Powerful Solutions for Electric Drives
Hairpins are bent parts made of insulated, enameled copper wire. They are used in the modern electric motors found in electric cars, hybrid vehicles, and e-bikes, where they replace the wound inductor coils that are part of conventional stators. Hairpin motors improve the power-to-weight ratio due to the packing density of the profile material.
WAFIOS offers state-of-the-art bending technology for producing hairpins, covering everything from small batches up to high volumes.
Machines
Machine comparison FMU E Series
- The new FMU E series is a unique machine concept for the production of hairpins and stator connection assemblies. It complements the successful FMU series in the e-mobility area.
- The simulation of the bending process opens new possibilities in the e-mobility sector, e.g. as a tool for feasibility analyses or collision control.
- The WAFIOS tool system for hairpins combines active rotary-draw bending with the agility of conventional wire bending tools. It prevents the material from slipping and increases the quality of complicated geometries.
- The newly developed infeed unit prevents deformations of the profiled material and enables - together with the tool system - the positioning of end legs.
- Our programming system WPS 3.2 EasyWay offers easy, geometric programming and a clearly arranged overview of the materials and tools used.
- The production process of the FMU E series can be complemented by insulation stripping, burr-optimized cutting and chamfering modules.
Please select Profilquerschnitt [mm²]
FMU 32 E
from 2
to 20.25 mm²
| Tensile strength max. | 400 N/mm² |
| Cross section max. | 20.25 mm |
| Thickness max. | 4.5 mm |
| Width max. | 8.0 mm |
| Bend-back clearance max. | 250 mm |
| Stroke, vertical table | + 70 / - 120 mm |
| Stroke, vertical table | +/- 90 mm |
| Stroke, slide | 95 mm |
| Dimension w x d x h | 1,600 x 2,300 x 2,250 mm |
| Weight without pay-off unit | approx. 3,600 kg |
| Upgradable to max. CNC axes | 24 |
| Profile cross-sections in [mm²] | 2 - 20.25 mm² |
FMU 40 E
from 2
to 30.25 mm²
| Tensile strength max. | 400 N/mm² |
| Cross section max. | 30.25 mm |
| Thickness max. | 5.5 mm |
| Width max. | 10.0 mm |
| Bend-back clearance max. | 450 mm |
| Stroke, vertical table | + 55 / - 175 mm |
| Stroke, vertical table | +/ - 90 |
| Stroke, slide | 130 mm |
| Dimension w x d x h | 2,040 x 3,120 x 2,400 mm |
| Weight without pay-off unit | approx. 5,900 kg |
| Upgradable to max. CNC axes | 24 |
| Profile cross-sections in [mm²] | 2 - 30.25 mm² |
