Efficient Hairpin Stator Line: Speed Up Electric Motor Production

 

The hairpin stator production line is a new energy motor production line designed for manufacturing stators. The stator is a core component of the motor, located on the motor's rotating shaft, and its primary function is to generate a magnetic field to drive the rotation of the rotor. The stator core, a key part of the stator, is used to produce the magnetic field and is one of the core components of the motor.

 

 

As a motor intelligent assembly manufacturing company established for over a decade, HONEST boasts an outstanding and extensive R&D team. They are committed to the research of innovative technologies and the continuous innovation of processes, providing customers with more efficient and high-quality hairpin stator production equipment.

 

HONEST's Hairpin Stator Production Line Specifications

 

Product Specification Overview:

 

1.Model Diversity: We offer a variety of stator outer diameter sizes, including 160mm, 180mm, 220mm, and 260mm, to accommodate various motor configurations.

 

2.Slot Abundance: The number of slots in the stator ranges from 48 to 96, providing clients with a broad selection to match different motor performance requirements.

 

3.Slot Liner Design: We utilize O-type, B-type, and other specially designed slot liners to ensure the stability and efficiency of the motor.

 

Production Line Overview:

 

The equipment is distributed in a circular layout, with the main conveying mechanism adopting a combination of conveyor belts and ferries.

 

Key Production Process Description

 

A. Slot Insertion Machine

 

Our slot insertion machine begins with an automatic positioning system that ensures the accurate placement of the stator at the pre-work station. Subsequently, it uses barcode scanning to quickly acquire product information data by reading the stator's QR code.

 

Insulation Paper Insertion: The mechanical arm picks up the core and accurately positions it to the slot liner feeding station. The insulation paper is supplied by a constant temperature material bin's roll system, and the equipment supports the switching between O-type and B-type slot liners to meet the needs of different stator specifications.

 

Creasing and Paper Feeding: The automatic creasing technique ensures the precise positioning of the insulation paper, and the closed-loop control paper feeding guarantees the accuracy of the paper delivery. The machine sequentially rotates to complete the insertion of the slot liner in each slot position, with automated operations effectively ensuring the continuity and efficiency of the actions.

 

B. Wire Forming Machine

 

Wire Straightening Automation: Our wire-forming equipment employs an automatic straightening technique to ensure that the wire achieves the required straightness upon entry into the machine. It is equipped with two sets of straightening wheels with fine-tuning functions, which precisely correct the wire in both vertical and horizontal directions.

 

Coil Formation: The 2D coil formation is achieved through mature CNC technology, offering good compatibility and effectively preventing damage to the enameled wire that could occur during the mold-forming process. The 3D coil formation utilizes die stamping technology to enhance the stability and efficiency of the wire forming process, enabling the completion of all coil types on a single machine for a stator.

 

C. Stator Wire Cup Insertion Machine

 

Precision Positioning: By accurately positioning the wire leads and insulation paper, the machine ensures the precision and reliability of the wire leads and insulation paper during the working process.

 

Wire Cup Insertion and Pressing: The wire cup is precisely inserted into the stator to a preset position. During the insertion process, a paper-blocking jig is used to prevent the insulation paper from shifting, ensuring the stability of the wire insertion process.

 

This entire process, through automation and precise control, not only improves production efficiency but also ensures the quality of each coil and the consistency of motor assembly.

 

D. Stator Wire Twisting Machine

 

Wire Protection Device: The wire protection device on the material picking module extends to hold the insulation paper on the stator, effectively preventing damage to the insulation paper during the twisting head process.

 

Precise Twisting Head: Each layer of the twisting head mold is independently controlled by a servo drive for rotation, while also being coordinated with the axial servo compensatory motion of the stator to ensure that the wire head twists according to the set spatial position, completing the end twisting. 

 

 

E. Stator Welding Machine & Post-Weld Inspection Machine

 

In the field of automated intelligent assembly for electric motors, the stator welding machine and post-weld inspection machine play an important role in both product quality and production efficiency.

 

Stator Welding Process

 

Automatic Welding with Gas Protection: The welding mechanism is activated to automatically complete the wire terminal welding action. High-quality welding is ensured through the use of protective gas during the welding process.

 

Precise Welding: The equipment is equipped with a laser welding machine, capable of providing efficient and precise welding technology.

 

Post-Weld Inspection Process:

 

Stator Appearance Inspection: Equipped with an intelligent system, it automatically inspects the appearance of the weld points, including aspects such as weld height and area, ensuring the reliability of the inspection results.

 

Automatic Re-welding: When the machine detects a substandard weld point, it can facilitate an automated re-welding process.

 

The combined use of these two machines exemplifies the efficiency and convenience of automated and intelligent equipment in production operations, ensuring the high quality of the welding process.

 

 

F. Coating and Dipping Equipment

 

Preheating & Automatic Coating: After weighing, the product first enters the preheating station, where it is evenly heated before being transported to the coating station by a handling mechanism for automated coating operations.

 

Automated Dipping: When the stator reaches the dipping station, it is also automatically dipped by the equipment, which can adjust the dipping angle of the stator as needed to achieve an even coating.

 

Curing & Re-weighing: After the coating and dipping processes are completed, they both go through a curing and secondary weighing stage. This allows for control over the coating and dipping processes, ensuring they meet quality requirements.

 

Advantages of HONEST's Hairpin Stator Production Line

 

1.Stop Positioning System: The use of a stop positioning system ensures precise material positioning, facilitating the execution of subsequent process actions.

 

2.Data Traceability: Each process is equipped with a QR code reading mechanism to obtain product information quickly, making it convenient for production management and tracking.

 

3.Intelligent Testing Equipment: Automatic detection of the product's appearance and performance aspects achieves efficient control over product quality, ensuring the stability and reliability of the products.

 

As a leading industrial automation equipment solution provider in China, HONEST has established a set of design and manufacturing standards that meet both international standards and the actual production needs of customers.

We are confident in our ability to provide you with efficient and high-quality haripin stator production equipment solutions and look forward to the opportunity to cooperate with you to explore the endless possibilities of industrial automation.