Hair­pin stator

Advanced man­u­fac­tur­ing of elec­tric motors

Hair­pin stator

The weld­ing of hair­pins by laser is an advanced tech­nol­o­gy, which is wide­ly used in the man­u­fac­tur­ing of elec­tric motors and gen­er­a­tors. Hair­pins are spe­cial cop­per or alu­minum pro­files, which are formed into a bob­bin shape and rep­re­sent a key com­po­nent for the per­for­mance of elec­tri­cal dri­ve sys­tems. The use of laser weld­ing in this con­text enables pre­cise and con­trolled con­nec­tions between the hair­pin ends, which ensures an effi­cient trans­mis­sion of elec­tric­i­ty and ther­mal stability.

Cen­tral motor component

Design of the sta­tor of a hair­pin motor

The sta­tor of a hair­pin motor rep­re­sents a cen­tral com­po­nent, which sig­nif­i­cant­ly con­tributes to the per­for­mance and effi­cien­cy of the motor. Com­pared to con­ven­tion­al elec­tric motors, the hair­pin motor is char­ac­ter­ized by an inno­v­a­tive design of its stator.

The sta­tor usu­al­ly con­sists of a lam­i­nat­ed iron core, which serves to strength­en the mag­net­ic field and max­i­mize the effi­cien­cy of the ener­gy con­ver­sion. The hair­pin tech­nol­o­gy refers to the spe­cial form of the coils in the sta­tor. Instead of tra­di­tion­al wire wind­ings, hair­pins are used here – spe­cial­ly formed, flat pro­files made of high­ly con­duc­tive cop­per or aluminum.

The hair­pins are posi­tioned in a pre­cise geo­met­ri­cal arrange­ment, to ensure opti­mal uti­liza­tion of the mag­net­ic flow. This inno­v­a­tive approach not only max­i­mizes the elec­tri­cal con­duc­tiv­i­ty, but also min­i­mizes loss­es due to eddy cur­rents, and improves ther­mal sta­bil­i­ty of the stator.

The inno­v­a­tive design of the sta­tor in a hair­pin motor con­tributes to achiev­ing high­er pow­er den­si­ties, improved effi­cien­cies and an over­all more com­pact design. This makes hair­pin motors an attrac­tive choice for appli­ca­tions where effi­cien­cy, com­pact­ness and per­for­mance are a cru­cial fac­tor, such as for exam­ple e‑mobility and oth­er high-per­for­mance applications.

Dili­gence and accuracy

Man­u­fac­tur­ing of hair­pin stators

The man­u­fac­tur­ing of hair­pin coils occurs via an auto­mat­ed wind­ing process, which ensures a pre­cise arrange­ment and align­ment. After wind­ing, the hair­pin wind­ings are insert­ed in the sta­tor, where­by par­tic­u­lar atten­tion is placed on the cor­rect posi­tion­ing and fix­a­tion. This step requires advanced machines and robot­ics, to achieve high accuracy.

After place­ment, the hair­pin wind­ings are con­nect­ed to each oth­er, to ensure elec­tri­cal con­ti­nu­ity. This can be achieved through weld­ing or oth­er con­nec­tion tech­niques. This is then fol­lowed by iso­la­tion of the wind­ings, to pre­vent elec­tri­cal short cir­cuits and ensure the integri­ty of the stator.

The com­plete hair­pin sta­tor runs through final qual­i­ty inspec­tions, in which para­me­ters such as elec­tri­cal resis­tance, iso­la­tion qual­i­ty and over­all per­for­mance are checked. This process ensures that the pro­duced hair­pin sta­tors cor­re­spond to the high stan­dards of the elec­tric motor indus­try and ensure reli­able per­for­mance in dif­fer­ent applications.

Com­plex process landscape

Chal­lenges dur­ing laser weld­ing of hairpins

The appli­ca­tion of laser weld­ing in the man­u­fac­tur­ing process of hair­pin sta­tors, par­tic­u­lar­ly for the con­nec­tion of the con­duc­tive hair­pin wind­ings, presents a num­ber of chal­lenges. The pre­ci­sion, ther­mal influ­ence, mate­r­i­al selec­tion and automa­tion are cru­cial aspects requir­ing care­ful attention.

  • Pre­ci­sion require­ments: Hair­pin wind­ings require extreme­ly pre­cise posi­tion­ing and align­ment dur­ing the laser weld­ing process, small devi­a­tions can result in qual­i­ty issues and loss­es in performance
  • Ther­mal influ­ence: the laser weld­ing process gen­er­ates heat which can influ­ence adja­cent mate­ri­als; con­trol of the ther­mal effect to avoid dam­age to sen­si­tive parts
  • Mate­r­i­al selec­tion: Selec­tion of mate­ri­als which can be weld­ed and are suit­able for the require­ments of the hair­pin sta­tor; con­sid­er­a­tion of the con­duc­tiv­i­ty and as well as heat resis­tance of the materials
  • Automa­tion and robot­ics: Inte­gra­tion of high­ly devel­oped robot­ic sys­tems, to ensure the pre­cise posi­tion­ing and fix­a­tion of the hair­pin wind­ings; automa­tion of the entire laser weld­ing process for effi­cien­cy and consistency
  • Weld seam qual­i­ty: Ensur­ing a con­sis­tent weld seam with­out defects or irreg­u­lar­i­ties; mon­i­tor­ing and con­trol of the weld­ing para­me­ters for opti­mum seam quality
  • Process speed: Opti­miza­tion of the laser weld­ing qual­i­ty to meet the pro­duc­tion require­ments with­out affect­ing the qual­i­ty; con­sid­er­a­tion of cycle times and through­put rates
  • Qual­i­ty con­trol: Imple­men­ta­tion of pre­cise qual­i­ty con­trol pro­ce­dures to detect weld­ing errors ear­ly; inte­gra­tion of imag­ing tech­nolo­gies or inspec­tion systems
  • Cost man­age­ment: effi­cient uti­liza­tion of resources and ener­gy to min­i­mize the over­all costs of the laser weld­ing process; con­sid­er­a­tion of invest­ment costs with regard to laser weld­ing equipment

Pre­ci­sion. Effi­cien­cy. Quality.

Our solu­tion

Thanks to the high dynam­ic range of the 4D.TWO, you can detect process devi­a­tions with a com­par­a­tive­ly low rate of pseu­do errors. With the com­bi­na­tion of chan­nels into com­bi chan­nels, you also save time dur­ing trou­bleshoot­ing, as you can clas­si­fy errors.

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If you would like to learn more about our prod­ucts and ser­vices, or would like to request a cus­tomized offer, please do not hes­i­tate to con­tact us. You can con­tact us by phone, via email or by using our con­tact form. We look for­ward to receiv­ing your enquiry!

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Con­tact us!

If you would like to learn more about our prod­ucts and ser­vices, or would like to request a cus­tomized offer, please do not hes­i­tate to con­tact us. You can con­tact us by phone, via email or by using our con­tact form. We look for­ward to receiv­ing your enquiry!

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Sched­ule con­sul­ta­tion appointment
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