This year the 1st Reutlingen E-Mobility Days – RED will take place.
The presentation around the revolutionary WAFIOS hairpin bending technology will be joined the companies Trumpf, Zeltwanger, Zeiss, Gom, Harrandt, Gebauer und Griller, Copaltec, Röscher und Witels-Albert have joined together.

RED focuses on the entire hairpin production process: bending technology, stripping with laser, welding and measuring technology. The result is a unique event that continues to grow with new exciting companies and solutions. Experience with us the revolution of hairpin manufacturing!

SpeedFormer

Flexible series production of hairpins

  • All hairpin geometries of a stator can be produced economically in batch size 1 by one machinery system
  • Reliable concept - From the development phase to series production thanks to our WAFIOS production technology integrated in prototypes as well as large-volume series
  • High output combined with minimum space requirements and low investment costs
  • Quality control by integrated verification of geometry features, e.g. leg position or contact surface, using intelligent camera technology
  • Flexible change of hairpin geometries without retooling due to 3d bending technology that does not require any shape-dependent tools

FMU 32 E, FMU 40 E

Hairpin bending machines for small series of hairpins

  • The simulation of the bending process opens new possibilities in the e-mobility sector, e.g. as a tool for feasibility analyses or collision control
  • The WAFIOS tool system for hairpins combines active rotary-draw bending with the agility of conventional wire bending tools. It prevents the material from slipping and increases the quality of complicated geometries
  • The newly developed infeed unit prevents deformations of the profiled material and enables - together with the tool system - the positioning of end legs
  • Our programming system WPS 3.2 EasyWay offers easy, geometrical programming and a clearly arranged overview of the materials and tools used
  • The production process of the FMU E series can be complemented by insulation stripping, burr-optimized cutting and chamfering modules

BMF 60

Busbar bending machine

  • Highest precision, even when processing smallest bending radii with minimum bending distances, due to specially designed bending tool
  • The cutting unit, designed for cutting off flat material, achieves optimum cutting quality, especially with respect to busbars
  • Unique twisting unit enables the production of very complicated bending geometries and an in-process change of bending levels (so-called "twisting"
  • Highest productivity as insulation stripping process via laser is fully integrated in the production process
  • High degrees of freedom during the insulation stripping process enable a flexible positioning of contact points
  • Machine-independent programming station and new simulation software for flat material enable feasibility tests directly at the customer's site

FTU 1.5, FTU 2.5

Bending machines for the serial production of copper coils

  • Significant increase in performance ensures optimized unit costs, especially in large-volume production
  • Highest quality, repeat accuracy and energy efficiency thanks to state-of-the-art drive technology
  • Application possibilities are more flexible and set-up times are shorter due to WAFIOS WPS 3.2 EasyCam
  • High compatibility with existing sets of tools from the FTU series
  • Insulation stripping device for the production of copper coils can be used (option)

Copaltec GmbH

Casting of stators

  • Optimum connection between component and cooling element
  • Reduction of operating temperature by more than 30 °C
  • Continuous output increased by more than 20%
  • Efficiency factor increased by 3%

ZELTWANGER Automation

Hairpin welding, X-CELL LRA flexible and modular

  • All-in-one hairpin welding system in the tightest of spaces based on the modular X-CELL LRA processing cell, the ZELTWANGER clamping device and an optimized process monitoring system.
  • The hairpin welding cell can be integrated into all production lines thanks to the freely selectable, standardized loading and unloading variants, e.g. from robot loading, tilting table, belt circulation or manual loading.
  • Optimal alignment of the pin geometry
  • Flexibly scalable for different product variants within a production line.

WITELS-ALBERT GmbH

Guiding straightening and feeding of process materials

  • Reliable components with high power density for the production of bus bars and hairpins
  • High variety of variants in different sizes
  • Actively configurable straighteners and straightening systems
  • Ready-to-install systems with features on demand
  • Semi-automatic straightening technology
  • Process simulation and Inline Wire Diagnosis

Feinwerktechnik Otto Harrandt GmbH

Wire inspection module

  • Measurement of the exact insulation layer thickness (±2,5 µm)
  • Determination of the outer geometry, raised and recessed defects (1 x 1 mm) and the position of the copper core in the conductor
  • Breakdown test (up to 6 kV)
  • Traceability for the exact position reference (up to 2 m/s)
  • 100% in-line solution with master AI database

Gebauer & Griller Metallwerk GmbH

Winding wires for e-mobility

  • State-of-the-art electric motors for automotive applications require new and sophisticated solutions - especially in the field of stator winding and insulation materials
  • GG - as a specialist for flat insulated copper winding wires for decades - developed different solutions suitable for variable applications, voltage levels and other special requests
  • Available solutions include: PAI-enameled flat wires, extruded PEEK insulated flat & round wires, extruded polyimide insulated flat & round wires, polyimide-film insulated flat & round wires

GOM  GmbH

Precise industrial 3D metrology, ATOS Q: The new compact outperformer

  • Powerful 3D scanner for complex inspection tasks
  • Compact dimensions of 340 mm x 240 mm x 83 mm and weight under 4 kg
  • Lightweight and flexible system with interchangeable lenses for small to medium-sized components
  • Measuring fields from 100 x 70 mm2 to 500 x 370 mm2
  • Two camera resolutions: 12 M and 8 M
  • Inspect with the latest GOM inspection software GOM Inspect Suite
  • Proven reliability and fast with real ATOS DNA
  • Protected optics and electronics for harsh production environments
  • Manual, semi-automated or automated operation possible
  • Maximum efficiency in the ATOS ScanBox 4105: Fast execution of serial measurements, reproducible measurement results and reduced operator influencee

Röscher GmbH

Construction and special equipment manufacturer for e-mobility

Röscher GmbH provides services in construction and special machine building and has special know-how in the following process steps of the production of hairpin stators:

  • 3D modelling of hairpin stators according to winding scheme
  • Insertion of insulation paper
  • Mounting and insertion of hairpin
  • Widening & twisting of hairpin stators
  • Cutting / shortening of hairpins in the stator

TRUMPF Laser- und Systemtechnik GmbH

Laser decoating

  • High Power Short Pulse Laser TruMicro with tailored beam profile for high fill factors
  • Fastest processing for all insulation types and layer thicknesses without copper removal
  • Scalable optics concept individual to wire size

Laser contactings

  • High Power TruDisk Laser, freely programmable scanning optics PFO and Vision Line Sensor System
  • Welding with low spattering and free of porosities using Bright Line Weld Multi-Spot waveguide
  • Scalable Power- and waveguide concept individual to wire size and arrangement
  • TRUMPF experts support in laser process development and realization with all technologies

You want to see all the innovations live in Reutlingen?

Please make your personal appointment
directly with Mr. Bauer

Martin Bauer
Manager - Technical Sales, E-Mobility

Phone  +49 7121 146-219
E-Mail  emobility@wafios.de