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As the demand for high-efficiency electric motors in new energy vehicles (NEVs) and other advanced industries continues to rise, the hairpin stator assembly line has become an essential part of modern motor manufacturing. With its ability to ensure precision, reliability, and scalability, this production line represents a leap forward in stator winding technology. Jieyun Intelligent Equipment (Suzhou) Co., Ltd. specializes in delivering advanced automated solutions that bring this complex process to life.

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Step-by-Step Process of the Hairpin Stator Assembly Line

1. Copper Wire Forming

The process begins with rectangular copper wire cut to precise lengths and bent into a unique hairpin shape. This ensures maximum slot fill factor, reduces electrical resistance, and enhances overall motor efficiency.

2. Hairpin Insertion

Automated insertion systems place the hairpins into the stator slots with high precision and alignment control. This step requires exact positioning to avoid damage to insulation layers and to maintain consistent coil geometry.

3. End Forming

Once inserted, the protruding ends of the hairpins are shaped, pressed, and positioned. This ensures that all terminals are correctly aligned, preparing them for the next stage of welding.

4. Laser or Resistance Welding

The terminal ends of the hairpins are joined through laser welding or resistance welding. These methods create strong, reliable connections that guarantee stable electrical performance under high current loads.

5. Insulation Treatment

For added durability and safety, insulation is applied to exposed areas using coating, heat-shrink tubing, or insulation paper. This prevents short circuits and ensures compliance with stringent safety standards.

6. Varnishing and Curing

The assembled stator undergoes a varnishing process, followed by thermal curing. This step improves mechanical strength, vibration resistance, and electrical insulation, making the stator more robust for demanding applications.

7. Online Testing

Before moving to the final stage, each stator is subjected to comprehensive in-line inspections. Tests include:

• Electrical properties (insulation resistance, high-voltage withstand, and resistance balance)

• Dimensional accuracy

• Visual inspection for surface or assembly defects

8. Final Assembly

In the final stage, the wound and processed stator is combined with the core structure, completing the stator assembly. The component is then ready to be integrated into the electric motor for further assembly.

The hairpin stator assembly line represents the intersection of precision engineering, automation, and innovation. From copper wire forming to final stator integration, every step requires accuracy, advanced equipment, and intelligent control systems.

By mastering each stage of this process, Jieyun Intelligent Equipment (Suzhou) Co., Ltd. provides cutting-edge solutions that help manufacturers meet the growing global demand for high-performance, energy-efficient motors. Their expertise ensures not only production efficiency but also the long-term reliability of electric drive systems powering the next generation of vehicles and industrial applications.

https://www.gwinsys.com/Hairpin-Stator-Assembly-Line.html
Jieyun Intelligent Equipment (Suzhou) Co., Ltd.

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