We design hairpin, I-pin and X-pin windings end to end — from the winding topology through producible 3D geometry to STEP models and process parameters. You get the finished design and the data behind it, not another tool to learn.What makes that possible: we solve the winding topology under your manufacturing constraints instead of drawing it, and we work in a model fast enough that a design question is answered while you are still asking it.
We have firsthand knowledge of manufacturing requirements because we develop and build our own production systems. However, when we design a winding, we do not limit our solution to the technologies we offer ourselves.
Regardless of whether your manufacturing process relies on our equipment, another insertion method, or an existing production line, we design the winding based on the actual conditions of your manufacturing process. The engineering model adapts to your requirements and constraints, not ours.
Our goal is to find the best manufacturing solution for your product, regardless of who supplies the necessary equipment or machinery.
And because engineering expertise should stand on its own, our services are not tied to prototype production, feasibility studies, or the purchase of machinery.
In most development projects for electrical windings, the electromagnetics, design, and manufacturing teams work with different models and tools. The electromagnetics team defines a winding design. It is not until the mechanical design phase that it becomes apparent that the winding cannot be implemented. Later, the manufacturing team discovers that certain bends, weld points, or pin geometries cannot be produced reliably using standard processes.
The result: Development begins anew with another round of iterations.
We work in a single parametric model in which the winding topology, the geometry of every individual conductor and the process constraints live together. Change the connection table and you immediately see it as geometry, as clearance and creepage, as bending and twisting feasibility.
There is no handover loss between electromagnetics, design and manufacturing — because there is no handover.
1 — We calculate windings instead of drawing them
Instead of manually designing possible winding variations, we define the requirements and use our solver to automatically generate feasible solutions.
Design preferences such as connection layers, layer schemes, parallel paths, or pin types are incorporated directly into the model.
As a result, only solutions that are technically feasible to manufacture are evaluated. The model systematically searches the entire solution space, rather than simply comparing a few variants. If no solution meets the requirements, this becomes immediately apparent.
2 — Immediate feedback on every design change
Simply adjust the layer offset, pin type, or conductor cross-section, and the entire model is automatically recalculated—including the geometry, electromagnetic properties, and manufacturing evaluation.
As a result, development questions that used to take days to answer can now be answered in just a few minutes.
Instead of analyzing only a few manually created variants, numerous potential windings can be automatically generated, evaluated, and sorted according to their properties.
Together, they create a seamless digital foundation for the entire development process and eliminate time-consuming coordination and handoff processes between disciplines.
The evaluation focuses on assembly processes, the insertion of the winding into the stator package, the accessibility of welded joints, and the complexity of the pin geometries.
If necessary, forming processes such as bending and twisting, as well as the effects of springback, are also analyzed and taken into account.
Hairpin, I-pin, X-pin, and hybrid pin designs. Number of layers, crowns, slot fill ratio, insulation, and the design of the stator package.
Each individual conductor is modeled separately across all relevant manufacturing stages, from the pre-bent pin to the fully welded winding.
Analysis of clearances and creepage distances, interference checks, validation of available installation space, assembly tables, comprehensive development reports, and STEP data for integration into CAD and CAM systems.
Slot, pole, and phase layouts, layer shifts, and parallel branches. The winding factor and the current distribution among the parallel branches are derived directly from the winding topology.
Deliberately limited scope: We provide all results determined by the stator winding. The performance of the entire machine also depends on the rotor geometry and design, which remain your responsibility.
Feasible winding solutions are evaluated and prioritized based on your criteria, whether in terms of performance, axial winding head height, pin complexity, number of distinct pin model, weld count, or insulation margin.
Design decisions that have already been made can be retained, while the remaining design space is specifically optimized. And if no solution exists, the reason for this is made clear. We identify the constraint that prevents feasibility, quantify the effects of relaxing this requirement, and highlight which alternative approaches would also fail to achieve the goal. In this way, dead ends in the development process are transformed into well-founded engineering decisions.
A stator family can use the same formed hairpins, bending tools, and insertion processes across multiple motor variants. The differences are limited to the welding side, where the connections and terminals are designed specifically for each product.
What’s new is that we can automatically identify and optimize such product families.
Instead of first developing an engine and then adapting a second variant to it, both variants are optimized together. Shared manufacturing costs are accounted for only once, while product-specific welding operations are evaluated individually. The result is a product family that is optimized not only in terms of performance but also in terms of manufacturing costs and the reuse of tools.
Scope of Work: The common bending side is selected from a previously determined set of suitable candidates. The optimal solution found is exact within this set of candidates, but has not been proven to be the global optimum among all theoretically possible solutions. The search space is expanded by adjusting a parameter and does not require the model to be rebuilt.
Winding topology and connection table —For each phase, each parallel branch, and each layer.
Pin family overview and forming parameters – Overview of the number of pin variants required, as well as their respective bending and twisting parameters.
3D geometry as a STEP assembly —every single conductor, ready for your CAD workflow, at every relevant stage of manufacturing.
Electromagnetic characterization— winding factor, branch balance, and symmetry properties.
Verification of clearances and creepage distances —analysis of the distances between the stripped conductor ends throughout the entire winding.
Slot cross-section analysis —Slot fillng ratio or insulating paper can be examined.
Design report – Documentation of the assumptions made, the options considered, and the reasons for selecting the final solution.
We support electric motor developers at OEMs and Tier 1 suppliers, as well as machine builders and equipment suppliers, who need windings that can actually be manufactured on their production lines.
We also work with companies that do not have their own hairpin design department and rely on external expertise for a specific development program.
From concept to series production: Our prototyping department is your development partner for traction drive stators based on hairpin technology. We manufacture prototypes and small production runs under realistic production conditions, ensuring the highest quality through advanced testing and measurement methods. A key focus is the optimization of winding head designs to maximize performance, efficiency, and compactness.
By producing A and C samples on equipment closely aligned with series production, we validate both product and process at an early stage. Combined with our expertise in automation and manufacturing, we provide a seamless path from initial concept to cost-efficient, scalable series production from a single source.
Whether it's manufacturability, weldability, insulation clearances, groove fill ratio, or production costs: Specify the constraint that is currently the most limiting factor for your project.
Contact
Sales E-Mobility
+49 711 / 3405-0
sales.eu@gehring-group.com
