In response to the rising demand for electric motors within the automotive industry, Comau has introduced an advanced suite of automated machinery tailored for the efficient production of hairpin stators.
With over half a century of experience, Comau has solidified its position as a global provider of assembly and machining solutions for the automotive sector. Their expertise spans the development of industrial robots and IoT platforms. Recently, the company expanded its offerings with a full lineup of machines dedicated to producing hairpin stators—key components in electric motors that power electric vehicles and require specialized production techniques.
New Hairpin Stator Manufacturing Solutions
To meet the evolving needs of electric vehicle manufacturers, Comau has launched an extensive range of machines specifically engineered for hairpin stator production. The new portfolio includes equipment for wire forming, insertion, twisting, and laser welding. Unlike one-size-fits-all systems, these machines are designed with flexibility and scalability in mind, enabling manufacturers to adapt as production requirements evolve.
Each unit has been optimized for a compact footprint and streamlined production setup. The automated process allows for real-time monitoring, ensuring that potential issues are identified early, minimizing downtime. Additionally, Comau focused on energy efficiency during the design phase, in line with the sustainability goals of electric vehicle production.
Advanced Wire Forming and Insertion Technology
The wire forming machine offers a fully automated process that handles tasks such as unwinding, straightening, paint stripping, cutting, 2D numerical control (NC) forming, and 3D mold shaping. The machine achieves a rapid cycle time of under 2 seconds. It also ensures high precision, with less than 0.2 mm deviation during the straightening phase. Configurable options for paint removal allow for either laser or mechanical processes, depending on specific needs.
This machine operates without manual intervention and features a high-speed gantry system for inserting formed wires into the stator. Insulating material is pressed between wires using a corolla press. The insertion machine accommodates various wire shapes, making it versatile for different product types.
Precision in Wire Shaping, Twisting, and Cutting
The process continues with specialized machines for wire widening, twisting, and cutting. These machines leverage precision servo and cam-driven technologies, offering customization based on specific end-product requirements. The design reduces burrs during cutting and ensures smooth twisting actions, with programmable settings for different stator models.
Laser Welding for High-Quality Connections
Comau’s wire welding machine utilizes laser technology to deliver deep weld penetration and high pull-out strength. The system supports multiple welding programs, catering to different part configurations. Manufacturers can choose between a standalone welding unit or a combined cutting and welding solution for increased production efficiency.
Global Production Capabilities
The hairpin stator modules are manufactured at Comau’s E-Motor Technology Center of Excellence in Shanghai. This strategic location allows Comau to efficiently serve a global market while staying connected to one of the world’s most dynamic hubs for electric vehicle development.
