Hairpin Technology

The introduction of traction electric motors manufactured with hairpin technology encouraged IMA AUTOMATION to invest in a research and development program for automatic machines to produce these types of motors. With a consolidated know-how in manufacturing special machines by IMA AUTOMATION ATOP we ensure high speed and accurate hairpin design to manufacture hybrid stators.

Forming and inserting technology

Slot insulation technology

It comes from a strong background experience of over 40 years developments on universal motor applications.

In this process the machine unwinds, folds and cuts the insulating paper strip and inserts the paper portions into the stator stack slots. The machine generates the insulating paper portions that will be inserted, one by one, into the stack slots, through the combination of paper translation and stator indexing. Insertion process is controlled for each single slot by verification of paper in position and detection of paper jam. Different insulation shapes are possible. Perfect fitting of insulation into the slot, give excellent stability and pull force such as to avoid the need of a calf.

Hairpin Forming and Inserting Technology

With a strong know-how in reels manipulation, IMA AUTOMATION offers hairpin forming machine with conductor feeding system, laser wire decoating, single hairpin creating and inserting stations.

This technology permits to perform all hairpin, pitches, lengths, product specification, thanks to the full integration of wire unrolling device, wire peeling by laser, which operate “ON FLY” mode to not interfere with hairpin forming process. Core of this process is the robot which is fully NC controlled and operate thanks to a 6-axis solution. Changing the hair-pin shape is easy, only acting on program parameters from the HMI. The hairpin so prepared, will be assembled into the nest which is being made of single or multiple layers. Shuttle with transfer heads, moving nests to the insertion stations through a portal system.

Stator assembly

Widening & Twisting Technology

IMA AUTOMATION ATOP has developed its own technology to best suit customer needs. It’s an extremely flexible solution based on NC controlled axis. There are three main elements linked in a unique process unit: the loading, the widening and the twisting process.

In this process the machine unwinds, folds and cuts the insulating paper strip and inserts the paper portions into the stator stack slots. The machine generates the insulating paper portions that will be inserted, one by one, into the stack slots, through the combination of paper translation and stator indexing. Insertion process is controlled for each single slot by verification of paper in position and detection of paper jam. Different insulation shapes are possible. Perfect fitting of insulation into the slot, give excellent stability and pull force such as to avoid the need of a calf.

Wire cutting solutions

IMA AUTOMATION ATOP presents different solutions for the wire cutting operation:

Multiple cut

It consists in multiple conductors cutting at constant length by means of NC mandrel.

Single cut

Extremely flexible operation for single conductor ends cutting.

Blade cut

A blade moves insisting on the same circumference of the hairpin crown.

Laser welding technology

The welding process is a key aspect for the hairpin technology and important part of IMA AUTOMATION ATOP know-how. It is made with optics using laser beam deflection with motorized mirror system on multi-axis devices. The laser unit includes generator, coaxial fibre and PFO head. There is an optical tracking system for accurate welding target detection with integrated camera. Independent units gripping and holding each couple of conductors to guarantee a perfect junction and position.

Electrical testing

IMA AUTOMATION ATOP has many years of experience on machine testing. In all the steps, we developed technologies installed on each machines offering to the customer the best solutions in terms of instruments, hardware and software.

Standard tests are always present on ATOP instruments:

  • Hi-pot test up to 3500 V at 30 mA
  • Surge test up to 6000 V
  • RL test for resistance and field measurement
  • Hi-current test up to 200 A
  • Insulation resistance up to 200 MΩ
  • Partial discharge - surge test/high-voltage measurements

Other processes integration

Automatic and flexible process solutions based on customer request are integrated with robot and 3D vision systems for the stator inspection and final control.

  • Quality control
  • Manual operations
  • Visual inspection

Hairpin Technology

The introduction of traction electric motors manufactured with hairpin technology encouraged IMA AUTOMATION to invest in a research and development program for automatic machines to produce these types of motors. With a consolidated know-how in manufacturing special machines by IMA AUTOMATION ATOP we ensure high speed and accurate hairpin design to manufacture hybrid stators.

Forming and inserting technology

Slot insulation technology

It comes from a strong background experience of over 40 years developments on universal motor applications.

In this process the machine unwinds, folds and cuts the insulating paper strip and inserts the paper portions into the stator stack slots. The machine generates the insulating paper portions that will be inserted, one by one, into the stack slots, through the combination of paper translation and stator indexing. Insertion process is controlled for each single slot by verification of paper in position and detection of paper jam. Different insulation shapes are possible. Perfect fitting of insulation into the slot, give excellent stability and pull force such as to avoid the need of a calf.

Hairpin Forming and Inserting Technology

With a strong know-how in reels manipulation, IMA AUTOMATION offers hairpin forming machine with conductor feeding system, laser wire decoating, single hairpin creating and inserting stations.

This technology permits to perform all hairpin, pitches, lengths, product specification, thanks to the full integration of wire unrolling device, wire peeling by laser, which operate “ON FLY” mode to not interfere with hairpin forming process. Core of this process is the robot which is fully NC controlled and operate thanks to a 6-axis solution. Changing the hair-pin shape is easy, only acting on program parameters from the HMI. The hairpin so prepared, will be assembled into the nest which is being made of single or multiple layers. Shuttle with transfer heads, moving nests to the insertion stations through a portal system.

Stator assembly

Widening & Twisting Technology

IMA AUTOMATION ATOP has developed its own technology to best suit customer needs. It’s an extremely flexible solution based on NC controlled axis. There are three main elements linked in a unique process unit: the loading, the widening and the twisting process.

In this process the machine unwinds, folds and cuts the insulating paper strip and inserts the paper portions into the stator stack slots. The machine generates the insulating paper portions that will be inserted, one by one, into the stack slots, through the combination of paper translation and stator indexing. Insertion process is controlled for each single slot by verification of paper in position and detection of paper jam. Different insulation shapes are possible. Perfect fitting of insulation into the slot, give excellent stability and pull force such as to avoid the need of a calf.

Wire cutting solutions

IMA AUTOMATION ATOP presents different solutions for the wire cutting operation:

Multiple cut

It consists in multiple conductors cutting at constant length by means of NC mandrel.

Single cut

Extremely flexible operation for single conductor ends cutting.

Blade cut

A blade moves insisting on the same circumference of the hairpin crown.

Laser welding technology

The welding process is a key aspect for the hairpin technology and important part of IMA AUTOMATION ATOP know-how. It is made with optics using laser beam deflection with motorized mirror system on multi-axis devices. The laser unit includes generator, coaxial fibre and PFO head. There is an optical tracking system for accurate welding target detection with integrated camera. Independent units gripping and holding each couple of conductors to guarantee a perfect junction and position.

Electrical testing

IMA AUTOMATION ATOP has many years of experience on machine testing. In all the steps, we developed technologies installed on each machines offering to the customer the best solutions in terms of instruments, hardware and software.

Standard tests are always present on ATOP instruments:

  • Hi-pot test up to 3500 V at 30 mA
  • Surge test up to 6000 V
  • RL test for resistance and field measurement
  • Hi-current test up to 200 A
  • Insulation resistance up to 200 MΩ
  • Partial discharge - surge test/high-voltage measurements

Other processes integration

Automatic and flexible process solutions based on customer request are integrated with robot and 3D vision systems for the stator inspection and final control.

  • Quality control
  • Manual operations
  • Visual inspection

Download the Hairpin Technology brochure

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