Hydraulic Coil Forming Machine with 30L Displacement and 20-120mm Stack Height — For Induction Motors, Compressors & Pumps
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Hydraulic Coil Forming Machine with 30L Displacement, 20-120mm Stack Height & PLC Programming for Stator Coils
Product Summary
Hydraulic Coil Forming Machine with 30L Displacement and 20-120mm Stack Height — For Induction Motors, Compressors & Pumps The Hydraulic Coil Forming Machine with 30L displacement and 20-120mm stack height is a specialized piece of equipment designed for final forming of stator coils after winding ...
Product Custom Attributes
Name:
Electric Motor Stator Coil Winding Final Forming Machine / Copper Wire / Aluminum Wire
Model:
ZZ160
Customized Service::
Available
Machine Size:
Middle Size
After-sales Service:
Engineers Available
Forming Power:
Hydraulic System
Warranty:
One Year
Displacement Of:
30L
Highlight:
Hydraulic coil forming machine with 30L displacement
,Coil forming machine for induction motors
,Hydraulic coil former with 20-120mm stack height
Basic Properties
Place of Origin:
China
Brand Name:
SMT
Certification:
ISO / SGS Audit
Model Number:
SMT-ZZ160
Trading Properties
Minimum Order Quantity:
1 Set
Price:
Negotiable
Packaging Details:
Wooden Case Suitable For Sea Transportation.
Delivery Time:
8-10weeks
Payment Terms:
T/T,L/C
Supply Ability:
1pcs / 8-10weeks
Product Description
The Hydraulic Coil Forming Machine with 30L displacement and 20-120mm stack height is a specialized piece of equipment designed for final forming of stator coils after winding insertion. Featuring a full hydraulic system driven by 30L/min cylinder displacement, this machine is engineered for stator inner diameters ranging from 30mm to 110mm and outer diameters up to 190mm. The machine adopts PLC programming with a user-friendly HMI touchscreen interface, enabling precise control over the forming process. Five independent oil cylinders work simultaneously to achieve inner expansion, outer wrapping, and end pressing, shaping the stator end coil’s inner diameter, outer diameter and height to approximate the final required dimensions. With a primary qualification rate exceeding 98.5% and a cycle time of ≤14 seconds per stator, this machine delivers consistent, high-quality results for motor manufacturers.
Main Technical Data
| Parameter | Value |
|---|---|
| Model | ZZ160 |
| Stack height | 20-120mm |
| Stator I.D | 40-120mm |
| Stator O.D | ≤190mm |
| Displacement of cylinder | 30L |
| Input | 380V/50/60Hz |
| Power supply | 2.5Kw |
| Machine weight | About 1000kg |
| Machine dimension (LxWxH) | 1200x750x2650mm |
|
Dimension |
(L)1640×(W)750×(H)1760mm |
Cause
In electric motor manufacturing, the transition from coil winding insertion to final assembly requires a critical intermediate step—coil forming. After coils are inserted into stator slots, the end windings typically have irregular shapes, inconsistent diameters, and uneven heights, making subsequent processes such as lacing, resin impregnation, and final assembly difficult and error-prone.
Traditional manual forming relies on skilled operators using hammers and specialized tools to reshape coil ends. This process introduces multiple quality issues. Inconsistent pressure leads to irregular coil shapes that affect motor balance and vibration. Coil edges are often damaged during manual forming, breaking the enamel insulation and creating electrical leakage paths. Uneven forming creates excess wire length that interferes with the lacing process. Slot insulation paper and wedges are frequently damaged during manual operations, compromising the motor’s electrical safety.
Furthermore, manual methods are fundamentally inconsistent. Two coils formed by the same operator can have measurable differences in shape and dimensions, leading to performance variations across production batches. As labor costs rise and skilled technicians become increasingly scarce, manufacturers need an automated solution that delivers precise, repeatable forming while eliminating the risks associated with manual operations.
Solution
Our Hydraulic Coil Forming Machine delivers a comprehensive automation solution that transforms the stator coil forming process. The machine is driven by a full hydraulic system with a 30L displacement, providing powerful and consistent forming pressure throughout the entire cycle. PLC programming precisely controls the sequence and force of all forming actions, ensuring repeatability from stator to stator.
The machine employs a five-oil-cylinder independent working design, with each cylinder assigned to a specific forming function—inner expansion to stretch the inner diameter to specification, outer wrapping to compress the outer diameter, and end pressing to achieve the required end height. This multi-axis approach ensures that all dimensions are formed simultaneously and uniformly.
The tooling design utilizes flexible principles of inner expansion combined with outer wrapping and edge forming, ensuring appropriate winding outer dimensions after the forming process. Changing stack height is accomplished by simply replacing adjustment washers without extensive tooling modifications.
Key performance metrics include a cycle time of ≤14 seconds per stator, a primary qualification rate of ≥98.5%, and a post-rework qualification rate of ≥99.5%. The forming process ensures that slot paper and wedges remain undamaged, no wire enamel is broken, and the stator core experiences no deformation or lamination lifting.
Application
This hydraulic coil forming machine is ideally suited for a wide range of electric motor applications. Typical applications include induction motors for industrial equipment, compressors for refrigeration systems, pump motors for water circulation and agricultural use, fan motors for HVAC systems, 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 with stack heights from 20mm to 120mm and outer diameters up to 190mm will benefit from this machine’s forming precision and production efficiency.
How It Works
The hydraulic coil forming machine operates through an integrated sequence of coordinated actions. The operator loads the stator onto the work station and secures it via the clamping mechanism. Through the HMI touchscreen, the operator selects the appropriate forming program, which stores parameters including inner diameter target, outer diameter target, and end height specification.
When the two-hand start button is activated, the PLC-controlled hydraulic system initiates the forming cycle. Step 1 — Inner Expansion: The inner expansion cylinder activates, driving expansion blades outward to stretch the coil’s inner diameter to the target dimension. This ensures that the inner bore is properly shaped for subsequent processes.
Step 2 — Outer Wrapping:Simultaneously, the outer wrapping cylinder applies controlled pressure from the outside, compressing the coil’s outer diameter to specification.
Step 3 — End Pressing: The end pressing cylinders form the upper and lower coil end heights to the required dimensions, ensuring uniform end turn shape. Each of the five oil cylinders works independently but is precisely synchronized by the PLC control system.
Throughout the forming cycle, the safety grating protection system monitors the operating zone. If an obstruction is detected, the machine automatically stops to prevent injury or workpiece damage. The entire forming cycle is completed in approximately 14 seconds, after which the finished stator is unloaded and transferred to the next process station.
How to Choose
Stator Size Compatibility: Verify that your stator’s inner diameter (30-110mm), outer diameter (≤190mm), and stack height (20-120mm) fall within the machine‘s operating range. For stack heights exceeding 120mm, custom tooling configurations may be required.
Forming Requirements: The machine supports five-cylinder independent working for inner expansion, outer wrapping, and end pressing. Confirm that this forming configuration matches your stator design—most induction motor stators are compatible with this multi-axis approach.
Production Volume: Evaluate your daily output requirements. With a cycle time of ≤14 seconds per stator, the machine can process approximately 250-300 stators per 8-hour shift. For higher throughput requirements, consider automated loading and unloading integration.
Changeover Frequency: For multi-product lines, the machine‘s adjustment washer system allows quick stack height changes. Assess your average batch size and changeover frequency to determine if this meets your production flexibility needs.
Integration with Production Line: Consider how the forming machine will integrate with upstream processes (winding insertion) and downstream processes (lacing, resin impregnation). The machine is designed for stand-alone operation but can be integrated into automated production lines.
FAQ
Q1: How does the 30L displacement hydraulic system compare to smaller systems?
A: The 30L displacement provides sufficient flow and pressure to drive five independent oil cylinders simultaneously, ensuring powerful and consistent forming action across all dimensions. Smaller displacement systems may struggle to maintain pressure when multiple cylinders operate concurrently.
Q2: What is the typical first-pass yield for stators processed on this machine?
A: Under normal operating conditions, the machine achieves a primary qualification rate of ≥98.5%. After rework of marginal parts, the qualification rate reaches ≥99.5%, ensuring reliable, consistent results across high-volume runs.
Q3: Does the machine require different tooling for different stack heights?
A: No. The machine can adjust for different stack heights by simply changing adjustment washers. This eliminates the need for complete tooling replacement when switching between stator models with different stack heights.
Q4: What safety features are included on this machine?
A: The machine is equipped with a safety grating protection system that monitors the operating zone, plus a two-hand simultaneous start button that ensures the operator‘s hands are clear before the machine begins the forming cycle. These features comply with international machinery safety standards.
Q5: Can this machine handle both copper and aluminum wires?
A: Yes. The hydraulic forming process applies controlled pressure that is suitable for both copper and aluminum winding wires. The key requirement is proper parameter adjustment via the PLC to avoid excessive pressure that could damage aluminum wire insulation.
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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