EDITOR’S CHOICE
FORMING INNOVATIONS!
WAFIOS
WAFIOS DEVELOPS A NEW AND REVOLUTIONARY
PROCESS FOR HAIRPIN PRODUCTION
Hairpins are challenging bent wire
components made of copper wire as the
core element, clad in a layer of insulation.
These electrically conductive parts are used
in the new generation of hairpin motors.
These components are subject to very
demanding requirements in terms of their
geometry and surface properties. Existing
manufacturing processes such as those
involving the use of automatic multi-slide
units or transfer systems usually entail a high
level of overhead in terms of tool set-up and
programming work, as well as substantial
tool costs.
With the wealth of experience that comes
from 125 years spent forming wires and
tube components of all kinds, WAFIOS
elected to shoulder the challenge of hairpin
production.
The result? Quite simply the most flexible
machine currently available on the market.
This flexible new process means that the
majority of hairpin geometries for a stator,
including the connection assemblies
required, can be manufactured in any
sequence without the need to change tools.
A patent for this bending process has been
applied for, a process that enables bending
work to be accurate and free of physical
EasyWay also allows you to import 3D
geometries automatically with STEP / IGES
files. After the co-ordinates have been
imported, the requisite bending program
can be produced automatically.
damage. This is a field in which WAFIOS has
many years of experience. The measurement
and feedback control algorithms this process
employs ensure that the machine is able to
monitor and control itself during production
operations. Even in situations where the
paint gets stripped inadvertently from the
contact points, WAFIOS is a competent
partner, one able to offer various solutions
to suit customer wishes.
There is also the option of integrating and
using the simulation tool to run through
the complete production sequence of
the bending component. The entire
process is simulated using a digital twin,
including machines, tools and workpieces
to create a dependable collision check in
advance. The entire production planning
process, including the programming
of parts, simulation, definition of cycle
time and the collision check, can be
performed in a parallel manner at an
external programming station. In addition,
simulation is used to establish the optimum
tool arrangement for the specific bending
part.
Geometric programming dispenses with the
need for the user to program individual CNC
axes. This speeds up the definition of hairpin
geometry.
Flexibility depends on the geometric
programming of bending parts and/or
hairpins. The WAFIOS controller WPS 3.2
+49 7121 146 309
www.wafios.com
Issue 35 PECM
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