In the manufacturing of new energy vehicle e-drive stators, the lamination process for silicon steel sheets hinges on two make-or-break factors: pressure-displacement accuracy and stack alignment.

Pressure Precision: Avoiding Gaps & Deformation

Excessive or inconsistent pressure can cause over-compression, leading to micro-gaps and deformation between laminations. Even slight misalignment in the stack can result in a distorted stator core — making winding or pin insertion impossible, and ultimately failing assembly specs.

Stack Alignment: Ensuring Hole Consistency for Hairpin Motors

The alignment of interlocking tabs is equally critical. These small contact areas are prone to misalignment during pressing, which can cause layer-to-layer shift. In hairpin motor stators, misaligned laminations lead to misaligned pin holes — causing copper wires to scrape, bend, or fail insertion entirely. This directly impacts motor performance, power output, and assembly yield.

Why It Matters

A deviation of just fractions of a millimeter in pressure or alignment can compromise the entire stator — affecting efficiency, NVH, durability, and manufacturability. In precision e-drive production, there’s no room for guesswork.

The Solution Lies In:

· Closed-loop force and position control

· Real-time monitoring of pressure and displacement curves

· Vision-guided or mechanical alignment systems

· Data-traceable pressing processes

Precision lamination isn’t just a step in the process — it’s the foundation of a high-performance e-drive.