Hairpin Motor Flat wire motor manufacturing process For Automobile Motor

The manufacturing process of flat wire motors is more complicated than that of ordinary motors, and it mainly relies on automated equipment for production.

The stator assembly is the core of the design of the flat wire motor. 

It is difficult to produce and has the characteristics of customization. After the design is finalized, any change in the line type and size of the wire requires re-customizing expensive tooling and molds, which has low compatibility. The complete manufacturing process of flat wire motor stator components includes paper insertion, coil forming, pre-insertion, integral insertion, flaring, twisting, flattening, welding, coating and varnish dipping, and copper nose welding. The degree of dependence is higher than that of round wire motors, especially the coil forming and welding process precision requirements are high and difficult, and professional high-end equipment is required.

For the key processes in the flat wire motor stator production line, 

Including coil forming, wire insertion, twisting and welding, which are difficult and highly dependent on automation, our company can provide a complete supporting line including forming machines, automatic wire insertion machines, and twisting machines and welding machines to realize highly automated operation of the stator production line.

The process flow of the flat wire motor rotor production line is:

Iron core inserting magnet steel-iron core injection molding-heating curing-rotor stacking-rotor dynamic balancing-rotor magnetization-surface magnetic detection-rotor press-fitting-laser marking. The entire production line has complicated procedures and high automation requirements, and the key processes include: iron core inserting magnetic steel, iron core injection molding, rotor stacking and rotor magnetization.

Flat wire motor assembly process: 

The rotor wire and assembly line are relatively simple, and the stator to wiring has multiple complex processes such as non-destructive bending, insertion, twisting, laser welding, and dipping of flat wires. By drawing on the past technical experience in the field of fuel vehicle gearboxes, our company has successfully mastered the assembly process of the flat wire motor stator wire, and has the technical capability of the overall solution for the three major process links of the flat wire motor stator, rotor, and assembly. Provide suitable flat wire motor manufacturing solutions for automobile manufacturers at home and abroad.