This July, NITTOKU Co., Ltd. released a processing system for square copper wires. The new production equipment line is based on the ES-1A segment conductor coil processing machine for motors of electrified vehicles (xEVs). Specifically, Amada Press System Co., Ltd. based in Kanagawa Prefecture, Japan, commercialized ES-1A forming machine.

Square Copper Wires for Small Motors

The ratio of xEVs in the automotive market is expected to increase sharply in the coming years. The motors, which are the main power source of xEVs, must become smaller and lighter and provide higher efficiency. As a result, using square copper wires is becoming mainstream for small and high-output motors.

Using the conventional processing method has been a challenge in changing and adjusting shapes of square copper wires. Also, pure copper, which is the material of square copper wires, has high thermal conductivity. To this end, stable coil molding is difficult, thus defects in processing precision occur. 

Enhanced Efficiency of Motor Production Process

NITTOKU combined its factory automation (FA) solution to Amada Press System’s coil processing technology for MEC spring molding machine and copper material evaluation technology. As a result, it enhanced efficiency, including higher speed, simplified process, and stable quality, of customers’ motor production processes.

NITTOKU holds a high share of the global market for coil winding machines.  

ES-1A Forming Machine

Meanwhile, ES-1A is a revolutionary forming machine. Specifically, the EMC Spring Molding Machine Division of Amada Press System developed ES-1A. It mobilized the know-how on its wire working technology nurtured in the production of torsion spring molding machines. The forming machine delivers high-speed and high-precision production in combination with the newly developed square copper wire winding system and a transfer system. The company’s propriety program operation enables the formation of up to 20 types of hairpins without changeover.

Accordingly, NITTOKU is considering the application of the square wire processing system to bus bar production and generator production processes.