Recently, China’s first X-PIN stator production line, jointly developed by Haosen and Quzhou Jidian, has made significant technological breakthroughs and successfully achieved stator mass production. Equipped with Haosen’s new generation of X-PIN technology, the production line currently maintains a stable daily output of above 800 units with a yield rate exceeding 92%, matching the performance of similar production lines operated by international mainstream automakers. This fully demonstrates Haosen’s globally leading intelligent manufacturing capabilities and engineering delivery expertise. (Data source: VREMT)

Currently, “cost reduction and efficiency increase”remain the core pursuit driving the development of industry. To support customers in deploying hairpin motor stator production capacity, Haosen continues to explore the boundless potential of X-PIN technology. Leveraging its profound technical expertise and R&D experience in the E-drive field, the newly developed generation of X-PIN technology for this production line achieves breakthroughs in process, precision, power density, and cost reduction and efficiency increase.

X-PIN winding is an innovative stator winding design. Compared with traditional stators, the welding design and manufacturing of X-PIN winding are more challenging. Haosen’s new generation of X-PIN technology optimizes the welding structure. Compared with current mainstream H-PIN stators in the market, the X-PIN winding reduces the welding end height by 8mm, copper wire consumption by 4.5%, and resistance value by 4.5%. This structural optimization not only improves the space utilization rate of the stator, but also reduces the raw material costs for customers. The dimensional reduction in welding end further decreases copper loss, improves motor efficiency, and extends the vehicle’s driving range. Under the same volume and weight, the X-PIN technology delivers higher output power, that is, greater power density and stronger dynamic performance.

The X-PIN cutting structure, developed independently by Haosen, achieves an effective service life of key components exceeding 2 million times, which is three times higher than the industry average. Meanwhile, it controls cutting burrs to below 0.07mm, ensuring the consistency of subsequent processes such as winding and welding. Moreover, for the X-PIN critical processes, Haosen has developed a brand-new X-PIN twisting process, automated welding technology and insulation treatment process. These advancements not only realize precise control over winding deformation, automated assembly/disassembly, high-speed low-spatter welding, but also significantly enhance insulation performance, further promoting the efficient mass production progress of stator.

Apart from continuous optimization of X-PIN structural design and manufacturing processes, Haosen has upgraded production automated equipment and assembly systems. The high-precision, high-speed wire forming machine enables automated wire insertion, minimizing manual operation and eliminating insulation failure risks at the source. This ensures that the PPK value (process performance index) of critical product’s dimensions remains stably above 1.67. Furthermore, the newly developed multi-power source wire pressing solution, integrated with 3D vision inspection technology, achieves 100% traceability of production data.

As the first mass production line supplier of X-PIN hairpin motors, Haosen’s intelligent production lines for hairpin motor have achieved world-leading standards in proprietary technologies, product performance, and delivery experience. As a leader in global E-drive technology innovation, Haosen not only has keen market insights and precise technical mastery in X-PIN motors, but also has achieved technological breakthroughs across multiple domains including MINI U-PIN motors, 10-layer hairpin motors, 800V high-voltage motors, and oil-cooled motors, with mass production lines already delivered. Meanwhile, Haosen continues to be technological forefront of industry technology and has simultaneously carried out technical reserves for axial motor equipment.

Taking independent control of core technology has always been the cornerstone of industrial development. Moving forward, Haosen will continue to deepen its technology R&D efforts, leveraging robust engineering delivery capabilities to provide cost-effective intelligent production solutions for automakers and Tier 1 suppliers, and contribute more high-efficiency, lightweight and intelligent localized turnkey engineering solutions to advance the development of new energy vehicle technology.