Bar-wound
Bar-Wound Stator Automated Mass Production Line Gen3 - High Compatibility
- CT = 31.5 s
- The production line consists of 92 stations in total, with an automation rate exceeding 95%
- Equipment and material consumption is reduced by 8%
- Full-automatic precision clamping is adopted for welding processes, achieving a first-pass yield of 99%
- A multi-channel layout is applied to prevent full-line shutdown caused by failure of individual equipment
- Quick-change interfaces are equipped; the model changeover time is 35 minutes, reserving flexible options for subsequent retrofitting and enables flexible production
Technical Features
Insulation Paper Insertion
PIN Forming
Basket Insertion
Expanding
Twisting
Laser Welding
- CT: ≤ 60 s/pcs (based on 48 slots)
- Forming dimensional accuracy: ± 0.15 mm
- The paper insertion length is automatically adjusted according to the core thickness, with an adjustment accuracy of ± 0.15 mm
- Equipped with forming heating function; temperature control accuracy: ± 3 °C
- Features automatic unwinding and tension control functions
- Anti-warping design for inserted paper sheets
- Equipped with paper debris cleaning function
- Automatic alarm for paper jamming
- CT: 1.25–1.5 s/pin
- Wire feeding length accuracy: ±0.1 mm
- Adopted innovative 2D/3D forming mode; hardware replacement is not required, and product changeover is realized via software. A single piece of equipment can satisfy the production of all wire types for one stator
- Integrated multiple processes including straightening, enamel stripping, 2D forming, 3D forming and pre-wiring into one unit
- Support flexible solution configuration according to customers' capacity requirements to achieve flexible production, with reserved interfaces for subsequent capacity expansion
- Modular design; molds, milling or laser stripping methods are optional for configuration
- Non-destructive cutting process is adopted
- Optional on-line automatic wedge insulation inspection function is available for configuration
- CT: ≤ 1.5 s/pin
- Equipped with wire pattern error-proofing function
- Effectively prevent wedge deformation
- Compatible with all types of flyer winding designs
- Arranges copper wires to avoid misalignment and messy wire terminals, improving basket winding quality
- The basket winding tooling adopts a flexible design and supports rapid changeover
- CT: ≤ 4.5 s/pin/gripper
- Equipped with Z-axis compensation function during the flaring process
- Effectively corrects pin positions
- Pin position inspection is implemented after flaring
- Adopts a unique gripper design and motion control to prevent damage to the enamel insulation of flat wires
- Featuring a flexible design, it is compatible with stators of different diameters and slot quantities; the number of grippers can be flexibly adjusted (max. support for 18 sets)
- CT: ≤ 60 s/piece
- Real-time torque monitoring is implemented to effectively prevent damage to the enamel insulation of flat wires
- Real-time mold entry force monitoring ensures no damage to products
- The rotation angle of each layer is controlled by an independent servo motor
- Each twisting die for every layer is equipped with an independent Z-axis compensation function, ensuring consistent height of the welding ends after twisting. No trimming is required, which significantly reduces copper wire loss
- Mold clamping is adopted to prevent displacement of U-Pins and L-Pins
- Pin position inspection and product cleaning functions are available after twisting
- CT: 0.2 s/weld spot
- A fully automatic clamping device is adopted, with a first-pass yield reaching 99%
- Adopting an advanced welding tooling design to ensure each pin per slot is equipped with independent driving force for gap‑free clamping
- Independent shielding gas assistance is configured to effectively reduce spatter and improve welding quality
- Fixtures for welding ends support automatic disassembly and assembly
- AI vision technology is applied to implement weld spot quality inspection
Process Section
Paper Insertion
PIN Forming
- I-pin Forming
- U-pin Forming
Auto-basket Setting
Final Insertion
Flaring
- Thermal Insulating Paper Flaring
- Flyer Flaring
Twisting
Flush Cutting
Welding
- Inner I-Pin Welding
- Busbar Welding
- Conventional Spot Welding
Inspection
- AOI Inspection
Drip Impregnation
Coating
Curing
Cooling
Cleaning
- Air Blower Cleaning
Testing
- EOL Testing
- Final Inspection
Marking
Other Products
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Electric Drive Assembly Automated Assembly and Testing Line
- Highly compatible modular design, supporting rapid model change, with the overall line automatic model change rate reaching 80%
- Process automation is achieved through robots, with an automation rate > 85%
- Adopting upper and lower three-dimensional line layout, significantly saving floor space
Inverter
Inverter Automated Assembly and Testing Line
- Fully automated assembly and inspection throughout the entire process, efficient and stable
- Supports non-stop material replenishment to ensure continuous operation of the production line
- Real-time monitoring of production status and timely warning of abnormalities
DC-DC
DC-DC Automated Assembly and Testing Line
- Overall line automation rate > 85%
- Adopt zero-point positioning system for higher assembly accuracy
- Two-stage heating process applied for stator assembly to effectively reduce heat loss
- Direct cabinet feeding via the 6th axis
- Full-process mistake-proofing & error prevention
- Fully automatic feeding and pressing assembly
- High precision in tightening and alignment on the assembly line, ensuring superior assembly consistency