Hairpin stator
fastest prototyping construction in the world
Hairpins are a trend technology in the field of electric motors. rectangular copper rods replace the coiled copper wires. Additive Drives offers the world’s fastest hairpin prototypes. Our promise: From the idea to the finished stator in 4 weeks!
Wavewinding, X-Pin, Hairpin and Next-Pin
The development of motor technology through additive drives has a significant impact on the overall efficiency of the application. By building small and medium series without tooling costs, the motors can be optimised and adapted for every application. The application of the technology is not limited to the automotive sector, but is also used in aviation, motor racing and industry.
Hairpin stator prototyping
Hairpin stator in just a few days: Our designs are scalable for small, medium and large series. Geometric design and material parameters are compatible with conventional manufacturing.
Voltage class: 48-1200V
Power: up to 800kW
Conductors per slot: 2-12
Size: 70-450mm outer diameter
Scalable for mass production
Benefits: No tooling, No welding, No twisting
Insulation materials: PAI, PI, PEEK
X-Pin
More power with the same installation space: The length of the winding head plays a decisive role in being able to extend the active length of the stator. X-pin technology enables shorter winding heads than conventional hairpin windings and has a significant impact on the power density of a motor.
Hairpin Advanced
Optimised winding heads and our patented NextPin technology enable significantly higher electric motor performance. 3D printing completely rethinks the designs
A new era of hairpin stators with up to 45% more power.
High performance applications
Highest power densities
Minimization of winding head lengths
Scalable for all sizes
Direct oil cooling
Optimized designs and cooling
Insulation materials: PAI, PI, PEEK
Wavewinding prototyping
With its flexible and innovative manufacturing processes, Additive Drives enables the rapid production of prototypes and high-performance small series in the field of shaft winding.
The flat wire wave winding has been specifically developed for electric mobility applications. Its compact design and high number of conductors in the slot make it ideal for high speed, high power density applications. The benefits at a glance:
– Compact design
– High number of wire crossings
– Fewer spot welds for greater process reliability
– Particularly suitable for stators with a high number of slots
Source: Schaeffler ELMOTEC STATOMAT GmbH
Next Pin: The best of both worlds
The Next-Pin combines the advantages of litz wire winding at high speeds with the benefits of hairpin technology in terms of copper fill level and industrialisability. The adapted conductor structure reduces the alternating current losses in the wire.
By using next-pin technology, losses can be reduced by 60% in the automotive sector, for example.
Applications
Electric motors move the world. Our motors are used in a wide variety of products and are customised for every application.