Electric Motor Winding Automation (EMWA) for Hairpin Stator High-Volume Production
Abstract
end shaping, twisting and welding, as well as intelligent assembly line integration. A numerical simulation model is established based on
forming accuracy, wire insertion cycle time, welding defect rate and overall equipment effectiveness (OEE). Discrete event simulation and
finite element analysis are adopted to simulate and analyze process parameters and cycle characteristics of the EMWA production line at different operational stages. The results show that the optimized EMWA production line reduces the springback of hairpin wires to 0.21 mm, cuts
the wire insertion cycle down to 47 seconds per workpiece, keeps the welding defect rate below 1.2%, and raises OEE to over 88%. It realizes
high-stability automated mass production of drive motor windings for new energy vehicles.
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DOI: http://dx.doi.org/10.70711/frim.v4i8.10016
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