BIHLER AUTOMATION SOLUTION FOR HAIRPINS, E-MOBILITY

Efficient and flexible hairpin production

Based on more than 40 years of experience in hairpin technology, Bihler's complete solution opens up new perspectives in the industrial mass production of these electrifying components.

The BM-HP 3000 production system with standardized machining processes combines all required process steps: Starting with the multi-stage straightening and the highly dynamic, slip-free feeding of the wire, the precise cutting, NC-controlled mechanical stripping of the coating, simultaneous chamfering of the pin ends, 2D pre-bending and 3D die-bending, all the way to the removal and mono-component storage.

You benefit from three times higher cycle rates than with sequential systems, easy and fast variant changes “on the fly”, and flexible scalability for future tasks.

Hairpin windings manufactured with Bihler technology

Highlights of the BM-HP 3000

All-in-one production of hairpins directly from the coil from flat wire
All common hairpin, connection pin and I-pin types can be produced
High output: 60 - 120 finished hairpins per minute
(depending on material cross section and leg length)
Cycle speeds are three times higher than with sequential systems
Flexible, rapid change of variants "on the fly"

Predestined for industrial mass production
100 percent reproduced top quality of parts
Additional machine and space requirements can be reduced
Flexibly adaptable to future tasks
Easy and save operation with central VariControl
Fully automated coil change

Modular process steps

Wire infeed after multilevel straightening

The production process begins with the multi-stage straightening of the flat enameled copper (1a) to eliminate residual curvature and batch variations. The RZV 2.1 (1b) feeds the wire directly from the coil at up to 3.2 m/s without slippage. The servo feed guarantees a repeat accuracy of
+/- 0.02 mm and ensures that the layer of insulation varnish is not damaged (three-point surface clamping).

Precise cutting

An NC module equipped with a cutting punch then cuts the enameled copper wire precisely to the straight length – without deformation and damage to the insulation layer and and with little cutting burr.

Isolation removal and chamfering of pin-ends

The next step sees the mechanical, accurate stripping of the enameled insulation layer and the simultaneous chamfering of the two pin-ends under NC control. A sensor unit performs continuous inline measurements of the thickness of the enamel coating and the combined thickness of the coating and the copper wire. The total cross-section loss of the copper wire remains below 0.05 milimeters. The pin ends obtain a pure metal surface.

2D preliminary bending

During 2D preliminary bending, powerful servo units ensure in a parallel-cycle swivel-bending process the correct geometry values, which can be freely programmed if required.

3D die-bending

The hairpins are given their final head shape in a subsequent 3D die bending process. NC units guarantee a plastic deformation that is gentle on the material and coating. The precise control of the servo units guarantees one hundred percent reproducibility of the hairpins with short cycle times. As option: Integration of the final component geometry measurement and inline adjustment.

Transport and mono-component storage

The final step is the removal of the finished hairpins via a conveyor belt for sorting and storage. Equipment on the last module includes clearly defined interfaces for further links enabling integration into complete production lines for stators or turnkey systems for electric motors.

BM-HP 3000 Hairpin Machine

Technology in Motion - Animation "Hairpin Production"

Scalable, compact automation solution

The BM-HP 3000 is based on the modular BIMERIC servo production system. It impresses with its high output of 60 to 120 finished parts per minute. Variant changes are particularly flexible: solely by calling up the stored data - at a constant machine cycle rate, without machine downtime and without worker intervention.

For future requirements, the hairpin machine can also be flexibly expanded with additional process modules or the arrangement of the modules can be adapted. The central VariControl VC 1 control system guarantees safe and simple operation of the machine and all processes. And complete production on one production system saves additional equipment and the space required for it.