A Flexible Assembly and Gripping Process of Hairpin Baskets †
Abstract
1. Introduction
2. Basics and State of the Art
2.1. Hairpin Technology
2.2. Process Chain of Hairpin Technology
2.3. Classification of Hairpin Shapes, Types and Topologies
2.4. Pre-Assembly of Hairpin Baskets
2.5. Hairpin Grippers
2.6. Gripping and Insertion of the Hairpin Basket
2.7. Hairpin Basket Grippers
3. New Approaches for the Assembly and Gripping of Hairpin Baskets
3.1. Vacuum Hairpin Gripper
3.2. Test Setup for Collaborative Hairpin Assembly
3.3. Software for Visual Support
3.4. Software for Collision Detection
3.5. Hairpin Basket Gripper
- ▪ Step 1: Upper and lower gripping unit are closed.
- ▪ Step 2: The entire gripper is indexed forward by one slot.
- ▪ Step 3: The upper gripping unit is opened.
- ▪ Step 4: The gripper moves into the alignment unit. One slot is aligned.
- ▪ Step 5: The upper gripping unit is closed.
- ▪ Step 6: The gripper moves out of the alignment unit.
- ▪ Step 7: The lower gripping unit is opened.
- ▪ Step 8: The lower gripping unit is indexed backwards by one slot.
- ▪ Step 9: The lower gripping unit is closed and the process starts at step 2 again.
4. Results and Discussion
4.1. Collaborative Hairpin Assembly
4.2. Hairpin Basket Gripper and Sequential Alignment
5. Conclusions
Author Contributions
Funding
Data Availability Statement
Conflicts of Interest
Abbreviations
N | Number of slots |
L | Number of layers |
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Criteria | Manual | Collaborative | Automated |
---|---|---|---|
Flexibility | + | 0 | − |
Error susceptibility | 0 | + | 0 |
Cycle Time | 10 s | 17 s | 1–2 s |
Invest | + | 0 | − |
Criteria | New Approach | State of the Art |
---|---|---|
Flexibility | + | − |
Error susceptibility | − | 0 |
Cycle Time | − | + |
Invest and setup costs | + | − |
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© 2025 by the authors. Published by MDPI on behalf of the World Electric Vehicle Association. Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/).
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Fraider, F.; Dreher, P.; Lindner, J.; Reichl, D.; Kößler, F.; Fleischer, J. A Flexible Assembly and Gripping Process of Hairpin Baskets. World Electr. Veh. J. 2025, 16, 503. https://doi.org/10.3390/wevj16090503
Fraider F, Dreher P, Lindner J, Reichl D, Kößler F, Fleischer J. A Flexible Assembly and Gripping Process of Hairpin Baskets. World Electric Vehicle Journal. 2025; 16(9):503. https://doi.org/10.3390/wevj16090503
Chicago/Turabian StyleFraider, Felix, Peter Dreher, Josette Lindner, Dominik Reichl, Florian Kößler, and Jürgen Fleischer. 2025. "A Flexible Assembly and Gripping Process of Hairpin Baskets" World Electric Vehicle Journal 16, no. 9: 503. https://doi.org/10.3390/wevj16090503
APA StyleFraider, F., Dreher, P., Lindner, J., Reichl, D., Kößler, F., & Fleischer, J. (2025). A Flexible Assembly and Gripping Process of Hairpin Baskets. World Electric Vehicle Journal, 16(9), 503. https://doi.org/10.3390/wevj16090503