Powerful Solutions for Electric Drives
Edgewise bent wire coils are conductive parts made from insulated copper or aluminum wire.
They are used in modern electric engines in electric cars, efficient pumps, industrial motors, and many other applications, where they provide a substitute for traditional round wire windings. Edgewise bent coils manufactured using WAFIOS technology are the thinnest on the market, allowing them to achieve the very highest copper fill factor in the stator. WAFIOS offers state-of-the-art bending technology and automation for manufacturing motor coils in small batches up to large quantities. By working with Gehring, Nagel, and LambdaResins, we can provide complete production solutions for axial flux motors and technology for individual process steps.
Maschinen
Machine comparison SpeedFormer
- Flexible change of hairpin geometries without retooling due to 3d bending technology that does not require any shape-dependent tools
- All hairpin geometries of a stator can be produced economically in batch size 1 by one machinery system
- The compatibility of machinery systems ensures a quick transfer of projects, if needed
- Reliable concept - from the development phase to series production - thanks to our WAFIOS production technology integrated in prototypes as well as large-volume series
- High output combined with minimum space requirements and low investment costs
- Quality control by integrated verification and control of geometry features, e.g. leg position or contact surface, using intelligent camera measuring technology
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SpeedFormer
Transfer bending machinery system "SpeedFormer" for producing hairpins in series
With the SpeedFormer, WAFIOS offers a completely new approach to the cost-effective production of hairpins for the latest generation of electric motors. The SpeedFormer is the first machine that unites three proven bending techniques from conventional wire and tube bending machines in one unique system. One of the bending techniques has been used for decades in WAFIOS CNC spring and wire forming systems and has now been modified and optimized for the bending of hairpins. This technique is used for simple hairpin bends and ensures highest production speeds.
Reliable operation from prototyping to series production – Identical bending process on the prototype and series production line
The manufacturing principle of the FMU E prototype is transferred one-to-one to large-scale production. Therefore, there are no risks in the transition from prototype production to series production. The SpeedFormer reduces series production cycle times from 6-10 seconds per hairpin to 1-1.5 seconds per hairpin. Identical production technologies, i.e. the same tools and bending techniques, are used in series production.
