Flat copper hairpin stator assemblies for high slot-fill, 800V-capable EV traction and rare-earth-free motor programs.
Request reference specifications and STEP models without a registration gate. We confirm the correct package after a quick project-fit check.
| Metric | Typical Range | Why It Matters |
|---|---|---|
| Voltage Platform | 400V / 800V class | Determines insulation stack-up, clearance, and validation depth before sample approval. |
| Copper Geometry | Flat wire / rectangular conductor by drawing | Bend repeatability and weld access determine whether the design can scale from sample to pilot. |
| Weld Evidence | Resistance, visual, pull or section review by plan | Hairpin stator quality is often gated by weld consistency, not copper mass alone. |
| Insulation Evidence | Hipot, IR, surge, PD planning | High-voltage stators need insulation proof before inverter and thermal testing. |
| Cooling Interface | Oil spray / water jacket / hybrid review | End-turn and slot thermal assumptions affect continuous torque and stator life. |
| Process Step | Buyer Evidence | Acceptance Gate |
|---|---|---|
| DFM and winding route review | Annotated winding diagram, bend-risk notes, weld access review, and open-issue list. | Copper bar geometry, slot liner stack-up, and end-turn envelope are frozen for samples. |
| Forming, insertion, and weld sampling | Bend repeatability checks, weld-resistance samples, visual inspection notes, and terminal layout photos. | No clearance conflict, weld resistance inside agreed limit, and phase connection route approved. |
| Insulation and electrical validation | Resistance, surge, hipot, insulation resistance, and partial-discharge planning records. | Electrical evidence meets the sample sign-off limits before thermal or dyno testing. |
| Pilot transfer control | Control plan for bending, insertion, welding, varnish/VPI, EOL tests, and outgoing inspection. | Pilot lot can repeat sample results with traceable lot and drawing revision records. |
Yes. Send winding drawings, lamination data, insulation requirements, and target test criteria for DFM review.
Send stator OD/ID, slot count, stack length, winding diagram, conductor size, insulation class, voltage class, terminal layout, and required electrical tests.
Yes, but the quotation should separate hand-built sample assumptions from pilot tooling, welding fixtures, and repeat-production controls.
Typical records include resistance, surge, hipot, insulation resistance, weld resistance sampling, dimensional inspection, and outgoing photos tied to drawing revision.
Inquiry Email
Include target torque/speed, quantity, and delivery location.
