Recently, Haosen has made a significant technological advancement in the field of drive motor intelligent manufacturing by successfully developing a flexible bending wire forming equipment for stator production in hairpin motors. This innovation not only overcomes critical technical challenges in the wire forming process but also demonstrates leading advantages in production efficiency, forming quality, and system flexibility, delivering dual value of “cost reduction + efficiency improvement” for customers.
Bending Forming: The Evolving Technology Aligned with Market Needs
With the rapid growth of new energy vehicles (NEVs) and high-efficiency energy-saving motors, hairpin motors are gaining increasing attention due to their superior efficiency and power density. However, manufacturing hairpin motors, particularly their stators, is highly complex. Among the stator manufacturing process, wire forming is the foundational step, and 3D forming, as a core operation, directly impacts production efficiency, cost control, and feasibility of downstream process.
Currently, there are two primary approaches for 3D wire forming of hairpin motor stators: die forming and bending forming. While die forming can achieve complex wire shapes, it suffers from inherent limitations—one specific die is required for each wire shape, leading to cumbersome setup and poor adaptability to today’s market trend of small batches and multiple variants. In contrast, bending forming offers high compatibility: by simply adjusting control parameters, the same machine can rapidly switch between any wire shape within the same wire gauge. This significantly boosts both production efficiency and flexibility, making it the preferred solution for meeting diverse market demands.
As a global leader in intelligent equipment solutions, Haosen has always been committed to driving industrial upgrading through technological innovation. Guided by deep insights into these technological trends and market pain points, and leveraging its extensive experience and profound process expertise in intelligent manufacturing, Haosen has independently developed the “Flexible Bending Wire Forming Equipment V1.0”, elevating the productivity of hairpin motor stator manufacturing to a new level.
Haosen Independently Develops CNC Wire Forming Equipment
Key Advantages:
High Speed: Featuring a lean mechanical structure and a high-dynamic-response hardware-software closed-loop control system, the equipment achieves a remarkable cycle time of 1 second per pin. While ensuring the precision of wire forming, it not only meets the demands of large-scale mass production but also consistently delivers high-quality wire shapes, providing customers with efficient and reliable production support.
High Flexibility: Both 2D and 3D forming utilize the bending method. Core algorithms enable precise, parameter-driven control of wire dimensions. Equipped with an automatic tool magazine, the system supports all mainstream pin types, including Hairpin, I-PIN, X-PIN, and MINI-PIN, enabling mixed production of different shapes within the same wire gauge. Recipe changes take just one click, eliminating the need for dedicated dies and drastically reducing changeover costs.
Modular Design: Built on a modular architecture, the equipment allows functional units to be independently detached and freely reconfigured. This enables quick change and supports fully customized solutions tailored to individual customer needs.
Intelligent Operation: Fully aligned with Industry 4.0 principles, the system integrates advanced intelligent functions such as automated scheduling, tool life management, equipment performance monitoring, and production data management. All production and machine status data are visualized in real time, empowering managers to make transparent, efficient production decisions.
High-Precision Quality Assurance: To meet the stringent requirements of non-cut-pin stators like X-PIN and MINI-PIN, the flexible bending wire forming equipment is specifically paired with Haosen's independently developed high-precision wire-type vision inspection equipment to form a quality closed-loop system, providing stable and reliable quality assurance for customer products.
As a pioneer in the intelligent manufacturing of drive motors, Haosen remains steadfast in its core philosophy of creating value for customers through technological innovation, deeply committed to the research & development, and industrial application of cutting-edge technologies. Looking ahead, Haosen will continue delivering end-to-end solutions, from single machine to the whole line, backed by ever more efficient equipment and robust process support. Haosen also looks forward to collaborating with industry partners to jointly advance the high-quality development of the NEV sector and contribute more Chinese manufacturing strength to the global energy transition.
