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Servo production and assembly systems
Servo system producing complete electric-motor hairpins from flat wire on the coil
ⓘ Manufacturer data (Bihler BM-HP 3000 page, BM-HP brochure 01/24, b on top 2023); depends on material cross-section and leg length. Values may change and vary; not binding on Boztaş.
Multi-stage straightening, slip-free feeding with the RZV 2.1, cutting, mechanical enamel stripping and pin-end chamfering, 2D pre-bending, 3D die bending and mono-component storage on the same machine; fully automated coil change.
Variants are changed solely by calling up stored data, at a constant machine cycle rate, without downtime or operator intervention; all common hairpin, connection pin and I-pin types can be produced.
A sensor unit continuously measures enamel thickness and the combined thickness of enamel and copper inline; total copper cross-section loss stays below 0.05 mm and the pin ends get a pure metal surface.
Standard hairpin line based on the BIMERIC servo production system; modular process steps, central VariControl VC 1, automatic coil change
Suited to: Industrial mass production of electric-motor stator hairpins
Measurement of the part geometry after 3D die bending and inline adjustment
Suited to: Hairpin geometries with tight tolerances
Additional process modules can be added or the module arrangement changed; defined interfaces on the last module for links to stator lines or turnkey electric-motor systems
Suited to: Complete stator production lines
| Feature | BM-HP 3000 |
|---|---|
| Performance | |
| Output | 60–120 finished hairpins per minute (depending on material cross-section and leg length) |
| Cycle rate | three times that of sequential systems (manufacturer) |
| Material | |
| Material | Enamelled flat copper wire, directly from the coil |
| Part types | Common hairpin, connection pin and I-pin types |
| Process steps | |
| Straightening and feed | Multi-stage straightening; RZV 2.1 servo feed up to 3.2 m/s, slip-free, repeat accuracy ±0.02 mm; three-point surface clamping protects the enamel |
| Cutting | To stretched length with an NC module and cutting punch; no deformation, little burr |
| Stripping and chamfering | Mechanical, NC-controlled enamel stripping; both pin ends chamfered simultaneously; inline measurement of enamel and total thickness; cross-section loss < 0.05 mm |
| Bending | Parallel-cycle 2D swivel pre-bending (geometry programmable) + 3D die bending with NC units |
| Output handling | Removal via conveyor belt for sorting and mono-component storage; interfaces for line links |
| Control | |
| Control | VariControl VC 1, central for all processes |
| Coil change | Fully automated |
| Dimensions and weight | |
| Dimensions / weight | — |
Manufacturer data (Bihler BM-HP 3000 page, BM-HP brochure 01/24, b on top 2023); depends on material cross-section and leg length.
Technical data is taken from information published by the manufacturer. The manufacturer may change it without notice, and values may vary with the model and the machine configuration. The data is for information only and is not binding on Boztaş; binding values are stated only in a written quotation.
Related industries: Automotive
According to the manufacturer, all common hairpin, connection pin and I-pin types, made from enamelled flat copper wire on the coil; output is 60–120 hairpins per minute depending on material cross-section and leg length.
No; stripping is mechanical and NC-controlled. A sensor unit continuously measures enamel and total thickness and the station processes each hairpin individually; total cross-section loss is generally below 0.05 mm, and four-sided chamfering of the ends is part of the same process.
No; variants are changed solely by calling up stored data, at a constant machine cycle rate, without stopping the machine and without operator intervention.
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