Hairpin electric motor have become a popular choice in new energy vehicles, industrial automation and other industries due to their high efficiency and high power density. However, in the production process, how to reduce costs while ensuring zero defect rate and achieving expected production capacity is a core issue that every manufacturing company must solve. Only by mastering efficient production processes and intelligent manufacturing solutions can we stand out in the fierce competition.

• High standard requirements for zero defective products:

Material selection: High consistency, high-performance copper wire and insulation materials are required. Any minor defects will affect product quality.

Production process: Winding, welding, insulation treatment and other links require extremely high precision control. If traditional process equipment does not have a high-precision control system, it will be difficult to meet the production requirements of its motors.

Detection technology: Traditional detection methods have limitations and it is difficult to detect minor defects, resulting in NG products entering the market and affecting the company's reputation.

• Production capacity does not match market demand:

Production fluctuations: If there are problems with product quality control in the early stage, there will often be downtime adjustments during the production process, resulting in fluctuations in the expected time of production capacity.

Delivery pressure: Due to the increase in market demand, customers' requirements for delivery cycles are getting shorter and shorter, and it is difficult for companies to increase production capacity while ensuring quality.

• Cost pressure brought by high quality and high production capacity:

Equipment investment: High-precision equipment is expensive and the initial investment is huge.

Material cost: High-performance materials are expensive and have a high waste rate.

Operation cost: High energy consumption and high maintenance costs further compress profit margins.

In the face of the above production problems, how can we strike a balance between achieving zero defective products, reaching the expected production capacity and keeping costs under control?

1. Strategy for Zero NG Products

First, in terms of material selection, highly consistent copper wire and insulation materials must be used. Due to the high precision requirements of its hairpin motors, Hollis uses advanced winding, welding and insulation processing technology processes on the automated production line to achieve high standards and high requirements for precision. Secondly, through intelligent testing equipment, the occurrence of minor defects can be effectively avoided to ensure that no NG products enter the market.

2. Strategies for Increasing Production Capacity

The hairpin electric motor automated production line is fully automated from raw material input to finished product output. The equipment failure rate is low, the production process is stable, and the production capacity will naturally increase. Moreover, the equipment beat control in the existing process can be achieved within 90S, which greatly improves production efficiency and capacity.

3. Cost Control Strategies

In the equipment optimization of the hairpin electric motor automated production line, we reduced unnecessary production processes. For example, the wire twisting process does not require flat cutting, effectively reducing the investment in automated equipment and reducing the quality control risks in the production process. At the same time, the fully electronically controlled design minimizes the failure of pneumatic components, and the maintenance cost is directly reduced.

Although there are many technical difficulties in the hairpin motor production line, it is not impossible to achieve zero NG products, increase production capacity and control costs in the production and manufacturing of hairpin electric motor. Motor manufacturers can stand out in the fierce market competition through the organic combination of technology upgrades, process optimization and cost control. HONEST Automation will continue to be committed to providing innovative intelligent equipment solutions for motor manufacturers to help them achieve high-quality, high-efficiency and low-cost production goals.