High-Precision Hydraulic Coil Forming Machine for EV Motors — For New Energy & Electric Vehicle Motor Manufacturing
<
>
High-Precision Hydraulic Coil Forming Machine for EV Motors — For New Energy & Electric Vehicle Motor Manufacturing
Product Summary
High-Precision Hydraulic Coil Forming Machine for EV Motors — For New Energy & Electric Vehicle Motor Manufacturing The High-Precision Hydraulic Coil Forming Machine is specifically engineered for new energy vehicle motors, including EV traction motors, hybrid motors, and high-performance industrial ...
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
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:
L/C,T/T
Supply Ability:
1pcs / 8-10weeks
Product Description
The High-Precision Hydraulic Coil Forming Machine is specifically engineered for new energy vehicle motors, including EV traction motors, hybrid motors, and high-performance industrial servo motors. Featuring a full hydraulic system with 30L displacement, PLC control, and a five-cylinder independent working design, this machine delivers exceptional forming precision for stators with tight dimensional tolerances. The machine is suitable for stator inner diameters from 30mm to 110mm, outer diameters up to 190mm, and stack heights from 20mm to 120mm. With a primary qualification rate of ≥98.5% and a cycle time of ≤14 seconds per stator, the machine meets the demanding production requirements of the EV industry. As the global transition to electric vehicles accelerates, this forming solution transforms a critical quality control bottleneck into a high-efficiency, high-reliability production process.
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
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 in several critical aspects that affect the coil forming process.
First, precision tolerances are tighter. EV motors operate at higher speeds and must meet stricter NVH (noise, vibration, harshness) standards. Irregular coil shapes that might be acceptable in an industrial pump motor become unacceptable in an EV traction motor, where even minor imbalances translate to audible noise and reduced driving comfort.
Second, EV motor stators frequently feature higher slot counts and more complex winding geometries. After coil insertion, the end windings have complex three-dimensional shapes that must be carefully formed to achieve consistent dimensions across all coils. Traditional forming methods struggle to handle this complexity without causing wire enamel damage.
Third, production volume requirements are dramatically higher. EV manufacturers need rapid cycle times without sacrificing quality. Manual forming cannot meet these requirements, and conventional automatic forming equipment often lacks the precision needed for EV applications.
Fourth, quality traceability has become mandatory. EV manufacturers need documented evidence that every coil meets specification, requiring automated equipment with data logging and reporting capabilities.
Solution
Our High-Precision Hydraulic Coil Forming Machine for EV motors delivers breakthrough performance for new energy vehicle production. The machine‘s full hydraulic system with 30L displacement provides the power and consistency required for high-volume EV stator forming.
The five-oil-cylinder independent working design enables precise control over inner expansion, outer wrapping, and end pressing operations. Each cylinder is independently controlled by the PLC system, allowing fine-tuning of pressure, speed, and stroke for each forming action. This level of control ensures that EV stators meet the tight dimensional tolerances required for high-speed operation.
The machine adopts a safety grating protection system and two-hand start button for operator safety, compliant with international standards. The PLC with HMI touchscreen enables recipe storage for multiple EV stator models, facilitating quick changeovers on production lines.
Key quality metrics for EV applications include a primary qualification rate of ≥98.5% and post-rework qualification rate of ≥99.5%. The forming process ensures no wire enamel breakage, no slot paper or wedge damage, and no core deformation—critical requirements for EV motor reliability.
For EV motor production lines, this machine is available as part of a complete manufacturing solution, including insulation paper insertion, winding, inserting, lacing, and testing equipment. Comprehensive technical consulting, staff training, and after-sales support ensure seamless integration.
Application
This high-precision hydraulic coil forming 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 and robotics, generators for power generation systems, and high-speed motors for advanced manufacturing applications. Any facility producing stators for EV motors requiring tight dimensional tolerances, high volume, and exceptional quality consistency will benefit from this advanced forming machine.
How It Works
The high-precision EV motor stator forming machine operates through an advanced PLC-controlled sequence. The operator loads the stator onto the work station and secures it via the clamping mechanism. Through the HMI touchscreen, the operator selects the EV stator forming program, which stores parameters for inner diameter, outer diameter, and end height to tight dimensional tolerances.
When the two-hand start button is activated, the PLC-controlled hydraulic system initiates the forming cycle. Phase 1 — Inner Expansion: The inner expansion cylinder drives expansion blades outward with precisely controlled pressure and stroke to stretch the coil’s inner diameter to the target EV specification.
Phase 2 — Outer Wrapping: The outer wrapping cylinder applies calibrated pressure from the outside, compressing the outer diameter to the required dimension.
Phase 3 — End Pressing: The end pressing cylinders form the upper and lower coil end heights, ensuring uniform end turn shape for consistent lacing and resin impregnation.
All five oil cylinders operate independently but are precisely synchronized by the PLC control system to ensure simultaneous completion of all forming actions. The safety grating protection system monitors the operating zone throughout the cycle. The entire forming cycle is completed in approximately 14 seconds. The HMI touchscreen provides real-time status monitoring, production count tracking for quality documentation, and fault self-diagnostic display for quick issue resolution.
How to Choose
Precision Requirements: EV motors require tighter dimensional tolerances than standard industrial motors. Confirm that the machine‘s positioning accuracy and forming pressure consistency meet your EV stator specifications.
Stator Size Range: Verify that your EV stator’s inner diameter (30-110mm), outer diameter (≤190mm), and stack height (20-120mm) are within the machine‘s specification. For larger EV stators beyond this range, custom configurations may be available.
Production Volume: For high-volume EV motor production, evaluate the machine’s cycle time of ≤14 seconds per stator. Calculate your required daily output to confirm this meets your production targets.
Quality Traceability: EV manufacturers often require documented quality data. The PLC with HMI provides production count tracking and parameter storage for quality reporting. For enhanced traceability, inquire about data logging options.
Integration with EV Production Line: For manufacturers building complete EV motor production facilities, consider integration with upstream processes (insulation insertion, winding, inserting) and downstream processes (lacing, testing, resin impregnation). Turn-key solutions including technical consulting and staff training are available.
FAQ
Q1: What makes this machine suitable for EV motor production compared to standard forming machines?
A: This machine features five-cylinder independent working for inner expansion, outer wrapping, and end pressing, all precisely controlled by PLC. This multi-axis approach achieves tighter dimensional tolerances critical for EV motors where even minor imbalances affect NVH performance. Standard machines with fewer cylinders cannot achieve the same precision.
Q2: How does the forming process protect wire enamel from damage?
A: The hydraulic system provides controlled, consistent pressure throughout the forming cycle, eliminating the impact forces common in manual forming. The PLC programming ensures that pressure is applied gradually, and the tooling design uses smooth contact surfaces to prevent enamel abrasion.
Q3: What is the typical throughput for an EV stator on this machine?
A: At 14 seconds per stator, the machine can process approximately 250-300 stators per 8-hour shift, depending on loading and unloading time. Actual throughput depends on operator efficiency and integration with upstream/downstream equipment.
Q4: Can this machine handle the high slot count stators common in EV motors?
A: Yes. The forming tooling uses flexible principles of inner expansion combined with outer wrapping and edge forming, accommodating various slot configurations including the high slot counts typical of EV motor designs.
Q5: Does the machine support data logging for quality traceability?
A: The PLC with HMI touchscreen provides production count tracking and parameter storage. For enhanced traceability including per-stator forming data logging, discuss your requirements with the supplier to configure the appropriate data acquisition options.
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.
Related Products
Contact Our Experts And Get A Free Consultation!
Our mission is to offer "High Quality" & "Good Service" & "Fast Delivery" to help our clients to gain more profits.
