Powerful Solutions for Electric Drives
Hairpins are bent parts made of insulated, enameled copper wire. They are used in the modern electric motors found in electric cars, hybrid vehicles, and e-bikes, where they replace the wound inductor coils that are part of conventional stators. Hairpin motors improve the power-to-weight ratio due to the packing density of the profile material.
WAFIOS offers state-of-the-art bending technology for producing hairpins, covering everything from small batches up to high volumes.
Machines
Machine comparison FUL Series
- High output, high flexibility
- Future-oriented machine concept, individual configuration for all kinds of application
- Convenient programming system WPS 3.2 EasyWay increases machine availability
- High quality standards ensure zero-defect production
- iQ Functions - Enhanced efficiency through intelligent process control
Please select wire diameter [mm]
FUL 16
from 0.12
to 0.8 mm
| Wire diameter | 0.12 - 0.8 mm |
| Wire strength | Rm = 2,600 N/mm² |
| Spring index | ≥4 |
| Outer spring diameter | max. 20 mm |
| Coiling direction | right and left |
| Feed speed | max. 240 m/min |
FUL 16+
from 0.12
to 0.8 mm
| Wire diameter | 0.12 - 0.8 mm |
| Wire strength | Rm=2600 N/mm² |
| Spring index | ≥4 |
| Outer spring diameter | max. 20 mm |
| Coiling direction | rechts und links |
| Feed speed | max. 260 m/min |
FUL 26+
from 0.2
to 1.6 mm
| Wire diameter | 0.2 - 1.6 mm |
| Wire strength | Rm = 2,300 N/mm² |
| Spring index | ≥4 |
| Outer spring diameter | max. 45 mm |
| Coiling direction | Right, left as option |
| Feed speed | max. 240 m/min |
FUL26+ 4speed
from 0.5
to 1.6 mm
| Wire diameter | 0.2 - 1.6 mm |
| Wire strength | Rm = 2,300 N/mm² |
| Spring index | ≥4 |
| Outer spring diameter | max. 45 mm |
| Coiling direction | Right, left as option |
| Feed speed | max. 240 m/min |
FUL 36+
from 0.5
to 3 mm
| Wire diameter | 0.5 - 3 mm |
| Wire strength | Rm = 2,300 N/mm² |
| Spring index | ≥4 |
| Outer spring diameter | max. 65 mm |
| Coiling direction | Right, left as option |
| Feed speed | max. 220 m/min |
FUL36+ 4speed
from 1
to 2.8 mm
| Wire diameter | 1 - 2.8 mm |
| Wire strength | Rm = 2,300 N/mm² |
| Spring index | ≥4 |
| Outer spring diameter | max. 65 mm |
| Coiling direction | Right, left as option |
| Feed speed | max. 500 m/min |
FUL 46
from 0.9
to 4.5 mm
| Wire diameter | 0.9 - 4.5 mm |
| Wire strength | Rm = 2,100 N/mm² |
| Spring index | ≥4 |
| Outer spring diameter | max. 95 mm |
| Coiling direction | Left, right as option |
| Feed speed | max. 175 m/min |
FUL56
from 1.5
to 5 mm
| Wire diameter | 1.5 - 5 mm |
| Wire strength | Rm = 2,100 N/mm² |
| Spring index | ≥4 |
| Outer spring diameter | max. 95 mm |
| Coiling direction | Right, left as option |
| Feed speed | max. 150 m/min |
FUL 76
from 2.1
to 7.5 mm
| Wire diameter | 2.1 - 7.5 mm |
| Wire strength | Rm = 2,200 N/mm² |
| Spring index | ≥4 |
| Outer spring diameter | max. 140 mm |
| Coiling direction | right and left |
| Feed speed | max. 130 m/min |
FUL 86
from 3.1
to 8 mm
| Wire diameter | 3.1 - 8 mm |
| Wire strength | Rm = 2,000 N/mm² |
| Spring index | ≥4 |
| Outer spring diameter | max. 150 mm |
| Coiling direction | Right, left as option |
| Feed speed | max. 130 m/min |
FUL 126
from 5.1
to 12 mm
| Wire diameter | 5.1 - 12 mm |
| Wire strength | Rm = 2,200 N/mm² |
| Spring index | ≥4 |
| Outer spring diameter | max. 220 mm |
| Coiling direction | Right, left as option |
| Feed speed | max. 100 m/min |
FUL 166
from 6.1
to 16 mm
| Wire diameter | 6.1 - 16 mm |
| Wire strength | Rm = 2,000 N/mm² |
| Spring index | ≥5 |
| Outer spring diameter | max. 240 mm |
| Coiling direction | Right, left as option |
| Feed speed | max. 70 m/min |
FUL 175
from 6.1
to 17 mm
| Wire diameter | 6.1 - 17 mm |
| Wire strength | Rm = 2,000 N/mm² |
| Spring index | ≥4 |
| Outer spring diameter | max. 240 mm |
| Coiling direction | Right, left as option |
| Feed speed | max. 70 m/min |
FUL 183
from 8.1
to 18 mm
| Wire diameter | 8.1 - 18 mm |
| Wire strength | Rm = 2,000 N/mm² |
| Spring index | ≥5 |
| Outer spring diameter | max. 300 mm |
| Coiling direction | Right |
| Feed speed | max. 70 m/min |
FUL 203
from 8.1
to 20 mm
| Wire diameter | 8.1 - 20 mm |
| Wire strength | Rm = 2,000 N/mm² |
| Spring index | ≥5 |
| Outer spring diameter | max. 300 mm |
| Coiling direction | Right |
| Feed speed | max. 65 m/min |
FUL 226
from 12.1
to 30 mm
| Wire diameter | 12.1 - 30 mm |
| Wire strength | Rm = 800 N/mm² |
| Wire diameter | 12.1 - 22 mm |
| Wire strength | Rm = 2,000 N/mm² |
| Outer spring diameter | max. 300 mm |
| Spring index | ≥4 |
| Coiling direction | Right, left as option |
| Feed speed | max. 65 m/min |
FUL 16+
- Standard machine with 7 CNC axes (8 CNC axes max.)
- Direct drive on infeed, form axis, and cut for improved accuracy and production rate
- Powerful infeed with 1 pair of feed rollers (optionally 2 pairs)
- Servomotor-driven mandrel height adjustment and mandrel displacement
- Vertical pitch and parallel pitch
- Robust cutting unit with rotary and straight cut
- - PTP coiling finger for initial tension control (option)
- Coiling pin holder with additional fine adjustment
- Increased output due to new "optimized 2" cut
