With the advancement of new energy vehicles and innovative manufacturing technologies, the demands for motor performance and efficiency are increasingly stringent. Traditional round wire motors struggle to meet the requirements of modern automobiles due to their low slot fill rate and high current density. In contrast, flat wire stators, with their advantages of high slot fill rate and low current density, enable flat wire motors to deliver higher power output and better thermal management performance within the same volume.

The hairpin stator welding machine is a crucial piece of equipment in the field of motor manufacturing, playing an essential role in ensuring welding quality, enhancing motor performance, and improving production efficiency. Welding is also a critical step in the manufacturing process of flat wire motor stators, with its quality directly impacting the performance and mechanical strength of the motor.

Welding is a process that involves joining metal parts by melting their surfaces and allowing them to fuse. This process alters the physical and chemical properties of the metals, creating a strong bond. The quality of a weld depends on factors such as welding temperature, pressure, and time. Selecting the appropriate welding method is essential for ensuring a high-quality weld.

Weld Methods

There are various welding methods, including TIG welding, laser beam welding, resistance welding, and so on.

TIG Welding (Tungsten Inert Gas Welding): The method utilizes a tungsten electrode and inert gas for welding and is widely applied in the welding of non-ferrous metals such as stainless steel, aluminum, and magnesium alloys. With the use of a tungsten electrode and inert gas protection, the weld bead is aesthetically pleasing, with minimal spatter and a stable arc.

Laser Beam Welding: This process connects metals, plastics, and composite materials using a high-power laser beam. It is characterized by concentrated heating, and minimal distortion of the weldment, and is suitable for precision welding, fine welding, and welding of magnetic materials. It has a significant advantage in applications where high precision and control of distortion are required.

Resistance Welding: This includes spot welding, seam welding, and butt welding. It works by generating heat through electrical resistance as the current passes through the workpiece, causing local heating, melting, or plastic deformation to achieve welding. Resistance welding is suitable for mass production, characterized by high production efficiency and low welding costs, and is ideal for welding sheets with similar thicknesses.

Different welding methods have their own advantages and applicable fields. Understanding your actual needs and choosing the appropriate welding method can lead to more efficient production. If you have any other questions about how to choose a welding method, feel free to leave us a message at any time.

HONEST Hairpin Stator Welding Machine

The HONEST Intelligent hairpin stator welding machine is an automated production equipment designed for laser welding of stators that have already had their winding inserted. During operation, it goes through processes such as stator tray inflow, code reading, protective fixture locking, automatic laser welding, protective fixture unlocking, and tray release.

Reasons to Choose HONEST Intelligent as the Welding Machine Supplier

1.The equipment features a modular and flexible design, compatible with various conditions.

2.The machine is equipped with specialized fixtures that clamp each group of wires, ensuring that each welding point is tightly and evenly pressed.

3.A vision system monitors and accurately locates each pin, with an MES system that automatically secures the wire ends, achieving automatic clamping and welding protection.

4.It is equipped with program interlocks, contoured tools, guiding mechanisms, protective systems, and sensor monitoring with an alarm system, ensuring safety in the production process.

5.High-precision sensors and vision monitoring systems are configured for precise welding of copper wires.

6.A cleaning mechanism is in place to effectively prevent spatter contamination of the stator during welding.

7.A 3D vision camera is configured to inspect the height and uniformity of the weld points, ensuring welding quality.

8.Yield Rate: With strict control over every process by HONEST Intelligent, the machine’s yield rate can reach over 98%, reducing material and resource waste, and ensuring product quality.

9.Operation Rate: The machine is stable in performance, with a normal operation time exceeding 90%, which is conducive to ensuring high production efficiency and output.

What’s more, our equipment meets the higher power output requirements of flat wire motors. It guarantees welding precision, production efficiency, and operational safety. While enhancing production efficiency, it also focuses on reducing production costs and saving on materials and time.

Moreover, HONEST Intelligent offers customized solutions for non-standard equipment. We will communicate in detail before and during the sale to understand your requirements, formulate a feasible solution, and then proceed with equipment manufacturing to ensure your requirements are accurately met. In the future, HONEST Intelligent will continue to provide customers with more advanced and intelligent welding solutions.

If you are interested in or have any questions about this equipment, please feel free to contact us at any time. We will provide you with more detailed information and a preliminary product quotation. We are looking forward to the opportunity to communicate and cooperate with you.