By implementing our next-generation winding techniques, HONEST Automation has achieved significant breakthroughs in X-pin motor stator production. This technology demonstrates significant advantages in X-pin stator production, driving innovation in next-generation hairpin motor stators.
X-pin: The Evolutionary Direction of Hairpin Motor Winding Technology
Naming and Features of X-pin Technology
X-pin is named for the "X"-shaped overlap of two copper wires at the welding point. Compared to the commonly used Hair-pins and I-pins in the market, the X-pin eliminates the straight-line segment at the welding end, significantly reducing the height and volume of the stator winding end.
Technical Advantages of X-pin
- Space Optimization: X-pin technology is more conducive to the spatial layout of electric drive systems and vehicles.
- Performance Enhancement: Compared to Hair-pins and I-pins, X-pin reduces heat loss in stator copper wires, decreases volume and weight, and improves power density.
- Cost Savings: The X-pin stator production process eliminates the need for cutting, saving costs for customers.
- Flexible Electromagnetic Design: X-pin maintains the flexible electromagnetic concept of motors, making it the "heart" of electric vehicles with stronger kinetic performance.
Manufacturing Challenges and HONEST Automation’s Innovative Solutions
Despite its many advantages, the widespread adoption of X-pin technology has been limited by the complexity of its manufacturing process. Below are the main challenges in X-pin manufacturing and HONEST Automation’s innovative solutions:
Challenge 1: Precision Control in Twisting Process
- Industry Status: Many companies use wire-cutting processes, which increase operational costs.
- HONEST Automation’s Solution: Through the innovative non-cutting hairpin stator twisting machine, HONEST Automation achieves a twisting flatness accuracy of ±0.5mm, ensuring consistency in copper wires and laying the foundation for subsequent welding processes. Our machine provides flexible manufacturing solutions, readily adapting to hairpin, X-pin, and mini-pin motor designs.
Challenge 2: Welding Process Difficulties
- Industry Status: X-pin forms a molten pool at the copper wire overlap, with the welding area close to the insulation coating, risking damage to the coating.
- HONEST Automation’s Solution: Utilizing self-developed pre-welding visual guidance and post-welding visual inspection technologies, HONEST ensures stable welding quality and significantly improves pass rates.
Challenge 3: Improving Insulation Fill Rate
- Industry Status: Traditional drip welding processes have low fill rates, affecting product insulation performance.
- HONEST Automation’s Solution: By adopting innovative dip coating technology and precise temperature-controlled heating, HONEST Automation has increased the insulation fill rate to 96%, with ongoing optimizations. This solution offers significant efficiency gains through rapid energization, low power consumption, and fast cycle times, coupled with high slot fill rates. Its simple design translates to reduced equipment complexity, minimal footprint, and substantial cost savings.
Industry Impact and Future Prospects of X-pin Technology
- Technical Support and Industry Leadership HONEST Automation’s self-developed X-pin stator intelligent manufacturing machines provide strong support for the evolution of hairpin motor technology, driving technological advancements in the new energy vehicle market.
- Continuous Innovation and Industry Empowerment HONEST Automation remains committed to technological innovation, providing more advanced technologies and stable solutions to fuel industry upgrades and support the continuous progress of the electric vehicle industry.
