Double Sides 25-100mm LD Stator Lacing Machine — For Induction Motors, Compressors & Pumps
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Double Sides 25-100mm ID Range Stator Lacing Machine with Double Needle Design and 0.45s/s Lacing Speed
Product Summary
Double Sides 25-100mm LD Stator Lacing Machine — For Induction Motors, Compressors & Pumps The Double Sides 25-100mm LD Stator Lacing Machine is an automatic solution designed for binding end coils of electric motor stators with stack height up to 120mm and outer diameter up to 160mm. This machine ...
Product Custom Attributes
Highlight:
Double sides stator lacing machine
,LD stator lacing tool for motors
,25-100mm stator lacing machine
Basic Properties
Place of Origin:
China
Brand Name:
SMT
Certification:
lSO/SGS Audit
Model Number:
BZ41
Trading Properties
Minimum Order Quantity:
1 SET
Price:
Negotiable
Packaging Details:
Plywood Box With Sealing
Delivery Time:
8-10 weeks
Payment Terms:
L/C,T/T
Supply Ability:
1 pcs/7-11 weeks
Product Description
The Double Sides 25-100mm LD Stator Lacing Machine is an automatic solution designed for binding end coils of electric motor stators with stack height up to 120mm and outer diameter up to 160mm. This machine adopts a vertical loading structure with two needles operating simultaneously on the upper and lower ends of the stator. The integration of servo-driven systems, programmable logic controller, and human-machine interface touchscreen automates the entire lacing process—from thread feeding and hooking to indexing and cutting. Designed for manufacturers of induction motors, compressors, fans, and pumps, the machine significantly reduces manual labor while delivering consistent, high-quality binding results. With lacing speeds of approximately 0.5-0.7 seconds per slot and the ability to achieve a primary qualification rate of ≥98.5% (≥99.5% after rework), this machine transforms stator binding from a labor-intensive bottleneck into an efficient, reliable production process
Main Technical Data
| Parameter | Value |
|---|---|
|
Model |
SMT-BZ41 |
|
Core length |
15-120mm |
|
OD Range |
≤Φ150mm |
|
ID Range |
Φ25-100mm |
|
End turn height |
≤40mm |
|
Lacing mode |
Slot by slot/Interval slot/Fancy lacing |
|
Lacing speed |
≈0.45 s/s |
|
Power supply |
3.5Kw |
|
Weight |
≈800Kg |
|
Dimension |
(L)1640×(W)750×(H)1760mm |
Cause
In electric motor manufacturing, the binding of stator end coils has long been a production bottleneck. After coils are inserted into stator slots, the protruding end windings must be tightly secured to prevent vibration, coil displacement, and wire fatigue during motor operation. Traditional manual binding requires skilled operators to individually wrap and tie binding threads around each coil end—a painstaking process that is not only slow but also highly inconsistent. Human error leads to variations in binding tension, spacing, and knot security, resulting in loose windings that increase vibration, produce noise, and compromise motor life expectancy.
As labor costs rise and skilled technicians become increasingly difficult to find, manufacturers face mounting pressure to maintain output while controlling costs. Manual binding also suffers from high rework rates—inconsistent binding often leads to coil movement during potting or resin impregnation, causing shorts or motor failure. For manufacturers producing medium-sized stators in the 25-100mm ID range, these challenges are particularly acute, as this size range covers a wide variety of motor types with varying production volumes and quality requirements. Without automation, manufacturers are forced to choose between accepting lower quality or investing in costly manual rework and testing.
Solution
The machine features a fully automatic lacing cycle controlled by industrial PLC with a user-friendly HMI touchscreen for parameter settings. Operators can store multiple lacing recipes, allowing quick changeovers between different motor models.
The machine employs a double-needle design—two servo-driven needles lace the upper and lower coil ends simultaneously, dramatically reducing cycle time while ensuring uniform binding on both ends. An automatic indexing mechanism accurately rotates the stator to align each slot with the lacing needles, eliminating positioning errors common in manual operations. The integrated thread feeding and cutting system automatically supplies binding thread and cuts it cleanly after each cycle—with no need to tie knots, as the machine secures the thread through its automatic knotting mechanism.
The machine supports three lacing modes programmable via the HMI: slot-by-slot lacing for full-coverage binding, interval lacing for applications requiring skip binding, and fancy lacing for complex binding patterns. Lacing tension is adjustable via the tension controller, ensuring optimal tightness for different thread materials and coil geometries. Built-in safety features include a safety grating protection system and two-hand simultaneous start buttons, ensuring operator safety during machine operation.
With primary qualification rates exceeding 98.5% and comprehensive fault self-diagnostic functions displayed directly on the touchscreen, the machine delivers consistent quality, reduced scrap, and dramatically lower labor costs. The vertical loading structure and movable tooling facilitate fast stator loading and unloading, effectively reducing operator fatigue and improving overall production efficiency
Application
This automatic double-sided stator lacing machine is ideally suited for a wide range of electric motor applications, including single-phase and three-phase induction motors for industrial equipment, compressor motors for refrigeration systems, pump motors for water circulation and agricultural use, fan motors for HVAC systems and cooling towers, generator stators for power generation equipment, washing machine motors for household appliances, and air conditioner motors for residential and commercial HVAC. Any manufacturing facility producing stators in the 25-100mm ID range will benefit from the machine‘s double-sided lacing capability, labor-saving automation, and consistent output quality.
How It Works
The automatic double-sided stator lacing machine operates through an integrated sequence of coordinated motions.
Step 1 — Workpiece Loading: The stator is loaded vertically into the working station and secured by the stator pressing device.
Step 2 — Parameter Setup: Through the HMI touchscreen, the operator selects the appropriate lacing program, storing parameters including lacing mode (slot-by-slot, interval, or fancy), lacing tension, rotation speed, and slot count.
Step 3 — Thread Feeding: The automatic thread feeding system supplies the binding thread to both needles, while the tension controller maintains consistent thread tension throughout the process.
Step 4 — Simultaneous Lacing: Two needles driven by servo systems lace the upper and lower coil ends simultaneously. The lacing process is governed by three coordinated motions: needle advance and retreat (moving into position to hook the thread), needle up and down movement (positioning the thread around the coil), and needle rotation (completing the wrap around the coil). All motions are precisely synchronized via the servo control system and PLC programming.
Step 5 — Indexing: After each lacing cycle, the servo-driven stator indexing mechanism rotates the stator to align the next slot with the needles.
Step 6 — Thread Cutting and Knotting: Upon completion of the lacing cycle for all slots, the automatic cutting device cuts the thread, and the knotting mechanism secures the end—eliminating the need for manual knot tying. The operator then unloads the finished stator and loads the next workpiece.
Throughout operation, the safety grating protection system and two-hand start buttons ensure operator safety. The touchscreen display provides real-time status monitoring, production count tracking, and fault self-diagnosis, displaying common malfunctions directly for quick resolution.
How to Choose
When selecting an automatic double-sided stator lacing machine for your production line, consider these key factors:
Stator Size Compatibility: Verify that your stator‘s inner diameter (25-100mm), outer diameter (≤160mm), and stack height (up to 120mm) fall within the machine’s operating range. For larger stators beyond these limits, industrial-grade models are available.
Slot Configuration and Lacing Requirements: Assess whether your application requires full slot binding or specific patterns such as interval skipping or fancy lacing. The machine supports all three programmable modes, providing flexibility for different motor designs.
Binding Thread Type and Tension: The machine accommodates various binding thread materials. The tension controller allows adjustment of binding tightness—critical for achieving optimal coil security without damaging wire insulation. For fine-gauge binding threads, finer tension control may be required.
Production Volume and Changeover Frequency: For multi-product lines, the HMI‘s recipe storage capability and fast tooling change are critical for minimizing downtime. Evaluate your average batch size to determine if the machine’s automation level meets your throughput targets.
Quality and Certification Requirements: For manufacturers requiring documented quality assurance, ensure the machine has undergone ISO or SGS audit certification. This machine is available with ISO/SGS audit report, providing formal verification of manufacturing quality and equipment reliability.
FAQQ1: How does the double-needle design improve production efficiency?
A: The machine features two needles that lace the upper and lower coil ends simultaneously. This design cuts the total lacing time in half compared to single-side machines that require flipping the stator or running separate cycles for each end.
Q2: What is the typical qualification rate for stators processed on this machine?
A: Under normal operating conditions, the machine achieves a primary qualification rate of ≥98.5%. After rework, the qualification rate reaches ≥99.5%, ensuring reliable, consistent results across high-volume runs.
Q3: Does the machine require manual knot tying?
A: No. The machine is equipped with an automatic thread feeding, cutting, and knotting system. The binding thread is automatically secured at both the beginning and end of each cycle—there is no need to tie knots manually.
Q4: What lacing patterns does this machine support?
A: The machine supports three programmable lacing modes via the HMI: slot-by-slot lacing (every slot receives one stitch), interval lacing (skip designated slots), and fancy lacing (complex binding patterns for special stator configurations).
Q5: Can this machine be integrated into an automated production line?
A: Yes. The machine is designed for integration with upstream processes such as coil winding and inserting, as well as downstream processes including shaping, testing, and impregnation. 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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