Machining
Electric Motor Spares SC45# Steel Shafts
SC45# low-carbon steel precision fan shafts engineered for concentricity and wear-resistance in home & commercial appliances.
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Factory Catalog
Specialized Stator Automation & Rotor Finishing Equipment
Precision-matched equipment engineered for ceiling fans, industrial coolers, water pumps, and HVAC compressor motors. Configured directly from our factory floor to Thessaloniki manufacturing yards.
Winding
Automatic Coil Winder for Cooler Motors
High-efficiency automated coil winder tailored for industrial cooler stators with variable copper/aluminum wire setups.
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Dual Station
Heavy Duty 2-Station Ceiling Fan Winder
Dual-controller, 1 kW 220V architecture engineered for uninterrupted batch winding of ceiling fan stators with PLC monitoring.
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CNC Multi-Head
8-Head CNC Coil Winder (3000 RPM)
High-velocity 8-spindle CNC winder for table fan and shaded-pole motors, achieving exceptional slot-fill uniformity.
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Hydraulic
HF-W50 Hydraulic Rotor-Shaft Press
Calibrated tonnage press preventing lamination shearing, designed for tight-tolerance rotor-shaft interference fitting.
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Ceiling Fan
HF-R40-2G Dual-Station Stator Winder
Microprocessor-controlled dual station winder specialized in external-rotor fan stators with precision wire tensioners.
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Insulation
HF-D50 Slot Insulation Paper Inserter
Integrated cutting, folding, and inserting machine executing slot-liner cell insertion in sub-second indexing cycles.
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Stator Press
Gear-Driven Stator Shaft Insertion Press
Heavy-duty hydraulic press delivering synchronous axial alignment for ceiling fan stators and core assemblies.
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Regional Focus
Precision Coil Forming in Thessaloniki’s Industrial Ecosystem
From the industrial manufacturing zones of Sindos to maritime retrofitting near the Port of Thessaloniki, motor quality demands mechanical perfection in coil end-turn profiling.
Industrial Estates of Sindos (VI.PE.TH)
Enterprises operating in Northern Greece's premier industrial park require intermediate and final forming machines for heavy induction, ventilation, and commercial refrigeration motors. When coils are inserted, overhang wires expand radially and axially. Our hydraulic and servo forming tooling compresses end-windings to within ±0.3 mm of CAD tolerances, guaranteeing non-interference with cast-iron end-shields.
Thessaloniki Port Maritime & Pump Rewinding
Marine bilge pumps, ballast systems, and thruster units repaired around the Thermaic Gulf face extreme salt-fog vibration. Hand-shaped end-turns suffer from uneven copper stress, causing microscopic enamel fissures. Our servo expandable forming mandrels deliver uniform circumference pressure, ensuring that post-varnishing resin penetration is monolithic and compliant with DNV/Bureau Veritas insulation norms.
Balkan Cross-Border HVAC & Agritech Assemblies
Thessaloniki serves as an export logistics hub into North Macedonia, Bulgaria, and the greater Balkans. Agricultural pump makers in the Axios valley and HVAC OEMs rely on standardized tooling changeovers. Our machines feature quick-swap segmented forming dies that adapt across IEC frame sizes 63 through 160 within 12 minutes, eliminating costly batch downtime.
Engineering Insights
Industrial Trends Driving Coil Forming Upgrades in Northern Greece
As EU Ecodesign directives tighten energy efficiency mandates, electric motor builders must shift from archaic pneumatic benders to calibrated servo-hydraulic coil expansion.
IE3 & IE4 Premium Efficiency Compliance
European Regulation (EU) 2019/1781 mandates strict IE3/IE4 minimum efficiencies for low-voltage induction motors. Higher efficiency demands a greater stator slot fill factor (often exceeding 78%). At this density, traditional manual hammer forming damages the slot liner and short-circuits phase-to-phase insulation. Automated, multi-step coil forming ensures uniform mechanical distribution without localized copper stress.
Labor Scarcity in Skilled Mechanical Winding
The Hellenic Statistical Authority notes an ongoing shortage of seasoned electro-mechanical technicians in Central Macedonia. Stator coil insertion and manual lacing are highly labor-dependent. By implementing synchronized intermediate forming machines prior to automated lacing, production cells reduce the required manual labor per stator from 45 minutes to under 8 minutes across small batch runs.
Air-Gap Protection & Acoustic Attenuation
Acoustic resonance in fan and pump assemblies is frequently traced to asymmetrical end-turn masses that distort rotor magnetic flux lines. High-speed forming tooling locks coil heads into symmetrical geometry, preventing axial creep into the rotor-stator air gap. This stability is critical for commercial chillers exported into Central European urban regions where sound limits are strictly enforced.
| Process Stage | Equipment Type | Primary Function in Stator Cell | Engineering Benefit for Greek Plants |
|---|---|---|---|
| Slot Insulation | HF-D50 Automatic Inserter | Creases, cuts, and pushes Nomex/DMD liners into slots | Eliminates earth faults in coastal high-humidity areas |
| Coil Insertion | Automatic Coil & Wedge Inserter | Simultaneous push of coil groups and composite slot wedges | Preserves magnet wire enamel coating from scratch flaws |
| Intermediate Forming | Hydraulic Stator Coil Former | Flattens end-turn heads and expands bore clearance | Ensures unobstructed passage for double-side lacing needles |
| Stator Coil Lacing | HF-BS20 Servo Lacing Machine | Diamond or continuous stitch binding of end windings | Prevents vibration fraying in heavy marine propulsion runs |
| Final Forming | Multi-Jaw Outer/Inner Forming Machine | Calibrates exact overall envelope height and OD | Ensures 100% fit into motor housing without end-cover contact |
| Shaft Assembly | HF-W50 Hydraulic Shaft Press | Controlled-tonnage interference pressing | Protects bearing races from axial lamination cocking |
Enterprise Authority
Why Motor Manufacturers Worldwide Rely on Zunqi
Combining 17+ years of international manufacturing experience in Dongguan, China, with customized engineering tooling and industrial Western-standard electrical architectures.
Tooling to Exact Part Print
Every forming jaw, expander core, and coil pusher is precision CNC-machined to your specific stator lamination drawing and physical prototype. No generic one-size-fits-all tolerances.
Single Source Integration
Eliminate inter-vendor friction. We deliver fully balanced stator lines—from slot insulation inserting, CNC winding, and wedge inserting, to multi-stage forming and rotor finishing.
Configurable Control Systems
Control panels can be configured with globally recognized component architectures—Siemens, Mitsubishi, Schneider, Delta, Omron, and SMC pneumatics—enabling easy local maintenance in Greece.
Pre-Shipment Video Acceptance
You send us your stator cores; we perform trial runs and provide complete high-definition video proof of performance before sea packing in fumigation-free, anti-rust export crates.
Procurement Guidance
Frequently Asked Questions for Buyers in Thessaloniki
Direct technical answers addressing electrical compliance, customs clearing at Thessaloniki Port, tooling turnaround, and production line upgrades.
Are the motor stator coil forming machines fully compliant with EU power grids? +
Yes. Greek industrial facilities in Sindos and Central Macedonia operate on a 400V 50Hz 3-phase system (or 230V single-phase for smaller auxiliary models). Our control cabinets, servo motor drives, and hydraulic power units are configured directly at our Dongguan factory to 400V/230V 50Hz, complete with CE-compliant emergency circuitry, safety enclosures, and Schneider or Siemens breakers.
What is the standard delivery timeline and port routing to Thessaloniki? +
Standard machines have an equipment build and tooling manufacturing cycle of 25 to 35 business days depending on custom core geometry. Sea freight directly to the Port of Thessaloniki (ThPA) typically requires 28 to 35 days transit. We provide all necessary commercial documentation, including EUR-compliant packing lists, CE declarations, and certificates of origin for smooth Greek customs clearance.
Can a single coil forming machine accommodate different stator stack heights and bores? +
Yes. Our forming machines utilize modular expanding mandrels and segmented outer squeeze shoes. Tooling sets can be swapped out within 15–20 minutes to handle different lamination outer diameters (OD), inner bores (ID), and stack heights ranging from 10 mm to over 160 mm. Numerical parameters are saved directly in the touchscreen HMI recipes for instantaneous recall.
How does the machine avoid nicking or scraping the magnet wire enamel during expansion? +
The forming fingers and radial expansion shoes are machined from high-grade Cr12MoV tool steel, vacuum heat-treated to HRC 58-62, and precision mirror-polished. Furthermore, the expansion movement is governed by proportional hydraulic valves or servo linear ball screws that deliver steady, smooth pressure rather than impact shock, eliminating enamel cracking and phase shorts.
What is the Minimum Order Quantity (MOQ) and after-sales support protocol? +
Our MOQ is exactly 1 set. We offer a comprehensive 1-year equipment warranty covering all core electrical and mechanical parts. For commissioning in Greece, we offer step-by-step remote video integration, detailed CAD/electrical wiring schematics, and overnight dispatch of standardized wearing spares, with on-site technician deployment available for turnkey lines.
