Efficient hairpin production

Electric mobility is gaining more and more momentum. Bihler has been involved intensively in the research and development of this new technology for several years and already offers groundbreaking automation solutions.


© Otto Bihler


© Otto Bihler


Automotive suppliers use these solutions to produce battery cell and module connectors completely mounted in carrier frames, ZSB circuits for direct drives, shielding sleeves, busbars as well as hairpins for stators.

At the “wire”, Bihler will present an efficient manufacturing solution for hairpins based on Bihler servo technology.

Complete manufacturing on one system

 The hairpin-like components are responsible for the safe and efficient power transmission in electric motors. They are manufactured with standardized machining processes directly from coils on a “Bimeric” production system. The servo system takes care of all process steps: starting with the highly dynamic, slip-free feeding of the wire, NC-controlled mechanical stripping of the coating with minimal cross-sectional losses, simultaneous chamfering of the pin ends, pre-bending and 3D die bending, through to the final measurement of the component geometry and inline readjustment.

Designed for industrial production

 Variant changes take place “on the fly”. Depending on the variant, the wire cross-section and the pin length, the output is between 60 and 120 hairpins per minute. The cycle speed is therefore around three times higher than with sequential systems, making the Bimeric ideal for industrial production. Additional bending machines, cost-intensive peripheral equipment and space requirements can be reduced by using this complete system.

wire 2020, hall 10 booth F 18

Otto Bihler Maschinenfabrik GmbH+Co. KG
Lechbrucker Strasse 15, 87642 Halblech/Germany
Contact person is Vinzenz Hörmann
Tel.: +49 8368 18-280