Typical Process Flow of Flat Wire Motor Stators  

Flat wire motors are commonly used in the new energy vehicle industry. These motors enhance performance by pressing multiple flat copper wires into insulating layers.

In the manufacturing process of flat wire motor stators, FOUK grippers are widely used for precise gripping, positioning, and handling of stators and their components. Key applications include inter-process transfer, stator flipping, and coil flaring.

  Inter-Process Transfer of the Stator  

The weight of flat wire stators is generally under 30 kg. Grippers are used to move stators from one workstation to another.
TR or TZ series grippers are suitable for this task. These models can be configured with self-locking and dustproof options to ensure safety and environmental adaptability.

Commonly used models: TZ125 / TZ160 / TR102 / TR115

  Stator Flipping  

During the coil insertion process, the gripper is used to flip the stator.A TP-TR series combined gripper is commonly chosen:

• The TR gripper provides stable clamping

• The TP gripper offers 180° rotation with an in-house developed high-performance buffer system, ensuring smooth and stable flipping.

 On-site usage of TP50-TR102 combined gripper

  Coil Flaring  

In this process, the ends of the coils (the flared portions) are shaped for subsequent twisting and welding.
The goal is to ensure proper electrical connection between coil ends and end rings.

Because the coils are small and require precise clamping, the TR28-64 gripper is an ideal choice — compact yet offers reliable gripping force.

Diagram: Coil flaring process

  FOUK's Expertise in Flat Wire Motor Manufacturing  

Flat wire stators contain numerous copper wires of different lengths.During gripping, these wires must be avoided, which requires long gripper fingers.

However, longer fingers increase the risk of housing deformation, leading to unreliable clamping.To solve this, FOUK has developed a gear-guided gripper (toothed guide rail), significantly enhancing gripping strength and stability.

Photo: Toothed guide rail gripper