Manufacturing of hairpin stators using collaborative robots

The electrification of the automotive powertrain has a major impact on production systems in related industries. A Berlin-Brandenburg, Germany, based research network engages the challenges of post-combustion production. As part of the research network, a living lab has been developed and set up based on the future needs of the automotive and supplier industry with the latest production technologies, focusing on electric hairpin motors. The living laboratory integrates energy monitoring and production assistant technologies guiding the process independent of the worker’s expertise. Unlike high-volume production, where automated systems are used for inserting hairpins into the stator, the solution involves collaborative robots seamlessly inserting hairpins, offering flexibility across stator types. This innovative approach replaces the manual process, marking a transformative shift in manufacturing techniques for diverse motor applications.