New process for hairpin production

May 2019 — Cost-effectively manufacture of so called hairpins shouldn’t longer be witchcraft. The wire parts previously bent by multi-slide automatic machines or transfer systems can now be produced with a new process in addition to the required connection modules without tool changes and in any sequence.

Hairpins are bent wire parts made of copper wire. They are coated with a lacquer layer. These current-carrying parts are used in “Hairpin motors” in the field of e-mobility. They are subject to high demands on geometry and surface. Production using multi-slide automatic or transfer systems is usually associated with high set-up and programming costs. In addition, there are considerable tooling costs. A newly developed process developed by German Wafios AG makes it possible to manufacture most of the hairpin geometries of a stator together with the required connection modules and without tool changes in any sequence. The process, for which a patent has been applied, permits precise and damage-free bending. Measurement and control algorithms ensure largely autonomous monitoring. 

The geometric programming eliminates the need to program individual CNC axes. This accelerates the setup of the hairpin geometry. The Wafios control “WPS 3.2 Easy Way” also supports the automated import of 3D geometries in Step/Iges format. After importing the coordinates, the bending program is created automatically. Optionally, a simulation tool can be used to play through the entire production process. Work preparation including part programming, simulation, cycle time determination and collision control can be carried out in parallel at an external programming station. In addition, simulation can be used to determine the optimum tool arrangement for the specific bent part.

Wafios AG
wire Russia 2019, Forum / C52
Tel.: +49 7121 146-0

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Partner Links
  • IWMA – International Wire & Machinery Association
  • ESF – European Spring Federation
  • ICFG – International Cold Forging Group