Comau has launched a comprehensive hairpin stator technology portfolio covering the entire stator manufacturing process, from hairpin wire forming to insertion, wire widening, twisting, and laser welding all the way to quality testing and control checks.
The expanded offer provides turnkey solutions for the entire motor assembly process from design through to execution.
As a critical structural and functional element within an electric motor, stator production is a complex process that necessitates high precision and control levels. Comau's fully configurable stator assembly line provides end-to-end manufacturing of hairpin stators with the scalability to move from a semi-manual to a fully automated process. Other benefits include an optimized footprint and lean production set-up, real-time process monitoring for enhanced quality assurance, and reduced operational and energy costs.
Wire Forming
- Fully automatic wire forming: unwinding → straightening → paint removal→ cutting → 2D NC forming → 3D mold forming
- High-efficiency wire forming CT per pin＜2 s
- Wire Straightness: ＜0.2 mm
- High flexibility, high compatibility, and high consistency of the pin forms
- High-precision cutting function, cutting, and chamfering are done at the same time in a single action without generating burrs
- Configurable laser/mechanical paint removal solution, ensuring high quality and cost-effectiveness
- Fully standardized functional module construction, compact design, and small footprint
Wire Insertion
- High automation rate, no manual intervention required
- Highly compatible with wire types
- Ultra-high-speed gantry movement with unwavering accuracy
- The corolla pressing is equipped with the insulating paper protection function
- Able to satisfy different special-shaped wire insertion requirements
Wire Widening
- Optimized gripper to avoid damaging paint film
- Quick changeover of standardized modules
- Multi-configuration wire widening solution adapts to different stator types
- Multi-program precision control solves copper wire rebounding
- Level and smooth mechanism ensures that the paint film will not be damaged
- Wire widening tooling ensures in-place wire separation using pass-through detection
Wire Twisting
- Twisting cylinder precisely controlled by the servo motor, smooth twisting process curve
- Ultra smooth twisting cylinder surface and wire/paper protection disk surface protects the wires from paint film damage
- Gear-driven twisting module with a small footprint and high flexibility
- Separated twisting module and drive for quick changeover and optimized maintenance
- Multi-layer twisting mechanism synchronized rotation to ensure the accuracy
Wire Cutting
- The overall cam rotating structure uses a single, simultaneous cutting process to craft highly flat pin ends with no burrs
- Special material and ultra-smooth wire clamping disk protect the wires from paint film damage
- Symmetrical design of the cutter increases the lifetime of the cutting tool and facilitates quick changes
- Special material and process adopted for the cutter, taking into account both the cutting force and lifetime of the cutter
Wire Welding
- Laser welding process ensures deep penetration, high pull-out force, high appearance grade
- Configurable welding process takes into account both quality and cost-effectiveness
- Product option 1: Single machine for the cutting and welding processes ensures high welding quality with a compact footprint
- Product option 2: combined cutting and welding station for better line efficiency. Laser movable design, large coverage, and high flexibility
Price: Contact the company for pricing
Comau LLC
Southfield, MI
(248) 353-8888
www.comau.com
