What needed to be engineered.
A leading electric powertrain manufacturer required a multi-station automated line to assemble stator cores and insert pre-formed hairpin copper windings under a strict 45-second takt time.
The process demanded zero manual handling deformation, ±12 µm radial insertion clearance, and 100% inline electrical insulation resistance (dielectric) testing before downstream varnishing.
How Draftdu solved it.
Draftdu engineered a synchronized 6-station rotary indexing assembly cell featuring servo-driven precision insertion tooling, a 6-axis robotic arm with custom vision-guided EOAT for hairpin alignment, and an automated high-potential (Hi-Pot) electrical test station.
We implemented closed-loop force-displacement monitoring on every insertion press and programmed custom safety interlocks with Omron light curtains and Siemens S7-1500 PLC control.
Measurable shop-floor results.
Cycle time was reduced from 68 seconds to 43 seconds (36% improvement), achieving consistent ±10 µm radial concentricity. Over 150,000 stator assemblies have been manufactured with zero field dielectric failures.
Engineering stack
Our senior engineering team can review your station cycle time, payload requirements, and part drawings.
Consult with Our Engineers ↗