In the production of high-performance electric motors, consistency at the smallest level can define the reliability of the entire system. Recently, CHCD achieved a major manufacturing milestone in the mass production of its 108-slot, 8-layer hairpin stator platform — successfully delivering uniform quality across all 432 welding points of the stator assembly.
This breakthrough marks an important step forward in overcoming one of the key challenges in large-scale hairpin stator manufacturing: maintaining stable welding quality and dimensional accuracy throughout complex production processes.
Tackling the Core Challenges of Hairpin Stator Production
The 108-slot, 8-layer hairpin stator structure presents significant technical demands across multiple manufacturing stages, particularly in forming precision, wire positioning, and welding consistency.
To improve both production efficiency and product reliability, CHCD’s engineering team focused on optimizing three critical processes:
Precision Hairpin Forming
CHCD redesigned the forming tooling structure to eliminate burrs on copper wire edges and reduce deformation during processing. By improving wire-end consistency at the source, the company established a more stable foundation for downstream assembly and welding operations.
Twisting & End Alignment Optimization
The engineering team standardized wire pressing and flaring parameters to achieve more consistent stator shaping. In parallel, CHCD upgraded the equipment control system and introduced a floating adjustment mechanism for the twisting process, significantly improving stator positioning accuracy during fixture loading.
These improvements effectively minimized wire-end misalignment and dimensional deviations after twisting.
Advanced Welding Process Development
Traditional welding pad methods were replaced with precision copper-wire clamping technology, enabling more stable weld positioning while reducing manual operation intensity.
Through repeated process validation and parameter optimization for fine-diameter copper wire welding, CHCD established a highly controlled welding process capable of maintaining consistent quality across all 432 weld points.
Engineering Consistency for Next-Generation Electric Motors
For high-speed and high-efficiency electric motors, welding consistency directly impacts electrical conductivity, thermal performance, durability, and overall motor efficiency.
By achieving stable and repeatable welding quality at scale, CHCD has further strengthened its manufacturing capabilities in advanced hairpin stator production — supporting the growing demand for high-efficiency rotating electrical systems in automotive and new energy applications.
With nearly 60 years of manufacturing experience, CHCD continues to focus on precision engineering, process innovation, and quality-driven production to deliver reliable rotating electrical solutions for global customers.
