„Efficient hairpin production“

Future-Oriented Automation Solution for Hairpins

The production of hairpins for electric motors demands dynamic machine solutions that ensure optimized throughput and are nevertheless flexible enough to cope with changing variants. Only in this way will it be possible to manufacture the volumes required in the future at market-compatible prices. At the same time, it is is not only top quality that is essential; space-saving dimensions also contribute to resource-friendly production.

The efficient manufacture of electric motors makes use of so-called hairpins which are installed in the stators and replace the coil.

Thanks to its 30 years of experience, Bihler can offer new prospects for the industrialization of production processes as part of an automated end-to-end solution for the manufacture of hairpins. To do this, the BM-HP 3000 production system brings together all the process steps in standardized form. These extend from the highly dynamic, slip-free infeed of flat wire directly from the coil, through the NC-controlled, dimensionally accurate mechanical removal of the isolating lacquer, the simultaneous chamfering of the pin ends, the 2D preliminary bending and 3D die-bending, and on through to the transport and mono-component storage. As option, it is possible to include a final measurement of the component geometry and an inline adjustment. The end-to-end manufacturing solution on a single production system saves additional equipment and the space this would require.

Three times the throughput of sequential systems

With an output of 60 to 120 finished parts per minute, it offers three times the throughput of sequential systems. Changes between variants can be performed “on the fly”, i.e. without slowing down the machine’s throughput, without shutting down the machine and without any intervention on the part of the operator. The BM-HP 3000 is operated and controlled easily and securely using the VariControl VC 1 controller. The hairpin machine is based on the BIMERIC production system which brings together all the standardized process components in a modular arrangement on the basic machine body. Depending on the requirements that arise, the arrangement of the modules can be subsequently adapted or extended by further modules.

Technology in Motion (Hairpin Production) - click here.

The process steps on the BM-HP 3000

Wire infeed after straightening

The precise straightening of the enameled copper wire (1b) contributes to the highly dynamic, slip-free infeed (1b) of up to a maximum of 3.2 m/sec. The repeat accuracy achieved during this process is +/- 0.02 millimeters.

More info RZV 2.1

Cutting

The enameled copper wire is cut accurately and cleanly to its stretched length – in exactly the way required for subsequent processing.

Mechanical isolation removal

The automatic removal of the isolation and simultaneous chamfering of the two ends of the enameled copper wire are performed mechanically. Online measurements guarantee a consistent copper core. During this process, the overall cross-sectional loss is less than 0.05 millimeters.

2D preliminary bending

During 2D preliminary bending, powerful servo units for the fast, accurate execution of multi-step tool movements ensure the correct geometry values, which can be freely programmed if required.

3D die-bending

The high-precision 3D die-bending process gives the heads of the hairpins their final shape. The top-quality characteristics and precise control of the process module ensure one hundred percent reproducibility

Transport and mono-component storage

The finished hairpins are ejected via a conveyor belt for unmixed, mono-component storage. The module is also equipped with open interfaces for further customer connections.