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WAFIOS: Innovative Production Solutions for Hairpins
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href="/fr/apercu-des-machines/machines-pour-la-mobilite-electrique/machines-de-fabrication-de-hairpis?tx_edxwm_maschinenausgabe%5Baction%5D=listDirect&tx_edxwm_maschinenausgabe%5Bbaureihe%5D=1324&tx_edxwm_maschinenausgabe%5Bcontroller%5D=Baureihe&tx_edxwm_maschinenausgabe%5Bmachine%5D=2142&cHash=dc288a15c299c6c4615054ffc2d4f0d9" hreflang="fr-FR" title="French" class="dropdown-item" ><span class="t3js-icon icon icon-size-small icon-state-default icon-flags-fr" data-identifier="flags-fr"><span class="icon-markup"><img src="/typo3/sysext/core/Resources/Public/Icons/Flags/FR.png" width="16" height="16" alt="" /></span></span> French </a></div></div></div></div><div class="mb-2 mb-lg-0"><div class="nav-item dropdown-center "><a class="nav-link dropdown-toggle fs-5" id="worldwide-menu" href="#" data-bs-toggle="dropdown" role="button" aria-expanded="false"><i class="fa-navlink fa-solid fa-earth-europe"></i></a><div class="dropdown-menu dropdown-menu-center dd-animate-1 slideIn" aria-labelledby="worldwide-menu" data-bs-popper="none"><div class="container"><a href="http://www.wafios.us" target="_self" class="dropdown-item"> WAFIOS US </a><a href="http://www.wafios.com.cn" target="_blank" class="dropdown-item" rel="noreferrer"> WAFIOS CN </a></div></div></div></div></div><button type="button" class="btn btn-link nav-link me-2 fs-5" data-bs-dismiss="offcanvas" aria-label="Close" ><i class="fa-solid fa-xmark"></i></button></div><div class="offcanvas-body"><div class="text-xl-center position-relative nav-motto-container ms-3 ms-xl-0 me-3"><div class="nav-motto-outer mx-xl-2 my-3 my-xl-0"><span class="nav-motto-inner d-inline-block px-xl-3">Products</span></div><div class="navbar-nav main-navbarnav me-auto"><div id="nav-item-3" class="level-1 nav-item dropdown"><a class="d-flex justify-content-between nav-link dropdown-toggle dropdown-item-3 parent-active" id="dropdown-menu-3" href="#" data-bs-toggle="dropdown" role="button" aria-expanded="false" title="Machines" > Machines <i class="fa-solid fa-chevron-down ms-3 mt-1 d-xl-none d-xxl-inline"></i></a><div class="level-2 dropdown-menu dd-animate-1" aria-labelledby="dropdown-menu-3"><a class="level-12 nav-link text-uppercase text-nowrap px-2 parent-active" href="/en/machines" target="_self" title="Machines" > Overview Machines </a><hr class="dropdown-divider"><div class="dropdown dropend"><a id="dropdown-layout-60" href="#" class="my-1 d-flex justify-content-between text-uppercase has-submenu dropdown-item dropdown-toggle dropdown-item-60 parent-active" data-bs-toggle="dropdown" aria-haspopup="true" aria-expanded="false" > Machines for E-Mobility <i class="fa-solid fa-chevron-right ms-3 mt-1 d-none d-xl-inline"></i><i class="fa-solid fa-chevron-down ms-3 mt-1 d-inline d-xl-none"></i></a><div class="dropdown-submenu dropdown-menu dd-animate-1" aria-labelledby="dropdown-layout-60"><a class="level-12 nav-link text-uppercase text-nowrap px-2 parent-active" href="/en/machines/machines-for-e-mobility" target="_self" title="Machines for E-Mobility" > Machines for E-Mobility </a><hr class="dropdown-divider"><a class="dropdown-item text-uppercase dropdown-item-1690" href="/en/machines/machines-for-e-mobility/sample-part-production" title="Sample Part Production" target="_self" > Sample Part Production </a><a class="dropdown-item text-uppercase dropdown-item-72 active" href="/en/machines/machines-for-e-mobility/hairpin-machines" title="Hairpin Machines" target="_self" aria-current="page"> Hairpin Machines </a><a class="dropdown-item text-uppercase dropdown-item-73" href="/en/machines/machines-for-e-mobility/busbar-machines" title="Busbar Machines" target="_self" > Busbar Machines </a><a class="dropdown-item text-uppercase dropdown-item-74" href="/en/machines/machines-for-e-mobility/inductor-coil-machines" title="Inductor Coil Machines" target="_self" > Inductor Coil Machines </a></div></div><div class="dropdown dropend"><a id="dropdown-layout-61" href="#" class="my-1 d-flex justify-content-between text-uppercase has-submenu dropdown-item dropdown-toggle dropdown-item-61" data-bs-toggle="dropdown" aria-haspopup="true" aria-expanded="false" > Spring Machines <i class="fa-solid fa-chevron-right ms-3 mt-1 d-none d-xl-inline"></i><i class="fa-solid fa-chevron-down ms-3 mt-1 d-inline d-xl-none"></i></a><div class="dropdown-submenu dropdown-menu dd-animate-1" aria-labelledby="dropdown-layout-61"><a class="dropdown-item text-uppercase dropdown-item-76" href="/en/machines/spring-machines/compression-spring-machines" title="Compression Spring Machines" target="_self" > Compression Spring Machines </a><a class="dropdown-item text-uppercase dropdown-item-81" href="/en/machines/spring-machines/spring-end-grinding-machines" title="Spring End grinding Machines" target="_self" > Spring End grinding Machines </a><a class="dropdown-item text-uppercase dropdown-item-77" href="/en/machines/spring-machines/torsion-spring-machines" title="Torsion Spring Machines" target="_self" > Torsion Spring Machines </a><a class="dropdown-item text-uppercase dropdown-item-1716" href="/en/machines/machines-for-e-mobility/inductor-coil-machines" title="Inductor Coil Machines" target="_self" > Inductor Coil Machines </a><a class="dropdown-item text-uppercase dropdown-item-78" href="/en/machines/spring-machines/extension-spring-machines" title="Extension Spring Machines" target="_self" > Extension Spring Machines </a><a class="dropdown-item text-uppercase dropdown-item-79" href="/en/machines/spring-machines/wave-spring-ring-coiling-machines" title="Wave Spring & Ring Coiling Machines" target="_self" > Wave Spring & Ring Coiling Machines </a><a class="dropdown-item text-uppercase dropdown-item-80" href="/en/machines/spring-machines/spiral-spring-machines" title="Spiral Spring Machines" target="_self" > Spiral Spring Machines </a></div></div><div class="dropdown dropend"><a id="dropdown-layout-62" href="#" class="my-1 d-flex justify-content-between text-uppercase has-submenu dropdown-item dropdown-toggle dropdown-item-62" data-bs-toggle="dropdown" aria-haspopup="true" aria-expanded="false" > Wire Bending Machines <i class="fa-solid fa-chevron-right ms-3 mt-1 d-none d-xl-inline"></i><i class="fa-solid fa-chevron-down ms-3 mt-1 d-inline d-xl-none"></i></a><div class="dropdown-submenu dropdown-menu dd-animate-1" aria-labelledby="dropdown-layout-62"><a class="level-12 nav-link text-uppercase text-nowrap px-2" href="/en/machines/wire-bending-machines" target="_self" title="Wire Bending Machines" > Wire Bending Machines </a><hr class="dropdown-divider"><a class="dropdown-item text-uppercase dropdown-item-85" href="/en/machines/wire-bending-machines/wire-bending-machines" title="Wire Bending Machines" target="_self" > Wire Bending Machines </a><a class="dropdown-item text-uppercase dropdown-item-86" href="/en/machines/wire-bending-machines/multiple-head-wire-bending-machines" title="Multiple-Head Wire Bending Machines" target="_self" > Multiple-Head Wire Bending Machines </a><a class="dropdown-item text-uppercase dropdown-item-1674" href="/en/machines/wire-bending-machines/transfer-bending-machine" title="Transfer Bending Machine" target="_self" > Transfer Bending Machine </a></div></div><div class="dropdown dropend"><a id="dropdown-layout-63" href="#" class="my-1 d-flex justify-content-between text-uppercase has-submenu dropdown-item dropdown-toggle dropdown-item-63" data-bs-toggle="dropdown" aria-haspopup="true" aria-expanded="false" > Tube bending machines <i class="fa-solid fa-chevron-right ms-3 mt-1 d-none d-xl-inline"></i><i class="fa-solid fa-chevron-down ms-3 mt-1 d-inline d-xl-none"></i></a><div class="dropdown-submenu dropdown-menu dd-animate-1" aria-labelledby="dropdown-layout-63"><a class="level-12 nav-link text-uppercase text-nowrap px-2" href="/en/machines/tube-bending-machines" target="_self" title="Tube bending machines" > Tube bending machines </a><hr class="dropdown-divider"><a class="dropdown-item text-uppercase dropdown-item-97" href="/en/machines/tube-bending-machines/tube-bending-centers" title="Tube bending centers" target="_self" > Tube bending centers </a><a class="dropdown-item text-uppercase dropdown-item-68" href="/en/machines/tube-bending-machines/single-head-tube-bending-machines" title="Single-head tube bending machines" target="_self" > Single-head tube bending machines </a><a class="dropdown-item text-uppercase dropdown-item-69" href="/en/machines/tube-bending-machines/multi-head-tube-bending-machines" title="Multiple-head tube bending machines" target="_self" > Multiple-head tube bending machines </a><a class="dropdown-item text-uppercase dropdown-item-200" href="https://www.wafios-wta.com/home/" title="Tube forming machines" target="_self" > Tube forming machines </a></div></div><div class="dropdown dropend"><a id="dropdown-layout-64" href="#" class="my-1 d-flex justify-content-between text-uppercase has-submenu dropdown-item dropdown-toggle dropdown-item-64" data-bs-toggle="dropdown" aria-haspopup="true" aria-expanded="false" > Straightening Machines <i class="fa-solid fa-chevron-right ms-3 mt-1 d-none d-xl-inline"></i><i class="fa-solid fa-chevron-down ms-3 mt-1 d-inline d-xl-none"></i></a><div class="dropdown-submenu dropdown-menu dd-animate-1" aria-labelledby="dropdown-layout-64"><a class="dropdown-item text-uppercase dropdown-item-71" href="/en/machines/straightening-machines/smooth-steel-straightening-machines" title="Smooth Steel Straightening Machines" target="_self" > Smooth Steel Straightening Machines </a><a class="dropdown-item text-uppercase dropdown-item-70" href="/en/machines/straightening-machines/reinforcing-steel-straightening-machines" title="Reinforcing Steel Straightening Machines" target="_self" > Reinforcing Steel Straightening Machines </a></div></div><div class="dropdown dropend"><a id="dropdown-layout-65" href="#" class="my-1 d-flex justify-content-between text-uppercase has-submenu dropdown-item dropdown-toggle dropdown-item-65" data-bs-toggle="dropdown" aria-haspopup="true" aria-expanded="false" > Chain Manufacturing Machines <i class="fa-solid fa-chevron-right ms-3 mt-1 d-none d-xl-inline"></i><i class="fa-solid fa-chevron-down ms-3 mt-1 d-inline d-xl-none"></i></a><div class="dropdown-submenu dropdown-menu dd-animate-1" aria-labelledby="dropdown-layout-65"><a class="dropdown-item text-uppercase dropdown-item-87" href="/en/machines/chain-machines/chain-bending-machines" title="Chain Bending Machines" target="_self" > Chain Bending Machines </a><a class="dropdown-item text-uppercase dropdown-item-88" href="/en/machines/chain-machines/chain-welding-machines" title="Chain Welding Machines" target="_self" > Chain Welding Machines </a><a class="dropdown-item text-uppercase dropdown-item-293" href="/en/machines/chain-machines/translate-to-english-kettenkalibriermaschinen" title="Chain calibrating machine" target="_self" > Chain calibrating machine </a></div></div><div class="dropdown dropend"><a 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aria-labelledby="worldwide-menu" data-bs-popper="none"><div class="container"><a href="http://www.wafios.us" target="_self" class="dropdown-item"> WAFIOS US </a><a href="http://www.wafios.com.cn" target="_blank" class="dropdown-item" rel="noreferrer"> WAFIOS CN </a></div></div></div></div></div></div><div id="direct-contact-offcanvas" class="offcanvas-footer d-block d-xl-none"><div id="c26" class="text-start d-none fixedGroupButton fixedPosition fixedPosition-right"><div class="btn-group-vertical btn-group-lg rotateFixedPosition rotate-0" role="group" aria-label="btn-26"><a href="/en/your-personal-contact-1#c1448" class="m-0 rounded-0 p-3 fs-3 btn btn-outline-primary" id="c27" role="button"><i class="fa-solid fa-phone m1 me-1"></i><span>Contact Phone</span></a><a href="/en/your-personal-contact-1#c1325" class="m-0 rounded-0 p-3 fs-3 btn btn-outline-primary" id="c30" role="button"><i class="fa-solid fa-envelope m-1 me-1"></i><span>Contact E-mail</span></a><a href="https://shop.wafios.com/" target="_blank" class="m-0 rounded-0 p-3 fs-3 btn btn-outline-primary" id="c63" role="button" rel="noreferrer"><i class="fa-solid fa-cart-shopping m-1 me-1"></i><span>Webshop</span></a></div></div></div></div></div></nav><div id="s72" class="jumbotron background-image p-5 mb-4 rounded-0"><div class="jumbotron-content"><div class="container"><div id="c138" class="text layout-102 text-dark bg-light border border-dark wafios" ><header class="header-138 h-1 text-start text-primary"><h1 class="text-primary"> Hairpin Machines </h1><h4 class="subheader text-dark"> Hairpins, I pins, stator connection assemblies and inductor coils for axial flux and radial flux motors </h4></header></div></div></div></div><nav aria-label="breadcrumb"><div class="container"><ol class="breadcrumb rounded-0"><li class="breadcrumb-item"><a href="/en/" title="Innovations for Wire and Tube" ><i class="fa-solid fa-house"></i></a></li><li class="breadcrumb-item"><a href="/en/machines" title="Machines" > Machines </a></li><li class="breadcrumb-item"><a href="/en/machines/machines-for-e-mobility" title="Machines for E-Mobility" > Machines for E-Mobility </a></li><li class="breadcrumb-item active" aria-current="page"> Hairpin Machines </li></ol></div></nav><div id="page-content" ><main class="main-content"><div class="container"><div id="c909" class="text my-5" ><header class="header-909 h-2 text-center"><h2> Powerful Solutions for Electric Drives </h2></header></div></div><div class="container"><div id="c908" class="text my-5" ><p class="text-center">Hairpins are bent parts made of insulated, enameled copper wire. They are used in the modern electric motors found in electric cars, hybrid vehicles, and e-bikes, where they replace the wound inductor coils that are part of conventional stators. Hairpin motors improve the power-to-weight ratio due to the packing density of the profile material.</p><p class="text-center">WAFIOS offers state-of-the-art bending technology for producing hairpins, covering everything from small batches up to high volumes.</p></div></div><div id="c1597" class="list my-5" ><header class="header-1597 h-0 text-center"><h1> Machines </h1></header><div class="tx-edx-wm"> <script type="text/javascript"> let machineLink = '/en/machines/machines-for-e-mobility/hairpin-machines?tx_edxwm_maschinenausgabe%5Baction%5D=getMachineData&type=210471&cHash=1fc5b94e2a085e6e598763c5d26d38f1'; let baureiheText = '/en/machines/machines-for-e-mobility/hairpin-machines?tx_edxwm_maschinenausgabe%5Baction%5D=getBaureiheText&type=210471&cHash=befe3bd2c297c04be1f989738bf092a3'; let filterLink = '/en/machines/machines-for-e-mobility/hairpin-machines?tx_edxwm_maschinenausgabe%5Baction%5D=getFilterData&type=210471&cHash=a3149dea97d4a30b4487b752aadb2ed4'; </script> <div id="baureihe-slider"> <div class="container"> <div class="baureihe-list-item px-4 "> <a data-machine="2235" data-baureihe="1350" data-url="/en/machines/machines-for-e-mobility/hairpin-machines/series/SpeedFormer?type=210471" data-urlmachinedata="/en/machines/machines-for-e-mobility/hairpin-machines/detail/SpeedFormer?type=210471" data-urlbaureihetext="/en/machines/machines-for-e-mobility/hairpin-machines?tx_edxwm_maschinenausgabe%5Baction%5D=getBaureiheText&tx_edxwm_maschinenausgabe%5Bbaureihe%5D=1350&type=210471&cHash=1df2e03202fa4b4670bd1b54c920b19b" data-urlfilterdata="/en/machines/machines-for-e-mobility/hairpin-machines?tx_edxwm_maschinenausgabe%5Baction%5D=getFilterData&tx_edxwm_maschinenausgabe%5Bbaureihe%5D=1350&type=210471&cHash=24498ff500e79a5c063cb1ba73df7fe0" href="/en/machines/machines-for-e-mobility/hairpin-machines/SpeedFormer"> <figure class="baureihe-slider-image mb-4"> <img class="img-fluid d-block" src="/fileadmin/_processed_/a/5/csm_SpeedFormer_-600x400pixel_300ppi_5684d85a3c.png" width="400" height="267" alt="" /> </figure> <div class="baureihe-slider-text"> <h3>SpeedFormer</h3> <p>Flexible system for series production of hairpins</p> </div> </a> </div> <div class="baureihe-list-item px-4 active"> <a data-machine="2199" data-baureihe="1324" data-url="/en/machines/machines-for-e-mobility/hairpin-machines/series/FMU%20E?type=210471" data-urlmachinedata="/en/machines/machines-for-e-mobility/hairpin-machines/detail/FMU%2040%20E?type=210471" data-urlbaureihetext="/en/machines/machines-for-e-mobility/hairpin-machines?tx_edxwm_maschinenausgabe%5Baction%5D=getBaureiheText&tx_edxwm_maschinenausgabe%5Bbaureihe%5D=1324&type=210471&cHash=fcf8fd61f9c5e43e7bf7abc10e2b5c9a" data-urlfilterdata="/en/machines/machines-for-e-mobility/hairpin-machines?tx_edxwm_maschinenausgabe%5Baction%5D=getFilterData&tx_edxwm_maschinenausgabe%5Bbaureihe%5D=1324&type=210471&cHash=e7d7106f1b2a625e4e2756ea3653b1b8" href="/en/machines/machines-for-e-mobility/hairpin-machines/FMU%20E"> <figure class="baureihe-slider-image mb-4"> <img class="img-fluid d-block" src="/fileadmin/_processed_/5/d/csm_I_FMU40E_012_EasyRobot_V1-1_ALL_-600x400pixel_300ppi_acab678bd9.png" width="400" height="267" alt="" /> </figure> <div class="baureihe-slider-text"> <h3>FMU E</h3> <p>Universal production system for hairpins, stator<br> connection assemblies and inductor coils for axial flux motors</p> </div> </a> </div> </div> </div> <section class="py-5 my-5 bg-light"> <div class="container"> <div id="baureihe-selected-compare"> <h2>Machine comparison FMU E</h2> <ul> <li>Unique machine concept for producing hairpins and stator connection assemblies , and for expanding the FMU series in the field of e-mobility</li> <li>Bending process simulation opens up new possibilities, especially with regard to feasibility or collision monitoring</li> <li>Patented hairpin tool system combines active rotary-draw bending with the agility of conventional wire bending tools, prevents the material from slipping, and increases the quality of complicated geometries</li> <li>Newly developed feed unit prevents deformations in the profiled material and – together with the patented tool system – enables positioning of end legs</li> <li>WPS 3.2 EasyWay programming system offers easy, geometric programming and a clearly arranged overview of the materials and tools used</li> <li>The FMU E series can be complemented by insulation stripping, burr-optimized cutting and chamfering modules.</li> </ul> </div> <div id="baureihe-selected-filter"> <div class="container"> <p>Please select Profilquerschnitt [mm²]</p> <div class="range_slider"> <input id='range1' type="range" value="14.125" min="2" max="30.25" step="0.01"> <div class="range_labels"> <span>2 mm²</span><span id='val1' class="rval">14.125 mm²</span><span>30.25 mm²</span> </div> </div> <div class="filter-button-reset mb-5"> <button id="filter-reset" class="btn btn-fancy"><i class="fa-solid fa-arrow-rotate-left"></i> Reset filter</button> </div> </div> </div> <div id="baureihe-selected-machines"> <div class="machine-cards-list"> <a data-min="2" data-max="30.25" data-url="/en/machines/machines-for-e-mobility/hairpin-machines/detail/FMU%2040%20E?type=210471" title="FMU 40 E" href="/en/machines/machines-for-e-mobility/hairpin-machines/FMU%20E/FMU%2040%20E"> <div class="machine-list-item active"> <h4>FMU 40 E <span>from 2<br />to 30.25 mm²</span> </h4> <table> <tr> <td>Tensile strength max.</td> <td> 400 N/mm² </td> </tr> <tr> <td>Cross section max.</td> <td> 30.25 mm </td> </tr> <tr> <td>Thickness max.</td> <td> 5.5 mm </td> </tr> <tr> <td>Width max.</td> <td> 10.0 mm </td> </tr> <tr> <td>Bend-back clearance max.</td> <td> 450 mm </td> </tr> <tr> <td>Stroke vertical table</td> <td> + 55 / - 175 mm </td> </tr> <tr> <td>Stroke horizontal table</td> <td> +/ - 90 </td> </tr> <tr> <td>Slider stroke</td> <td> 130 mm </td> </tr> <tr> <td>Dimensions w x d x h</td> <td> 2,040 x 3,120 x 2,400 mm </td> </tr> <tr> <td>Weight without pay-off unit</td> <td> approx. 5,900 kg </td> </tr> <tr> <td>Upgradable to max. CNC axes</td> <td> 24 </td> </tr> <tr> <td>Profile cross-sections in [mm²]</td> <td> 2 - 30.25 mm² </td> </tr> </table> </div> </a> </div> </div> </div> </section> <div id="baureihe-selected-machine-single" class="mb-5"> <div class="machine-single-header container"> <h2>FMU 40 E</h2> <p><strong>FMU E – revolutionary rotary-draw bending process for hairpin production</strong><br> This flexible new process means that the majority of hairpin geometries for a stator, including the stator connector parts required, can be manufactured in any sequence without the need to change tools. The patent-pending bending process enables bending work to be accurate and free of physical damage.</p> <p><strong>Outstanding flexibility with WPS 3.2 EasyWay programming system</strong><br> Flexibility depends on the geometric programming of bending parts and/or hairpins. The geometric programming dispenses with the need for the user to program individual CNC axes. This speeds up the definition of hairpin geometries. The WAFIOS WPS 3.2 EasyWay control unit also allows you to import 3D geometries automatically with STEP / IGES files. After the coordinates have been imported, the required bending program can be produced automatically.</p> </div> <div class="container mt-5" id="machine-single-downloads-container" > <h3>Further information</h3> <div class="col-lg-6 offset-lg-3"> <form> <div class="form-group"> <label for="downloads-language-selection">Show Documents from Language</label> <select class="form-control" id="downloads-language-selection"> <option value="-1">All</option> <option value="0">German</option> <option selected value="1">English</option> </select> </div> </form> </div> <div class="machine-single-downloads show-language-1"> <div class="download-item language-0"> <div class="download-image"> <img alt="L_FMUE_V1-2_DE.pdf" src="/fileadmin/_processed_/2/2/csm_L_FMUE_V1-2_DE_dbed553a62.png" width="170" height="240" title="FMU E" /> </div> <div class="download-info"> <div><b> FMU E</b> <small>(German)</small> <br><br> </div> <a 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