaged.
With a cycle time of 60 seconds per unit, the equipment’s overall efficiency and precision represent a leading standard within the industry.
Suitable for the end-twisting (forming) process of flat-wire stators used in the drive motors of new energy vehicles (NEVs).
Supports both conventional twisting—where all layers within a plane are twisted to the same angle—and next-generation twisting—where layers within the same plane are twisted to different angles—thereby accommodating complex winding topology designs.
Positioned within the production line downstream of the wire insertion machine and upstream of the welding machine, the unit twists the hairpin ends into the precise geometric configuration required for subsequent welding.
The system is compatible with stators having an outer diameter ranging from 100 mm to 500 mm, supporting up to 12 layers, and accommodating various slot counts and flat-wire specifications.
Key Functions
Automatically clamps and positions the stator at the twisting station;
A gantry-style lifting mechanism drives the twisting die downward to execute multi-layer synchronous or step-by-step twisting, guided by C-axis rotational profiles and Z-axis compensation algorithms;
Real-time pressure feedback monitors the twisting force to prevent damage to the wire insulation;
Automatically performs angle verification (via vision or laser measurement) immediately after the twisting process is complete;
Equipped with a quick-change module for the twisting die and a dedicated tool-changing cart to facilitate rapid model changeovers;
Assembly precision during equipment installation is verified using a portable 3D coordinate measuring system (CMM) with dial indicators.
Core Features
1. High-Precision Twisting Control: Achieves a twisting head control precision of ±0.2°. Through proprietary Z-axis compensation and C-axis rotational profiling algorithms, it ensures angular consistency across the ends of all multi-layer flat-wire windings. 2. Multi-layer Simultaneous Twisting + Variable Angles within a Single Layer: Supports the simultaneous twisting of up to 12 layers of flat wire; features a new-generation function for varying twist angles within a single layer, accommodating more complex motor winding designs.
3. Wire-Friendly Tooling with Efficient Quick-Change: The twisting head tooling features a mirror-polished finish and smooth transitions, minimizing the risk of scratching the flat wire's insulation layer.
The tooling utilizes a quick-change modular design; when paired with the dedicated quick-change trolley for the twisting head, model changeover time is reduced to ≤ 15 minutes. Compatible with stator outer diameters ranging from 100 mm to 500 mm.
4. Comprehensive Inspection and Safety Features: Equipped with a post-twist angle inspection function; pressure feedback provides real-time monitoring of twisting force, with automatic alarm and machine shutdown in the event of an overload.
5. High-Rigidity Gantry Structure: Features a gantry-style overhead design, ensuring exceptional overall rigidity and strong resistance to eccentric loads.
6. International Safety Standards: The sheet metal enclosure and safety guarding designs fully comply with CE requirements.
Equipment Dimensions (L × W × H): 3.0 m × 2.5 m × 2.5 m
Cycle Time: ≤ 60 s / piece
Compatible Stator Outer Diameter Range: 100 mm ~ 500 mm
Maximum Number of Twisting Layers: 12 layers
Twisting Angle Control Accuracy: ±0.2°
Twisting Method: Gantry-style overhead operation; fixed angle per layer / variable angles within a single layer (New Generation)
Post-Twist Inspection: Angle inspection capability included (Vision / Laser-based)
Pressure Feedback: Included; provides real-time monitoring of twisting force
Control Algorithm: Internally developed (Proprietary): Z-axis compensation + C-axis rotation curve
Tooling Features: Mirror-polished finish with smooth transitions; Quick-change modules + Dedicated quick-change trolley
Equipment Installation Precision: Installed using a mobile 3-axis dial indicator alignment method
Power Supply: 380V / 50Hz; Total power consumption: approx. 35 kW
Air Supply: 0.5 ~ 0.7 MPa; Air consumption: approx. 400 L/min
Equipment Weight: Approx. 6 tons
Model Changeover Time: ≤ 15 minutes (including tooling replacement)
Safety Standards: Sheet metal enclosure and safety designs comply with CE requirements
