Mounting solutions for hairpin stators

From simultaneous engineering to development and verification of manufacturing processes, we are your partner for hairpin assembly. Together with our customers we develop efficient systems for the serial production of hairpin stators.

We ensure that a prototype that can easily be assembled in CAD can also be produced in real series production. Therefore we put great emphasis on an optimal stator basket design.

Felix Brosa, Team Leader Powertrain Solutions Manufaktur, thyssenkrupp System Engineering
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From prototypes to automated serial production

The prototype phase is decisive for successful series production. We manufacture prototypes and small series and further develop them in close cooperation with our customers. The development of a series system is already possible at an early stage of the prototypes. We evaluate the feasibility of automated assembly of the hairpin stators and optimize the basket design. We ensure the reliability of the production processes in advance through prototype tools.

PHiL modular and scalable software solution
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Process research in our own technology centre

We have specialized in the hairpin technology because, unlike the usual coiling methods, it can be solved by the assembly technique familiar to us. It meets the requirements of series production in automotive engineering. We develop and examine the entire process chain in our specially built pilot plant - from bending the hairpins to impregnating the stator.

We cover the complete value chain:

  • Slot insulation
  • Bending and assembly of hairpins
  • Necking and twisting
  • Welding the hairpins
  • Assembly and welding of contact elements
  • Impregnation
  • Electrical test

Interview with our expert

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Benefits of our solution

Features of our prototype production

Series Delivery time Quantity Speed
0 series12-15 weeks, depending on stator design1-5Depending on manual or semi-automated production
A series (functional pattern)15 weeks1-1520%, faster due to automation/tooling approach
B series (pre-serial samples)10 weeks if the A-series is used as a base15040%, faster due to automation/tooling approach
C series (zero/ pilot)20 weeks, if the B-series is used as a base50060%, faster due to automation/tooling approach

Features of our prototype production

Series Delivery time Quantity Speed
0 series12-15 weeks, depending on stator design1-5Depending on manual or semi-automated production
A series (functional pattern)15 weeks1-1520%, faster due to automation/tooling approach
B series (pre-serial samples)10 weeks if the A-series is used as a base15040%, faster due to automation/tooling approach
C series (zero/ pilot)20 weeks, if the B-series is used as a base50060%, faster due to automation/tooling approach