High-Speed Double Sides Stator Lacing Machine for EV Motors — For New Energy & Electric Vehicle Motor Manufacturing
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High-Speed 200 Stitches/Min Double Sides Stator Lacing Machine with Electronic Cam Control for EV Motors Featuring Fancy Lacing Mode
Product Summary
High-Speed Double Sides Stator Lacing Machine for EV Motors — For New Energy & Electric Vehicle Motor Manufacturing The High-Speed Double Sides Stator Lacing Machine is specifically engineered for new energy vehicle motors, including EV motors, hybrid motors, and high-performance industrial motors. ...
Product Custom Attributes
Highlight:
high-speed stator lacing machine
,double sides stator lacing machine
,EV motor 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 High-Speed Double Sides Stator Lacing Machine is specifically engineered for new energy vehicle motors, including EV motors, hybrid motors, and high-performance industrial motors. This advanced machine features a full-servo control system with electronic cam technology, achieving lacing speeds of up to 200 stitches per minute—double the speed of conventional lacing equipment. Designed for stators with high slot counts and large dimensions, the machine handles stator outer diameters up to 190mm, inner diameters from 30mm to 110mm, and stack heights from 50mm to 130mm. The electronic cam control enables seamless switching between different lacing modes, including slot-by-slot lacing and fancy lacing for stators with varying coil end heights. With primary qualification rates exceeding 98.5% and the ability to meet the demanding quality standards of the EV industry, this machine transforms EV stator binding from a production bottleneck into a high-efficiency, high-reliability 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
The rapid growth of the electric vehicle industry has created unprecedented demand for high-quality, high-volume electric motor production. EV motors differ fundamentally from traditional industrial motors: they feature higher slot counts, larger dimensions, and more complex winding geometries. The binding of EV stator end coils presents unique challenges that conventional lacing equipment cannot adequately address.
First, speed is critical. Most new energy motor stator lacing machines currently achieve stable lacing speeds of only 90-100 stitches per minute—far below the throughput required for mass EV production. Second, EV motors often have varying coil end heights across different slots, requiring fancy lacing patterns rather than simple slot-by-slot binding. Traditional mechanically controlled machines cannot handle these complex patterns without frequent adjustment and high reject rates. Third, the transition between different lacing modes in conventional machines often results in missed cycles, leading to thread loosening and product defects. As EV production scales globally, manufacturers urgently need lacing automation specifically designed for the demands of new energy motor manufacturing.
Solution
Our High-Speed Double Sides Stator Lacing Machine for EV motors delivers breakthrough performance through advanced electronic cam control technology. The machine adopts a virtual master axis that drives all slave axes via electronic cam profiles, achieving perfect synchronization of all movements. This electronic cam approach corresponds to different stator binding requirements, enabling flexible phase and slave axis position settings.
The key innovation is the ability to achieve lacing speeds exceeding 200 stitches per minute—more than double the speed of conventional machines. This dramatic speed increase is accomplished without sacrificing quality, as the electronic cam system ensures precise synchronization of needle advancement, hooking, and stator indexing.
For stators with varying coil end heights (common in EV motors), the machine supports fancy lacing modes where each servo axis uses independent cam parameter sets for different slot configurations. The electronic cam system implements buffer blending, allowing seamless switching between multiple cam tables without empty cycles—eliminating the thread loosening and defects that plague conventional machines.
The machine features a vertical loading structure with double-needle design for simultaneous upper and lower end lacing. Automatic thread feeding, cutting, and knotting systems eliminate manual intervention. Safety features include a safety grating protection system and two-hand start buttons. The HMI touchscreen allows operators to set rotation speed, adjust tension, and select between slot-by-slot, interval, and fancy lacing patterns
Application
This high-speed stator lacing machine is specifically designed for new energy vehicle motor manufacturing. Primary applications include EV traction motors for pure electric vehicles, hybrid vehicle motors for HEV and PHEV platforms, high-performance servo motors for industrial automation, aerospace motors for aircraft and drone applications, and high-speed motors for advanced manufacturing systems. Any facility producing stators for new energy vehicle motors requiring high lacing speed, complex pattern capability, and exceptional quality consistency will benefit from this advanced machine.
How It Works
The high-speed EV motor stator lacing machine operates using advanced electronic cam technology.
Step 1 — Workpiece Loading: The stator is loaded vertically and secured by the stator pressing device.
Step 2 — Program Selection: Through the HMI touchscreen, the operator selects the appropriate lacing program—slot-by-slot for uniform stators or fancy lacing for stators with varying coil end heights.
Step 3 — Virtual Master Axis Control: The system employs a virtual master axis that drives all slave axes (needle advance/retreat, needle up/down, needle rotation, stator indexing) via electronic cam profiles. This ensures perfect synchronization of all movements.
Step 4 — Electronic Cam Operation: For slot-by-slot binding, a fixed cam table executes each cycle. For fancy lacing (required for stators with different coil end heights), each servo axis uses independent cam parameter sets. The electronic cam system implements buffer blending, pre-loading the next cam table while the current one executes, enabling seamless transitions without empty cycles.
Step 5 — Simultaneous Double-Side Lacing: Two servo-driven needles lace the upper and lower coil ends simultaneously. The servo system precisely controls needle indexing, hooking, and stator indexing.
Step 6 — Automatic Thread Management: The automatic thread feeding system supplies thread to both needles. Upon cycle completion, the automatic cutting and knotting systems secure the ends without manual intervention.
Step 7 — Unloading: The operator 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 displays real-time production status and fault diagnostics.
How to Choose
Speed Requirements: For high-volume EV motor production, lacing speed is critical. Standard machines achieve 90-100 stitches per minute; this machine achieves speeds exceeding 200 stitches per minute. Calculate your required output to determine if the speed advantage justifies the investment.
Coil End Height Variation: Assess whether your stator design has uniform coil end heights or varying heights across different slots. Uniform stators can use slot-by-slot mode; stators with varying heights require fancy lacing mode with independent cam profiles for different slots.
Slot Count and Configuration: EV motors often have high slot counts. Verify that the machine‘s indexing accuracy and programmability can accommodate your specific slot configuration and complex winding patterns.
Quality Certification Requirements: For EV industry applications, ISO and SGS certification are often required. This machine can be supplied with formal certification upon request, providing documented quality assurance.
Integration with EV Production Lines: For manufacturers building complete EV motor production facilities, consider integration with upstream processes (insulation insertion, winding, inserting) and downstream processes (shaping, testing, resin impregnation). Turn-key solutions including technical consulting and staff training are available.
FAQQ1: How does electronic cam technology improve lacing speed compared to conventional machines?
A: Electronic cam control uses a virtual master axis to precisely synchronize all movements, eliminating mechanical delays. Conventional machines achieve 90-100 stitches per minute; this electronic cam machine exceeds 200 stitches per minute—more than double the speed.
Q2: What is fancy lacing and when is it required?
A: Fancy lacing refers to binding patterns that accommodate stators with varying coil end heights. In EV motors, different slots may have different over-hang heights due to complex winding patterns. Fancy lacing allows skipping certain slots or applying multiple stitches where needed. The electronic cam system handles fancy lacing by using independent cam parameter sets for each slot configuration.
Q3: How does the machine prevent thread loosening when switching between lacing patterns?
A: The electronic cam system implements a buffer blending mode. The next cam table is pre-loaded and cached while the current cam table is still executing. Once the current cycle completes, the new table automatically takes effect without empty cycles—eliminating the thread loosening and product defects that occur with conventional machines.
Q4: Can this machine handle both standard induction motors and EV motors?
A: Yes. The machine is suitable for a wide range of motor types including EV motors, air conditioner motors, washing motors, compressor motors, fan motors, generator motors, and pump motors. The programmable control system allows storage of different lacing patterns for various motor types.
Q5: What is the typical throughput for an EV stator on this machine?
A: At 200 stitches per minute, a 48-slot EV stator requires approximately 14 seconds for complete lacing (not including loading and unloading time). Actual throughput depends on slot count, lacing pattern complexity, and operator efficiency, but represents a significant improvement over conventional machines.
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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