Labor Saving Automatic Motor Winding Machine for Stator OD 110-210mm — For Industrial Motors, Pumps & Compressors
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Labor Saving Automatic Motor Winding Machine for Stator OD 110-210mm — For Industrial Motors, Pumps & Compressors
Product Summary
Labor Saving Automatic Motor Winding Machine for Stator OD 110-210mm — For Industrial Motors, Pumps & Compressors The Labor Saving Automatic Motor Winding Machine is engineered for stator outer diameters from 110mm to 210mm, accommodating stack heights up to 260mm and supporting copper or aluminum ...
Product Custom Attributes
Name:
Motor Stator Slot Automatic Coil Inserting Machine
Model:
SMT-QX08
Stator I.D.:
110-210mm
Stator O.D.:
≤260mm
Dimension:
(L)2370×(W)1260×(H)1710mm
Basic Properties
Place of Origin:
China
Brand Name:
SMT
Certification:
ISO / SGS Audit
Model Number:
SMT-QX08
Trading Properties
Minimum Order Quantity:
1 Set
Price:
Negotiable
Packaging Details:
Plywood Box With Sealing.
Delivery Time:
8 - 14 weeks
Payment Terms:
T/T,L/C
Supply Ability:
1pcs / 7 - 13 weeks
Product Description
The Labor Saving Automatic Motor Winding Machine is engineered for stator outer diameters from 110mm to 210mm, accommodating stack heights up to 260mm and supporting copper or aluminum winding wire with diameters from 0.2mm to 1.2mm. This fully automatic equipment integrates servo-driven winding, precision tension control, and programmable logic controller operation to automate the entire coil winding process. Designed for manufacturers of industrial motors, pumps, compressors, and fans, this machine significantly reduces labor dependency while delivering consistent, high-quality windings. With features including automatic indexing, wire break detection, and touchscreen parameter control, it transforms stator production from a labor-intensive operation into an efficient, reliable manufacturing process.
Main Technical Data
| Parameter | Value |
|---|---|
| Model | SMT-CW3.0 |
| Stator OD | 170-260mm |
| Stator ID | 100-200mm |
| Stack Height | 90-220mm |
| Paper Thickness | ≤0.38mm |
| Cuff Height | 3~7.5mm |
| Cycle time | ≈120pc/min |
| Power supply | 6Kw 3 phases 380V/50Hz |
| Weight | 1050kg |
| Dimension | (L)2350×(W)1100×(H)1500mm |
Cause
The traditional stator winding process has long been a bottleneck in electric motor manufacturing. Manual winding requires skilled operators to carefully guide copper wire into each stator slot, a process that is not only time-consuming but also highly inconsistent. Human error leads to variations in coil tension, spacing, and alignment, resulting in uneven windings that affect motor performance, increase vibration, and reduce product life. A typical manual winding operation requires 16 labor hours per stator, with four skilled operators working simultaneously to produce just two stators per day.
As labor costs continue rising and skilled technicians become increasingly scarce, manufacturers face mounting pressure to maintain production output while controlling costs. The manual process also suffers from high material waste — copper scrap losses in manual winding can be substantial, often exceeding 1,200g per stator. Additionally, inconsistent winding quality leads to elevated rejection rates, forcing manufacturers to choose between accepting lower quality or investing in costly rework and testing. For manufacturers producing medium to large stators in the 110-210mm OD range, these challenges are particularly acute, as larger coils are more difficult to wind manually and require greater precision to achieve proper slot fill and electrical performance.
Solution
The machine features a fully automatic winding cycle controlled by a programmable logic controller with a user-friendly touchscreen interface for parameter settings. Operators can store multiple winding recipes, allowing quick changeovers between different motor models.
The machine employs a high-precision servo-driven winding head that ensures consistent wire tension throughout the entire winding process. An automatic indexing mechanism accurately rotates the stator to align each slot with the winding head, eliminating positioning errors common in manual operations. The integrated wire break detection system automatically stops the machine when abnormalities are detected, preventing scrap and protecting the workpiece.
With the ability to wind multiple stators per hour versus only two per day by manual methods, the machine delivers dramatic productivity improvements. The automated process significantly reduces material waste — copper scrap losses are minimized, and the consistency of automated winding ensures that every stator meets the same quality standards. Machine features include manual, single-step, and fully automatic operational modes, facilitating both debugging and production runs. The touchscreen display provides real-time status monitoring and fault self-diagnosis, displaying common malfunctions directly on the screen for quick resolution.
Application
This automatic stator winding machine is ideally suited for manufacturing medium-sized electric motors across multiple industries. Typical applications include three-phase induction motors for industrial equipment, compressors, and pumps; single-phase motors for household appliances such as washing machines and air conditioners; fan motors for HVAC systems; generator stators for power generation equipment; and water pump motors for agricultural and industrial use. Any manufacturing facility producing stators in the 110-210mm OD range will benefit from the machine‘s labor-saving capabilities and consistent output quality.
How It Works
The automatic winding machine operates through an integrated eight-step sequence.
Step 1: The stator is placed on the inserting station and accurately located by dedicated tooling. A pneumatic clamping system secures the stator to prevent movement during operation.
Step 2: The wound coils and insulation wedges are prepared at the inserting position, with wedge length preset according to motor specification.
Step 3: The wedge feeding system delivers the insulation wedge to the cutting unit, where it is automatically cut to the preset length.
Step 4: The cut wedge is then formed in the forming cavity to match the stator slot profile.
Step 5: Under the cooperation of the servo driving system and pneumatic system, the inserting pusher pushes the coil and the formed wedge into the stator slot simultaneously, completing coil positioning and wedge locking in one operation.
Step 6: The inserting speed is controlled in different sections — different speeds are applied during guiding, pressing, and final positioning to ensure smooth insertion and avoid damage to the coil and wedge.
Step 7: All parameters, including wedge length, inserting depth, and inserting speed, are set and monitored through the human-machine interface, which also provides status display and malfunction alarm functions.
Step 8: After insertion is completed, the stator is released and removed for the next process such as lacing, shaping, or testing.
How to Choose
When selecting an automatic stator winding machine for your production line, consider these key factors:
Stator Size Compatibility: Verify that your stator’s outer diameter (110-210mm), inner diameter (60-150mm), and stack height (≤190mm) fall within the machine’s operating range. If you handle larger stators beyond this range, discuss custom configurations with your supplier.
Slot Configuration: Confirm your stator‘s slot count (24-48 slots) and slot geometry. The machine supports standard slot configurations; for non-uniform slot distributions or complex winding patterns, ensure the control system supports programmable skip-winding functionality.
Wire Type and Diameter: The machine accommodates both copper and aluminum wires. Consider your wire diameter range — smaller diameters may require finer tension control, while larger diameters may need slower winding speeds to prevent breakage.
Production Volume and Changeover Frequency: For multi-product lines, the machine’s recipe storage and quick parameter adjustment capabilities are critical to minimizing downtime. Evaluate your average batch size to determine if the automation level meets your throughput targets.
Integration with Existing Lines: Consider how the winding machine will integrate with your upstream processes (insulation paper insertion) and downstream processes (lacing, testing, assembly).
FAQ
Q1: How much labor savings can I expect compared to manual winding?
A: Manual winding operations typically require 16 labor hours per stator and produce only 2 stators per day with multiple operators. Our automatic winding machine can produce many times that output with a single operator monitoring the process, significantly reducing direct labor costs and freeing skilled workers for other tasks.
Q2: What is the first-pass yield of this winding machine?
A: The machine achieves a first-pass yield exceeding 99% under normal operating conditions. The automated winding process eliminates human errors in tension control, positioning, and wire arrangement that commonly cause defects in manual winding.
Q3: Does the machine support automatic fault detection?
A: Yes. The machine features a built-in fault self-test function. Common faults including wire breaks, tension abnormalities, and positioning errors are displayed on the touchscreen monitor, allowing operators to quickly identify and resolve issues without extensive troubleshooting.
Q4: What winding wire materials does this machine support?
A: The machine is compatible with both copper wire (CU) and aluminum wire (AL) within the supported diameter range. Parameter adjustments via the HMI allow quick optimization for different wire materials and diameters.
Q5: Can the machine be integrated into an automated production line?
A: Yes. The machine is designed for integration with upstream processes such as insulation paper insertion and downstream processes including lacing, shaping, and testing. Conveyor and robotic integration options are available upon request.
Production Line Solutions
SMT offers comprehensive technical consulting and turn-key project services for AC motor, DC motor, and BLDC motor manufacturing. Our services include motor cost evaluation, manufacturing know-how, staff training, and complete project implementation. Our solutions serve various applications including new energy automobile motors, servo motors, generators, three-phase motors, pump motors, compressor motors, household appliance motors, and other induction motors. We specialize in stator and rotor core assembly, slot insulation, automated winding, inserting, fusing, and resin impregnation technologies for diverse stator sizes and slot configurations.
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