Heavy-Duty Automatic Stator Winding Machine for OD 120-300mm — For Large Industrial Motors, Generators & Compressors
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Heavy-Duty Automatic Stator Winding Machine for 120-300mm OD with High Slot-Fill for Industrial Motors
Product Summary
Heavy-Duty Automatic Stator Winding Machine for OD 120-300mm — For Large Industrial Motors, Generators & Compressors The Heavy-Duty Automatic Stator Winding Machine is purpose-built for large industrial motor production, handling stator outer diameters from 120mm to 300mm, stack heights from 50mm to ...
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
Highlight:
heavy-duty stator winding machine
,automatic stator winder for large motors
,industrial stator winding machine 120-300mm
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 Heavy-Duty Automatic Stator Winding Machine is purpose-built for large industrial motor production, handling stator outer diameters from 120mm to 300mm, stack heights from 50mm to 200mm, and wire diameters from 0.6mm to 1.2mm for heavy-gauge copper wire winding.Designed for high slot-fill industrial applications, this robust machine features a heavy-duty machine architecture with exceptional structural rigidity to absorb extreme forces generated during winding and insertion of thick wires. With servo-controlled multiple axes, programmable winding patterns, and automated coil placement, this equipment transforms the production of large induction motors and permanent magnet synchronous motors from manual-intensive operations into efficient automated processes, delivering consistent quality, reduced labor dependency, and improved throughput.
Main Technical Data
| Parameter | Value |
|---|---|
| Model |
SMT-QX08 |
|
Stator I.D |
60-150mm |
|
Stator O.D |
≤210mm |
|
Core Length |
≤190mm |
|
Tooling stroke |
≤90mm |
|
Compatible wire |
CU/AL |
|
Slot number range |
24-48 slots |
|
Power supply |
380V/50/60Hz 5Kw |
| Weight |
1050kg |
| Dimension |
(L)2370×(W)1160×(H)1710mm |
Cause
Large industrial motors — used in compressors, heavy pumps, generators, and industrial machinery — operate under extreme electrical, thermal, and mechanical demands. The winding process for these large stators presents unique challenges beyond those of smaller motors. The combination of large stator dimensions and high slot-fill requirements generates extreme mechanical forces that standard equipment simply cannot withstand.
Heavy-gauge winding wire, often 0.6mm to 1.2mm in diameter, is stiff and difficult to handle manually. Operators struggle to achieve proper tension control and uniform wire layering, resulting in uneven windings, wasted copper, and compromised motor performance. The high slot-fill requirements demand that maximum copper be packed into each slot to achieve superior efficiency and power density, but manual methods consistently fall short.
As skilled labor becomes increasingly difficult to find and retain, manufacturers of large motors face critical production bottlenecks. The transition from manual coil insertion to automated production has become not just an efficiency improvement but a competitive necessity.However, standard automation equipment often fails when confronted with the demands of large stator production — machine deflection during winding leads to positioning errors, wire damage, and unacceptable reject rates.
Solution
Our Heavy-Duty Automatic Stator Winding Machine is engineered specifically to overcome the challenges of large motor production. The machine is built with exceptional structural rigidity to absorb the extreme forces generated during the winding and insertion of heavy-gauge wires, ensuring absolute positional accuracy and operational stability without machine deflection.
The equipment features an automated high slot-fill insertion system with precise tooling and guided insertion profiles that safely pack maximum copper into large industrial stators. This design minimizes insulation damage while achieving the superior efficiency and power density required by modern industrial standards.
Key technical specifications include stator outer diameter capacity of 120-300mm, stack height up to 200mm, and support for induction motors and permanent magnet synchronous motors. The machine incorporates servo-controlled axes for each movement — wire feed, head rotation, and carousel indexing — providing variable speed, smooth motion, and fine tension control. Programmable winding parameters store number of turns, skipping patterns, and multi-layer arrangements, allowing quick changeovers between different stator models by simply loading a different program and swapping minimal tooling.
The machine also includes integrated automated coil insertion stages that push coils into the stator slots in a single step after winding, improving cycle time and ensuring uniform coil placement. Built-in diagnostics track production counts, detect wire breaks, and can measure coil quality for assurance. The touchscreen interface allows easy setup of winding sequences and adjustment of parameters on the fly.
Application
This heavy-duty winding machine is specifically designed for manufacturers of large industrial motors. Primary applications include high-power induction motors for industrial compressors and pumps; permanent magnet synchronous motors for heavy machinery; generator stators for power generation systems; and large fan motors for industrial ventilation. Any facility producing electric motors with stator outer diameters from 120mm to 300mm and requiring high slot-fill rates, heavy-gauge wire handling, and robust construction will benefit from this equipment.
How It Works
The heavy-duty winding machine operates through a fully automated sequence controlled by CNC programming. The operator loads the stator onto the work station and secures it with the pneumatic clamping system. Through the HMI touchscreen, the operator selects the appropriate winding program, which stores parameters including number of turns, winding pattern, multi-layer arrangements, and skip-winding configurations.
Once initiated, the servo-driven winding head advances, guided by closed-loop tension control that maintains consistent wire tension throughout the winding process. The indexing mechanism rotates the stator precisely, aligning each slot with the winding head. For complex multi-layer windings, the control system automatically manages layer transitions, wire direction changes, and inter-layer insulation placement.
After winding completion, the integrated coil insertion stage automatically transfers the wound coil into the stator slot in a single operation, eliminating manual coil handling. The machine‘s built-in diagnostics continuously monitor production counts, detect wire breaks, and track quality metrics. Fault conditions trigger automatic machine stoppage and display error messages on the HMI for quick operator resolution.
How to Choose
Stator Size Requirements: Confirm that your stator‘s outer diameter (120-300mm) and stack height (50-200mm) fall within the machine’s capacity. For stators at the upper end of these ranges, verify that the machine‘s structural rigidity and winding stroke are adequate.
Slot-Fill Requirements: High slot-fill applications demand machines with robust insertion mechanisms and precise tooling. Evaluate your target slot-fill percentage to ensure the machine’s insertion system can achieve your required copper density without damaging insulation.
Wire Gauge and Material: The machine supports wire diameters from 0.6mm to 1.2mm. For applications with extremely heavy-gauge wire or aluminum wire, discuss customization options with your supplier to ensure proper tension control and wire handling.
Production Volume and Integration: For high-volume production lines, consider integrating the winding machine with upstream insulation insertion equipment and downstream testing stations. The machine supports conveyor and robotic integration.
FAQQ1: What is the maximum stack height this heavy-duty machine can handle?
A: The machine supports stack heights up to 200mm. For applications beyond this range, custom configurations may be available upon request.
Q2: How does the machine prevent wire damage during high slot-fill winding?
A: The machine employs guided insertion profiles and precise tension control to safely pack maximum copper into stator slots while minimizing insulation damage. The closed-loop tension management system continuously adjusts to prevent excessive stress on the wire.
Q3: Can this machine handle both induction motors and permanent magnet motors?
A: Yes. The machine is designed for both induction motors and permanent magnet synchronous motors. The programmable control system allows storage of different winding patterns for various motor types.
Q4: What is the typical return on investment period for this equipment?
A: ROI varies by production volume and labor costs, but manufacturers typically achieve payback within 12-24 months due to reduced labor costs, lower scrap rates, and increased throughput compared to manual winding operations.
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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