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Hairpin Stator Section Frequent Answer Question

Honest| 2024-03-11|Return

I think you may have some questions you want to ask about the stator. Here is a summary of some of the questions, I hope to solve your problems. Of course, if you have other questions, you can contact us at any time and we will have dedicated personnel to answer your questions.

Q1: During the process of 2D molding and 3D molding of the hairpin, how does HONEST HLS control these key parameters such as molding speed, pressure, and displacement?

A: 2D molding is controlled by the servo and speed, pressure, and displacement are controlled through servo parameters; 3D molding is also a pressing action performed by a servo, the speed, pressure, and displacement are controlled by the parameters of the servo.


Q2: How does HONEST HLS ensure that the force on the end of the hairpin is uniform and perpendicular to the end face of the stator core when the copper wire is inserted into the stator core?

A: There are two sets of needle disks for inserting the card to position the card in the circumferential direction and radial direction. When inserting, the end of the card is only more than ten millimeters outside the positioning needle disk, which can well ensure the position of the end of the card.

Q3: Has HONEST HLS considered the possibility that the perpendicularity and roundness of the core itself will change after the core is operated at a stress-bearing station such as winding press-fitting? If so, how was it prevented?

A: A protective mechanism can be added to prevent possible deformation of the iron core during the winding press commissioning process.

Q4: How does HONEST HLS consider the errors caused by different reference conversions when the winding is expanded and when the end is twisted? How does HONEST ensure that the winding can effectively enter the twisting mold when 1 or 2 PINs do not enter the mold? Can the device detect and alarm in time?

A: The main structure layout of the expansion and twisting heads of our equipment is the same. There is no difference in benchmarks. The guide feet of the twisting head mold are very large, which can ensure that the copper wire enters the mold smoothly. If 1 or 2 wires do not enter the mold, temporarily unable to achieve the alarm.

Q5: How does HONEST HLS control the end height difference that occurs when twisting the head, to what tolerance can it be guaranteed and what are the perceived key influences?

A: First of all, when twisting the head, the crown end and the welding end of the hairpin have chucks to insert the copper wire to prevent the copper wire from moving. Secondly, when we twist the head, the stator will cooperate with the downward pressure to eliminate the oblique pulling force generated when twisting the wire.

Here we would like to give you a supplementary introduction to our hairpin stator twisting machine:


Our equipment is connected with the front and rear machine heads using the method of pallet transportation + conveying line, which mainly completes the automatic transfer of the stator to the twisting position, the automatic paper protection of the paper protection needle, and the automatic twisting of the wire.

If you want to know more something about the
hairpin stator twisting machine, please click the link and then you will be redirected to the product details page.

Q6: Is the leveling process for twisted heads a must, is there a possibility of not leveling, and does HONEST HLS have the relevant technology reserves?

A: We are also doing related verification and R&D. Not cutting the head will put very high requirements on the wire-making machine and the forming mold. At present, we still need to retain the flat-cutting process.

Q7: How does HONEST HLS deal with the spattering that occurs during the laser welding process?

A: Welding with a circular spot while blowing shielding gas.


Q8: For the resistance brazing process of soldering copper plates on the lead wires, how does HONEST HLS consider its welding effect and post-weld detection?

A: The conventional approach is to take photos to confirm the appearance and determine some appearance defects. The internal welding effect is subject to off-line spot inspection.

Q9: Cleaning system composition and application

A: There will be air blowing and dust cleaning during the production process, including peeling paint, inserting paper, expanding, twisting, cutting flat, and welding. After welding, the product will be cleaned by blowing and dusting.

Please feel free to contact us anytime.


Tel/Wechat/WhatsApp: +8618923732990


Address: 7th Floor, Building D, No. 2, Dafu Industrial Zone, Kukeng Community, Guanlan, Longhua District, Shenzhen, China.