Shanghai, Jun 25, 2026
During CWIEME Shanghai 2026, held from June 24 to 26, Comau showcased its advanced hairpin stator manufacturing technologies for new energy vehicle drive motor production, with a focus on its high-performance welding solutions. Designed for one of the most critical processes in hairpin motor manufacturing, the solution combines welding quality, production efficiency and process flexibility to help customers tackle manufacturing challenges driven by the continuous evolution of electric drive systems.
As one of the core processes in hairpin stator production, laser welding plays a decisive role in determining motor electrical performance, power density, product consistency and long-term fatigue reliability. Comau’s laser welding solutions meet exacting industry requirements for key parameters such as weld penetration, pull force and weld appearance, while allowing flexible customization based on different product specifications to achieve an optimal balance between product quality and investment efficiency.
To cater to varying production volumes and cycle time requirements, Comau offers welding solutions in multiple configurations. Among them, the integrated cutting and welding workstation is specifically developed for highly automated production environments. By completing both cutting and welding operations in a single clamping cycle, the solution minimizes deformation and positional deviation of copper pins caused by inter-process transfer, improving joint positioning consistency and further enhancing processing precision and product yield. At the same time, the integrated design reduces manual loading/unloading and fixture changeover time, helping optimize overall line cycle time.
To further enhance process flexibility, the cutting and welding solution adopts a modular platform design that can be flexibly expanded according to production requirements. It can also be upgraded to a dual-station parallel configuration for high-throughput mass production scenarios, thus reducing loading and unloading time while increasing overall output. In addition, its movable laser welding head further extends the processing range, enabling more efficient adaptation to rapid product changeovers and upgrade requirements across multiple e-drive platforms and product variants.
Beyond welding, Comau also provides end-to-end solutions covering the entire hairpin stator assembly process, including wire forming, insertion, widening, twisting, cutting and laser welding, delivering complete coverage from standalone core equipment to fully automated assembly lines.
Leveraging modular and standardized design principles, Comau’s hairpin stator production lines offer high scalability, supporting flexible upgrades from semi-automated cells to fully automated lines. This enables customers to efficiently adapt to different stator designs and production volumes while ensuring manufacturing precision, consistency and repeatability.
Furthermore, the integration of advanced real-time process monitoring systems ensures robust quality management and full-process traceability. By optimizing equipment layout, improving production efficiency and reducing energy consumption, Comau helps customers shorten project lead times and accelerate time-to-market.
With decades of expertise in electric drive systems, e-powertrain and new energy vehicle manufacturing, Comau provides global OEMs and Tier 1 suppliers with end-to-end solutions spanning process development, engineering design and full line delivery. As the NEV industry continues to evolve toward higher performance and greater efficiency, Comau is committed to driving innovation in e-drive manufacturing through smarter, more flexible and scalable technologies that speed time-to-market for next-generation e-drive solutions.
