Automatic Stator Winding Machine — Advanced Winding Technology with Comprehensive Technical Support & Training
The Automatic Stator Winding Machine is the result of relentless engineering refinement, combining advanced winding kinematics with intelligent process control to produce stator coils of exceptional quality. Unlike conventional winders that treat every coil the same, our machine employs adaptive winding algorithms that adjust wire tension, winding speed, and needle trajectory in real time based on stator geometry and wire properties. This level of process sophistication ensures that even complex multi-pole stators with tight slot geometries are wound perfectly, cycle after cycle.
The machine's 5-axis synchronized motion system enables sophisticated winding patterns — including concentrated windings, distributed windings, and 8-shaped continuous winding — that were once only possible on machines costing twice as much. The servo-driven tensioner maintains constant wire tension from the first turn to the last, preventing the common defects of loose coils, wire overlap, and insulation damage that plague lower-quality winding equipment.
Main Technical Data
| Parameter |
Value |
| Model |
R160 |
| Wire diameter |
Φ0.08~Φ1.0mm |
| Max.Rotation Speed |
3200r/min |
| Suitable wire |
copper/aluminum |
| Max. Transfer distance |
≥170mm |
| Diameter of frame |
Φ20-Φ120mm |
| Power supply |
220V, single phase, 50/60Hz, 1.5kW |
| Machine weight |
About 750kg |
| Machine dimension (LxWxH) |
1550 x 1250x 1300mm |
| Dimension |
(L)1500*(W)1700*(H)1550mm
|
Key Selling Points
1. Advanced Winding Process Technology Our machine supports multiple winding methodologies on a single platform:
- Needle Winding: For inner-slot stators (BLDC, inverter motors, automotive motors) with slot widths as narrow as 1.2 mm
- Flyer Winding: For outer-slot stators (fan motors, hub motors) requiring high-speed bulk winding
- 8-Shaped Continuous Winding: For high-power-density EV and servo motors, reducing copper loss by 5–8% and improving three-phase symmetry to within ±2°
2. Intelligent Process Monitoring Built-in sensors monitor wire tension, winding count, coil resistance, and machine vibration in real time. If any parameter deviates from the programmed tolerance, the machine automatically pauses and alerts the operator — preventing defective stators from entering downstream assembly. This in-process quality control reduces scrap rates to below 0.5%.
3. Modular Design for Future Upgrades The machine's modular architecture allows field upgrades as your production needs evolve. Additional winding heads, expanded stator diameter capacity, integration with automated loading/unloading systems, and connection to MES/Industry 4.0 platforms can all be added without replacing the base machine. This protects your investment for years to come.
Manufacturing Process & Quality Assurance
Every Automatic Stator Winding Machine is built to exacting standards in our precision manufacturing facility:
1. Precision Machining: Critical mechanical parts (machine bed, spindle housing, needle assembly) are machined on 5-axis CNC machining centers with tolerances held to ±0.005 mm. Each part is inspected with coordinate measuring machines (CMM) before assembly.
2. Assembly & Wiring: Experienced technicians assemble each machine following standardized work instructions. All electrical wiring is labeled, routed in dedicated cable chains, and tested for insulation resistance and grounding continuity.
3. Commissioning & Testing: Each machine undergoes a minimum 72-hour continuous runtime test, winding actual stators under production conditions. We verify winding accuracy (CMM measurement of coil placement), repeatability (100 consecutive cycles measured), thermal stability, and noise/vibration levels. Only machines that pass all tests receive a calibration certificate and are approved for shipment.
4. Final Inspection & Packaging: A final quality audit covers documentation, spare parts completeness, paint finish, and safety labeling. The machine is then prepared for export packaging as described in our shipping section.
Operation & Maintenance
Getting Started (First 3 Days):
- Day 1: Machine familiarization, safety briefing, HMI navigation, loading/unloading practice
- Day 2: Recipe creation, parameter adjustment, sample winding with your products
- Day 3: Troubleshooting, basic maintenance, production optimization
Daily Operation Checklist:
- Power on and perform machine homing (2 minutes)
- Verify air pressure and lubrication levels
- Load wire spool and thread through tensioner and needle
- Load stator fixture and select winding recipe
- Run 3 test cycles, verify coil quality
- Begin production; monitor HMI for alerts
Company Strength
With over 15 years of experience in motor manufacturing equipment, our factory spans 12,000 square meters and houses CNC machining centers, precision grinding equipment, and a dedicated assembly workshop. We serve customers in over 40 countries, providing complete motor production solutions from standalone winding machines to fully automated stator assembly lines. Our in-house R&D team continuously refines winding algorithms and mechanical designs to keep our customers at the forefront of motor manufacturing technology.
Pre-Sales & After-Sales Service
Pre-Sales Engineering Support:
- Free winding feasibility assessment based on your stator drawings
- Sample winding service using your materials (we cover return shipping)
- Detailed technical proposal with machine configuration, layout drawing, and ROI analysis
- Factory visit invitation with live machine demonstration
Installation & Training:
- On-site installation by certified technician (5–7 working days)
- Comprehensive operator and maintenance technician training (3–5 days)
- Training materials in your language (English, Spanish, Russian, Arabic available)
- Post-installation follow-up calls at 1 week, 1 month, and 3 months
After-Sales Technical Support:
- 24/7 remote technical support via video call (TeamViewer / WhatsApp / WeChat)
- Guaranteed response within 4 hours for urgent issues
- Spare parts dispatched within 48 hours (DHL / FedEx express)
- Free software and firmware updates for the lifetime of the machine
- Optional annual maintenance contract with scheduled on-site service visits
Warranty Terms:
- 12-month comprehensive warranty covering all manufacturing defects
- Warranty does not cover consumable parts (wire nozzles, belts, filters) or damage from improper operation
- Extended warranty available: 2 years (+8% of machine price), 3 years (+15%)
Q: How long does it take to learn to operate the machine?
A: With our on-site training, most operators become proficient in basic operation within 3 days. Full mastery including recipe creation and troubleshooting typically takes 2–3 weeks of hands-on practice.
Q: What happens if the machine has a problem and we cannot resolve it remotely?
A: If remote diagnosis cannot resolve the issue, we will dispatch a technician to your facility. For customers under warranty, technician labor is free (customer covers travel and accommodation). For out-of-warranty machines, we charge a daily service fee at a competitive rate.
Q: Can the machine be integrated with our existing production line?
A: Yes. The machine supports standard industrial communication protocols (Modbus, Ethernet/IP, Profinet) and can be integrated with automated loading/unloading systems, conveyor lines, and MES systems. Our engineering team can provide custom integration solutions.
Q: Do you offer training for our maintenance staff to handle repairs independently?
A: Yes, we offer an advanced maintenance training program (3 additional days) that covers mechanical disassembly/reassembly, electrical troubleshooting, servo motor replacement, and control system diagnostics. Graduates of this program can handle 90% of common maintenance issues without external support.
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.
