High-Precision Stator Winding & Coil Shaping Equipment
Purpose-engineered for industrial motor plants, e-mobility drives, fan coils, and heavy-duty HVAC assemblies across Lower Silesia.
Precision End-Turn Forming: Overcoming Mechanical Limits in Stator Production
Within modern electric motor assembly lines, Stator Winding Shaping (forming) represents the critical mechanical bridge between automated wire insertion and final double-side lacing. In fractional horsepower drives, industrial pumps, and electric vehicle traction stators alike, improper coil overhang profile leads directly to catastrophic phase-to-phase shorts, wire enamel cracking, and housing interference fit failures.
Our stator shaping machinery implements hydraulic and multi-segment servo-driven expandable tooling that distributes radial and axial stress uniformly across the copper or aluminum coil bundle. By coordinating inner expanding mandrels with outer wrapping molds, the end-turns are contoured into precise geometries that prevent slot wedging movement while preserving the stator bore concentricity within ±0.02 mm.
Dual-Stage Expansion & Compaction Mechanics
Eliminates localized wire displacement, ensuring maximum slot clearance without weakening dielectric enamel coatings.
Synchronous Multi-Axis CNC Servo Control
Programmable ram strokes and holding pressures stored directly as individual recipe parameters for fast retooling.
| Technical Parameters | Mid-Volume Line | Automotive / EV Grade Line |
|---|---|---|
| Stator O.D. Compatibility | Ø30 mm – Ø160 mm | Ø60 mm – Ø280 mm |
| Stack Height Range | 10 mm – 150 mm | 20 mm – 300 mm |
| Forming Cycle Speed | 6 – 10 seconds/cycle | 4.5 – 7.5 seconds/cycle |
| Tooling Material Spec | Cr12MoV (HRC 58-62) | SKD11 / DC53 Vacuum Treated |
| Drive System | Pneumatic / Hydraulic | Full Servo + Proportional Valve |
| Concentricity After Forming | ≤ 0.05 mm | ≤ 0.02 mm |
Lower Silesia Industrial Integration & Regional Trends
Why Wrocław has emerged as Central Europe’s strategic hub for advanced electric motor manufacturing and automation retrofits.
E-Mobility & Battery Corridors
Wrocław and the surrounding special economic zones (Wałbrzych and Legnica SEZ) sit at the center of Europe's largest EV drivetrain supply belt. Our machines handle high slot fill-factor hairpin and concentrated winding profiles essential for Tier-1 traction motors.
EU Ecodesign (IE4/IE5) Compliance
Stringent European environmental directives require Polish electric motor OEMs to cut rotor/stator electrical resistances. Precise intermediate and final coil forming ensures that denser wire groupings fit tightly without causing air gap degradation.
Nearshoring & Modernization
European manufacturers migrating assemblies closer to core EU automotive hubs in Poland rely on turnkey motor lines. We offer backward-compatible tooling arrays that slot into existing plant cells while offering standardized European CE compliance.
Zunqi Intelligent Equipment: Verified Engineering Heritage
Combining 17+ years of dedicated export integrity with ISO-monitored stator tooling customisation.
Custom Tooling from Client Samples
Every winding, inserting, and shaping die is custom-machined directly from your engineering CAD/3D drawings or sent physical sample stators. We validate tooling via extensive test-runs before export crating.
Tier-1 Control Integration
We configure electrical enclosures to European industrial maintenance preferences: Siemens, Mitsubishi, Omron, Schneider, or Delta PLCs and HMI interfaces. Dual-voltage configurations (230V 1P / 400V 3P 50Hz) standard.
Complete Turnkey Line Synergy
Beyond individual forming stations, we supply matched stator production suites: Paper Insulating → Multi-Head Winding → Automated Inserting → Pre-Forming → Double-Side Lacing → Final Forming → Rotor Turning.
Frequently Asked Questions for European & Polish Buyers
Addressing common technical specifications, logistics, CE certifications, and tooling integration queries.
How do you verify tooling clearance for non-standard stator geometries?
Before precision machining begins, our tooling engineers analyze your stator CAD drawings (slot openings, stack depth, winding overhang). Clients typically express physical lamination stacks to our Dongguan facility, allowing us to perform full cycle validation and record high-speed video acceptance tests prior to final crating.
Can equipment be integrated into existing Wrocław production cells?
Yes. Our stator winding shaping machines offer standalone cycling with optical safety light curtains or fully interlocked PLC communication protocol handshakes (such as Profinet or Ethernet/IP) to fit robot-loaded linear cell layouts common in Lower Silesia's modernized facilities.
What is the standard European delivery protocol and shipping duration?
Machines are wrapped in VCI rust-preventative barriers, bolted down, and sealed within fumigation-free solid export plywood cases. Typical sea freight transit to ports such as Gdańsk or Hamburg averages 28 to 35 days, with direct rail freight via the New Silk Road (Chengdu/Xi'an to Małaszewice/Wrocław) available in approximately 16 to 18 days.
What after-sales, warranty, and spare part provisions are included?
Every machine includes a comprehensive 1-year mechanical and electrical parts warranty. Critical wearing components (forming pushers, expanding segments, microswitches) ship as an onboard starter maintenance kit. We provide ongoing remote engineering video assistance and fast spare part dispatches for long-term line continuity.
Upgrade Your Stator Production Line Today
Connect with Zunqi’s application engineering team. Send your stator blueprints and lamination stack dimensions for a rapid feasibility analysis and quotation within 9 hours.
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