Hairpin Stator Production
INDUSTRY CHALLENGES
-
01Complex, tightly coupled processes challenge production stability.
-
02
Limited flexibility leads to long changeovers and high production costs.
-
03
Multiple quality checkpoints complicate defect prevention and yield improvement.
INDUSTRY SOLUTION
TZTEK's hairpin stator production line covers key processes including wire stripping, hairpin 2D/3D forming, automated paper insertion, opening, twisting, cutting, welding, varnish application, and end-of-line performance testing.
A high-flexibility forming and inspection system supports mixed-model production across hairpin types, with automatic tooling changeover and full in-line inspection after 3D forming to ensure dimensional accuracy and yield. Precision motion control with axial and radial compensation enables multi-layer twisting and accurate hairpin insertion. A vision system provides pre-weld guidance, automatically selects the appropriate welding program, and supports intelligent skip-point control for consistent weld quality.
Post-weld 2D and 3D inspection systems provide full-dimensional inspection of hairpin stators, including advanced 3D weld inspection for comprehensive quality control.
KEY ADVANTAGES
-
Integrated process flow with servo closed-loop control and intelligent in-line monitoring for improved line stability.
-
Modular quick-change tooling and standardized programs for shorter changeovers and lower costs.
-
Full-process in-line inspection with traceability and multi-point defect containment to drive higher yield.
