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The miracle of hairpin technology: Why this new electric motor stator technology is taking the auto industry by storm
With the booming electric vehicle market, hairpin technology, as an innovative motor stator technology, is gradually attracting the attention of automakers. This technology is unique in that it uses flat copper strips for winding, providing higher efficiency and better motor performance than traditional technologies. So how exactly did hairpin technology come to attract widespread attention in the ever-evolving automotive industry?
How the hairpin technique works
Hairpin technology is a winding technology for stators of electric motors and generators. This method primarily uses solid, flat copper strips, also known as hairpins, which are shaped like the name, with the curved part resembling a hairpin. Compared with traditional round wire windings, the use of copper bars allows the stator slots to be filled more densely, thereby improving the efficiency of the motor.
The hairpin stator is designed so that the end of each hairpin can be twisted before welding to ensure a secure connection.
Structure and manufacturing process of hairpin stator
The structure of the hairpin stator is similar to that of a conventional stator, but differs in the winding system. The stator consists of multiple layers of insulated steel sheets with copper strips replacing the long round wire. This design not only improves the stator filling rate, but also helps to reduce current loss.
Manufacturing Process Overview
The manufacturing process of the hairpin stator is mainly divided into four steps: hairpin manufacturing, assembly and twisting, welding and interconnection, and insulation treatment. Each step is crucial to the quality of the final product.
Hairpin Manufacturing
During the hairpin manufacturing process, flat copper wire is loaded into a machine, continuously unwound and passed through several stages to remove excess bends and stress. Next, the copper wire will be bent according to different design requirements to form a U-shaped or I-shaped hairpin structure.
Assembly and twisting
During assembly, all hairpins are inserted into the stator slots as designed and twisted to configure the winding pattern. At this point, ensuring high-precision positioning is crucial for the subsequent welding process.
Soldering and interconnection
During the welding stage, the ends of the hairpins are connected to each other through laser welding technology to ensure stable electrical connection and high-efficiency welding quality.
Insulation treatment
After welding, the copper ends need to be insulated to prevent damage to the stator from heat and other environmental influences.
Application of hairpin technology in the automotive industry
As hairpin technology continues to mature in automotive applications, more and more automakers are beginning to adopt this technology. For example, the 2008 GM Chevrolet Tahoe Hybrid was the first production vehicle to use hairpin technology. In addition, companies such as Volkswagen Group, BMW and Tesla are also gradually adopting this innovative technology in their electric vehicles.
The hairpin technology has become a highlight in the electric vehicle market with its high filling rate, excellent speed-torque performance and good automation characteristics.
Future Challenges and Prospects
Although hairpin technology has demonstrated its superiority in many aspects, the production process still faces many challenges, such as welding defects and material costs. Therefore, relevant technologies and processes must be continuously improved. In the future, as governments and businesses increase their investment in hairpin technology research, we may see more innovations and breakthroughs.
Through hairpin technology, as well as continued improvements in production efficiency and cost reductions, the future of electric vehicles looks brighter. Will this technology become a key factor in the popularization of electric vehicles?
