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
- Unique machine concept for producing hairpins and stator connection assemblies , and for expanding the FMU series in the field of e-mobility
- Bending process simulation opens up new possibilities, especially with regard to feasibility or collision monitoring
- Patented hairpin tool system combines active rotary-draw bending with the agility of conventional wire bending tools, prevents the material from slipping, and increases the quality of complicated geometries
- Newly developed feed unit prevents deformations in the profiled material and – together with the patented tool system – enables positioning of end legs
- WPS 3.2 EasyWay programming system offers easy, geometric programming and a clearly arranged overview of the materials and tools used
- 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 horizontal table | +/- 90 mm |
| Slider stroke | 95 mm |
| Dimensions 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 horizontal table | +/ - 90 |
| Slider stroke | 130 mm |
| Dimensions 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 |
FMU 32 E
FMU E series – Revolutionary rotary-draw bending process for hairpin production
This flexible new process means that the majority of hairpin geometries for a stator, including the stator connector parts required, can be manufactured in any sequence without the need to change tools. The patent-pending bending process enables bending work to be accurate and free of physical damage.
Outstanding flexibility with WPS 3.2 EasyWay programming system
Flexibility depends on the geometric programming of bending parts and/or hairpins. The geometric programming dispenses with the need for the user to program individual CNC axes. This speeds up the definition of hairpin geometries. The WAFIOS WPS 3.2 EasyWay control unit also allows you to import 3D geometries automatically with STEP / IGES files. After the coordinates have been imported, the required bending program can be produced automatically.
Further information
