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Automated Hairpin Winding: What Role Does Precision Twisting and Welding Play in Motor Durability?

2025-10-18

The manufacturing of high-performance motors using hairpin technology is a multi-step process, and the final stages—the twisting and welding of the hairpin ends—are just as critical as the initial insertion performed by the Hairpin Winding Machine. The overall durability and longevity of the motor hinge on the quality of these electrical joints. A poor weld joint introduces high resistance, leading to localized hotspots, energy loss, and potential failure under load.

Our automated Hairpin Winding Machine integrates or seamlessly interfaces with high-precision twisting and laser/arc welding stations. The twisting mechanism must accurately rotate the copper ends to align the conductors for welding while preventing damage to the surrounding insulation. The subsequent welding process uses controlled energy to create a metallurgically sound, low-resistance connection that can reliably carry high currents. By automating this entire process, we eliminate the variability and inconsistencies inherent in manual assembly. The machine guarantees that every single electrical connection within the stator winding is uniform, robust, and designed for maximum current flow and thermal management, directly enhancing the motor's power density and long-term operating reliability.

Salle 1 et 2, n° 95, rue Sanxiang, zone de développement de Kunshan, Kunshan, Chine E-mail: sales01@cyd-auto.com Tel: +8615995673508 Tel: +8615995673508

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Machine à enrouler à l'épingle

Machine à décaper le vernis

Machines de pressage à stator

Machine de dilatation du stator

Machines de torsion de stator

Machine de découpe à stator

Machine de soudage au laser à stator

Machine d'insertion de stator

Machine d'essai de revêtement de stator

Ligne de production de stators automatisés

Automated Hairpin Winding: What Role Does Precision Twisting and Welding Play in Motor Durability?