What is the state of the art in hairpin forming, inserting, and welding automation?

Hairpin forming is done with CNC hairpin benders or presses that make the shape of the specification. Alliance works directly with suppliers of this type of equipment to integrate into our systems.

Hairpin insertion can be done by populating a fixture and pressing them into the stator. Some OEMs have asked Alliance for different insertion solutions that involve robotics and manual stations.

Hairpin welding requires accurate pin lengths and crowding the pins together that will be welded. Alliance has used laser welding to make the connections, along with the options for TIG and MIG welding.