Heavy Copper
CJL-7 Flat Coil Winding Machine
Drive: CNC multi-axis servo
Application: EV & Alternator coils
Slot Wedge Compatibility: Integrated
Engineered for high dielectric integrity, repeatable cycle times, and heavy-duty industrial stator laminations. Backed by ISO9001 certification and factory direct calibration.
Operating from our dedicated industrial facility in Sanmen, Zhejiang, Rilvo integrates in-house precision die machining, mechanical assembly, and rigorous ISO9001 quality audits.
Stator paper inserting is arguably the single most critical dielectric foundation in high-efficiency electric motor assembly. Whether manufacturing starter motors, brushless DC (BLDC) automotive powertrains, hermetic compressor pumps, or industrial high-voltage induction motors, an undetected pinhole puncture, torn slot liner cuff, or misaligned edge cuff guarantees dielectric breakdown under surge voltage testing. As an OEM and global exporter with nearly three decades of dedicated production experience, Zhejiang Rilvo Automation Equipment Co., Ltd. designs automated stator paper inserting machines that eliminate scrap rates, maintain precise edge-cuff geometries, and adapt seamlessly across complex lamination stack depths.
Engineering Imperative: The primary failure mode during subsequent stator coil insertion or needle winding stems from irregular paper cuff forming or material thinning during the pushing stroke. Advanced stator paper inserting machines utilize precise servo feeding paired with tungsten-carbide cold-forming dies to control fold curvature down to ±0.05 mm, preventing insulation embrittlement.
Automated slot cell inserters execute a coordinated high-speed sequence: paper decoiling, incremental stepping, bilateral cuff forming (single or double hem), precision shear cutting, transverse paper folding into U- or B-profile geometries, and mechanical ram-insertion into the stator stack slots. On conventional pneumatically controlled inserting machines, stroke velocity fluctuates with air pressure drops, frequently causing incomplete cell insertion in laminations above 80 mm stack height. Rilvo's latest generation custom OEM machines deploy multi-axis servo synchronization, pairing rotary indexing servo tables with precision linear ballscrew insertion rams.
This closed-loop motion architecture ensures that the paper insertion ram enters the slot cell at a programmable velocity profile: decelerating gently as the paper cuff engages the far-side lamination edge, thereby preventing cuff buckling, and accelerating during the return stroke to maintain cycle benchmarks of 0.35 to 0.65 seconds per slot, including stator indexing.
Capable of processing high-rigidity Nomex®, DMD, NMN, polyester films (Mylar®), and composite insulating laminates ranging from 0.15 mm to 0.50 mm thickness without die galling or jam cycles.
Quick-release die sets and expandable indexing mandrels reduce changeover downtime between distinct frame sizes (e.g., NEMA 48 to 56, or custom IEC stators) to under 25 minutes.
Programmable human-machine interfaces support variable slot geometries: uniform full slots, skip-slot patterns, step-insulation, and asymmetric lamination configurations in a single pass.
Procurement directors and automation project engineers are navigating structural shifts in electric motor design. As end markets prioritize Class H thermal dissipation, miniaturization, and higher slot-fill ratios for high-voltage EV and solar mobility applications, traditional stand-alone insulation inserters are being phased out in favor of intelligent, integrated workstations.
Automotive traction motors operating on 800-volt inverter buses experience extreme partial discharge (corona) phenomena. As a result, procurement trends reflect a shift toward multi-layer micro-composite papers (such as Nomex-polyimide laminates). These rigid papers are prone to delamination when folded by dated mechanical linkages. Procurement teams are mandating custom OEM machines with servomotor-regulated pre-creasing and heated die stations to set paper memory before insertion without cracking the outer barrier layer.
With flat rectangular wire (Hairpin) technology dominating next-generation alternators and traction motors, slot liner geometry has transformed. Conventional round-wire motors tolerate slight variations in cell depth. Hairpin designs, by contrast, demand near-zero clearance between the slot cell paper and the lamination iron to maximize slot copper volume. Sourcing specifications now emphasize B-shape or asymmetric fold profiles with laser measurement inspection integrated directly within the insertion station.
Modern factory standards reject post-process quality audits in favor of in-line failure prevention. Future procurement specifications standardise high-resolution optical inspection cameras mounted to the inserting die fixture. Every inserted paper slot is photographed and analyzed via edge AI to confirm cuff height symmetry, absence of axial tilt, and total cell clearance in milliseconds, ejecting defect stators automatically before reaching downstream winding systems.
Headquartered in the Shatianyang Development Zone of Sanmen, Taizhou, Rilvo combines nearly three decades of engineering pedigree with end-to-end manufacturing oversight.
Over 150 machining units in our 60,000 m² facility ensure every die set, guide blade, and push-rod is machined from hardened tool steels without external machining delays.
Awarded High and New Technology Enterprise status in Zhejiang Province, driven by our 36-engineer R&D team led by national-level model engineering specialists.
Before shipment, customer-supplied lamination cores and insulation media undergo uninterrupted trial production runs, backed by complete video documentation and telemetry logs.
Located two hours from Ningbo Port, we provide FOB, CFR, CIF, and EXW trade terms, full CE documentation, and direct English, Spanish, Russian, and German support desks.
Critical engineering considerations, tooling capabilities, and commercial criteria for OEM procurement officers.
Our standard custom machinery covers stator outer diameters (OD) from 30 mm to 260 mm and core stack heights from 10 mm to 300 mm. For heavy industrial generators or specialized subfractional micro-motors, our 36-member R&D engineering department produces fully tailored frames and customized mechanical stroke depths.
We combine high-hardness tungsten steel cuff-forming dies with programmable dual-rate servo feeding. The edge cuff is creased under controlled radial tension rather than abrupt mechanical shock, and the insertion guides are hand-polished to mirror finishes (<Ra 0.2), minimizing friction against the slot liner material.
Yes. Via multi-axis CNC interpolation and programmable HMI recipe storage, our inserters can process skewed stator slots up to 15 degrees, as well as alternating slot patterns where slot depth or opening widths vary along the core circumference. Changeover involves calling up the parameter set and exchanging the mechanical die set.
Standard models with custom tooling dies typically ship within 30 to 45 business days from receipt of core lamination drawings and sample approval. Turnkey stator lines encompassing slot paper insertion, coil winding, wire embedding, and wedge closing are scheduled on an 8 to 12-week build cycle.
Every unit undergoes customer-sample pre-acceptance testing at our Zhejiang factory before packing in seaworthy wooden crates. We provide detailed English electrical schematics, digital video maintenance modules, spare wear-parts bundles, and encrypted remote PLC diagnostics. Field technicians are dispatched for on-site line commissioning upon request.
As a verified Chinese manufacturer and direct exporter, Zhejiang Rilvo supports FOB (Ningbo or Shanghai), CIF, CFR, and EXW agreements. Commercial settlement is conducted via T/T or confirmed irrevocable L/C in USD or EUR, supported by formal factory inspection documentation and ISO9001 compliance sheets.
Provide your stator lamination drawings, insulation paper specifications, and required daily cycle yield. Our applications engineering team will deliver a customized die proposal, cycle time analysis, and quotation within 24 hours.