Harrandt measures hairpins faster than the eye can blink.

With an intelligent test module, we make it easier for our customers to install hairpins without errors.

In stator production, manufacturers rely on the highest precision so that the individual hairpins with special curvature are absolutely identical in their geometric features and can be safely installed. That is why our e-mobility customers trust in Harrandt's technological know-how and process-oriented approach.

Starting Point and Challenge

Fluctuations in the hairpin wire quality as well as different methods of cutting to length and bending can result in finished hairpins deviating minimally in size and angle of bend. This can cause serious problems in e-motors during the subsequent assembly. In order for our customers to meet their requirements for the error-free assembly of hairpins and the highly precise setting of the hairpin legs, they rely on Harrandt's expertise to optimize their production processes. The objective: a safe and reliable check of the function-critical bending angles and lengths - taking into account the fast cycle time of 1 second.

Our Solution

We were able to prove the technical feasibility of the demanding task with preliminary tests at the inquiry stage. We then carried out a series of tests with different image processing systems to ensure the required resolution for error detection. We had to take into account various special bends in the hairpins and calibrate the system, and our own developed evaluation software, accordingly. At the same time, we had to devise a suitable transport system that would transport the hairpins quickly but stably and would allow for high-precision measurements to take place. The finished solution is: The hairpin is transferred to the transport system by a robot and measured by two parallel scanners at a transport speed of up to 2 m/s. The data is calculated into a point cloud so that the evaluation software can check both the angle of curvature and other dimensions such as leg lengths, stripped areas and straightness of the hairpin legs. The final high-voltage test ensures that no damage was caused to the insulation layer of the hairpin during the bending process.

Reliable and process-stable measured data despite sensitive components - Harrandt technology makes it possible.

The Result

Our hairpin test module now enables an automated test system in which every hairpin is measured and checked for deviations before assembly. Random measurements or manual testing using form templates are no longer necessary. In addition, matching ensures the best possible assembly of the hairpins. Another great advantage of the hairpin module is that it can be easily retrofitted in existing lines.

Our case studies