1. Introduction of Non-cutting Hairpin Stator Twisting Machine
The hairpin stator twisting machine consists of a tray feeding manual lifting mechanism, a tray double-speed chain, a tray stator positioning and lifting mechanism, a stator gantry transfer mechanism, an upper and lower insulation paper protection pin disk mechanism, a twisting mechanism, a twisting mold positioning mechanism, and a tray discharging manual lifting mechanism.
2. Working Principle of Hairpin Twisting Machine
The tray, provided by the customer, is transferred from the trolley to the double-speed chain via our custom-made manual lifting mechanism. The tray is then conveyed along the double-speed chain to the transfer position, where RFID information on the tray is read, and a laser displacement sensor measures and evaluates the stator thickness. The system automatically switches to the corresponding program for the specific model.
The tray and stator are precisely positioned sequentially by the tray stator positioning and lifting mechanism. The gantry transfer mechanism grips the stator and moves it to the twisting position. The upper and lower insulation paper protection pin disk mechanisms extend to position and protect the copper wires and insulation paper. The twisting mold positioning mechanism delivers the twisting mold to the twisting position.
The twisting mechanism first performs wire twisting on layers 1 and 2, then sequentially twists layers 3 and 4, followed by layers 5 and 6. After twisting is completed, the insulation paper protection pin disk mechanisms retract. The gantry transfer mechanism then grips the stator and moves it to the unloading position, while the twisting mechanism resets the six-layer mold.
The stator tray is conveyed along the double-speed chain to the unloading position, where the manual lifting mechanism transfers the tray from the double-speed chain back to the trolley for discharging.
3. Compared with Traditional Twisting Equipment, What are the Innovations of Hairpin Twisting Machine?
（1）The equipment adopts a fully motor-driven mode without pneumatic control components, enhancing operational efficiency and reducing the failure rate of the equipment.
（2）The system features automatic model identification and automatic switching of twisting programs, reducing the error rate caused by manual operations and achieving full automation.
（3）The twisting mold is easy to clean and can be entirely removed from the equipment for maintenance, ensuring convenient operation.
（4）No trimming is required after twisting, reducing the cost of trimming equipment.
（5）The twisting process shares Z-axis data for every two layers, making it unaffected by the number of product slots or layers.
（6）Compatible with X-PIN and mini-PIN products.
4. The Key Features of the Equipment Include:
Precise control of the wire length for customer product line types, optimized twisting head parameter design, and meticulous design of the twisting mold's outer diameter, slot depth, slot width, and transition fillet.
5. What Specific Benefits Can this Equipment Bring to the Electric Vehicle Hairpin Motor Manufacturing Industry?
（1）The simplification of the stator trimming process reduces equipment costs associated with stator manufacturing.
（2）The applicability for products such as Hai-pin, X-PIN, mini-PIN, and others is further expanded, transforming the traditional twisting method.
（3）The twisting mold is easy to clean, allowing the entire mold to be removed from the equipment for maintenance, ensuring user-friendly operation.
6. How Non-Cutting Hairpin Twisting Machines Improve Production Efficiency?
A. The entire equipment features a fully electronic control design, significantly enhancing production efficiency.
B. Optimization of motion programs eliminates unnecessary and idle waiting, improving overall efficiency.
C. Motor performance debugging.
7. Advantages of this Equipment in Maintenance
(1) The twisting mold is designed for easy maintenance—its positioning mechanism allows adjustable travel, enabling the mold to be moved to the lower insulation paper protection pin disk mechanism. This design allows personnel to directly remove the entire mold for maintenance and cleaning.
(2) Components are primarily connected using a top-down locking method to facilitate easy disassembly. For screws that are difficult to remove, additional through-holes are incorporated to simplify the process.
(3) Lifting rings are added to certain interchangeable components to facilitate easy disassembly.
8. The Impact of this Equipment on the Environment
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A protective cover is added on top of the machine enclosure to reduce the impact of dust on the equipment.
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Protective covers are added to critical transmission components to minimize the impact of debris or dust.
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A dust flow and collection groove are added to the bottom of the twisting mold for improved maintenance and cleanliness.
9. Development Trend of Hairpin Motor Stator Production Technology
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The production process of motor stators is advancing toward automation and intelligence. The introduction of automated production lines significantly enhances production efficiency and reduces labor costs.
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The production process of motor stators is continuously being optimized and simplified.
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In terms of materials, the use of hairpin motor is becoming increasingly widespread.
10. What is the Quality and Precision of the Hairpin Stator Twisting Machine?
The flatness of the end face can reach ±0.8mm, which enhances the reliability of the motor's performance. The flatness after trimming is 0.5mm.
The improved accuracy makes the product more reliable and ensures that the subsequent welding and assembly processes meet the required standards.
The Non-cutting hairpin stator twisting machine, innovatively developed and upgraded by HONEST Automation, offers lower costs and improved motor stator performance. If you're looking for an efficient Hairpin stator twisting solution, feel free to consult with our technical experts. We’ll provide tailored professional advice to help you enhance production efficiency and product quality.
