As the world moves faster toward electric vehicles, hairpin motor technology is important for improving performance and efficiency. Used widely in both passenger and commercial EVs, hairpin stators are a modern alternative to conventional wire winding methods.
Hairpin motors use flat, U-shaped copper bars instead of round wire coils. These bars look like hairpins. They are made from enameled copper wire with a lacquer coating.
These bars fit perfectly into the stator stack. This improves the slot fill rate. As a result, it boosts power density and thermal performance. It also reduces noise, vibration, and harshness (NVH).
To meet the growing demand for EV production, advanced hairpin winding machines are essential. Our team designs our automated systems for high-volume manufacturing, covering the complete stator production process.
Wire Forming
● Cycle time: 1.5s/pc
● Inline insulation testing
● Quick-change wire reel system
Paper Insertion
● Cycle time: 1.3s/groove
● Dual-channel configuration supports up to 96 slots
● Compatible with high lamination stacks
Wire Insertion
● Vision-monitored insertion
● Supports geometry
● Fast wire cup replacement
Widening
● Simultaneous widening up to 16 slots
● 3D vision-assisted inspection
● Quick-swap iris tool
Twisting
● Cycle time: 60s
● Torque-multiplied drive
● Adaptable insertion molds
● Closed-loop Z-Theta compensation
Welding
● High-stability marble platform
● Precision linear motor
● quality checks before and after welding
Separate process cells manage each phase. These cells can work alone or as part of a system, based on your production needs.
For related technologies like needle winding, or linear winding, please visit our Winding Technology section.
Looking for a scalable hairpin winding solution?
We offer customized hairpin winding machines for any production scale.
Contact us today to learn more.
