Stator Tooling
DQ-2 Alternator Stator Coil Inserting Machine
Simultaneous servo-controlled coil and slot wedge paper embedding. Eliminates enamel scuffing during multi-strand automotive copper wire insertion.
Configured specifically for starter alternators, permanent magnet DC systems, and high-efficiency induction stators operating in Brazil's industrial hubs.
Simultaneous servo-controlled coil and slot wedge paper embedding. Eliminates enamel scuffing during multi-strand automotive copper wire insertion.
Designed for heavy starter rotors and compact DC motor armatures with dual-flyer servo tensioners, keeping slot stack precision tightly calibrated.
Programmable CNC multi-spindle coil grouping for monophasic and triphasic industrial induction motors with constant-tension payoffs.
Precision inverter DC fusing system for commutator tangs. Delivers ultra-low thermal dissipation, ensuring zero carbon base burning.
High-speed slot cell forming, cutting, and inserting at speeds up to 0.5s/slot. Compatible with Nomex, DMD, and polyester film insulations.
Engineered for rectangular magnet wire manipulation, edge-wise winding, and continuous conductor forming for high slot fill factor e-mobility motors.
Microcomputer-controlled resistance welding for starter terminals and brush assemblies with closed-loop pressure and current feedback monitoring.
Automated circular seam and lead joining station for segmented BLDC stator cores with indexed multi-station rotary tables.
Navigating the dual challenges of high coastal humidity and heavy-duty manufacturing across Salvador, the Camaçari Petrochemical Pole, and the Aratu Port Complex.
The Camaçari Industrial Complex demands flameproof (Ex d) and severe-duty medium-voltage electric motors. Our automated lines incorporate precision slot insulation and trickle impregnation cycles, preventing microscopic voids in dielectric resins that cause partial discharge in volatile refinery atmospheres.
Salvador's supply chain logistics support heavy automotive fleets across Northeast Brazil. Our machines—such as the DQ-2 coil inserter and SDN-32ZH fusing units—allow local component builders and tier-1 rebuilders to handle diverse OEM rotor and stator frames with modular retooling under 20 minutes.
Operating near the Bay of All Saints exposes motors to airborne ocean salinity (cloretos). We equip our production machinery with tropicalized pneumatic manifolds, IP65 control enclosures, and automated trickle varnish dispensing that achieves Class H insulation standards without solvent blistering.
Industrial machinery deployed across Bahia faces sustained relative humidity above 80% coupled with elevated ambient temperatures. Conventional open-air dip impregnation frequently results in uneven resin coverage, air entrapment, and premature dielectric breakdown under NBR 17094 standards. Rilvo's automated horizontal trickle varnish units eliminate air bubbles by rotating the pre-heated stator at controlled angular velocity while directly injecting catalyzed resin onto the end windings.
Furthermore, local electrical grids can experience intermittent voltage transients. Rilvo assembly lines integrate 100% automated surge testing (up to 5kV) and inter-turn short-circuit detection directly into the coil winding and inserting station, certifying zero latent winding damage before downstream assembly.
How legislative decarbonization and regional industrial policy are reshaping electric motor production lines across Brazil.
Brazilian Law No. 10,295 establishes stringent Minimum Energy Performance Standards (MEPS). Producing IE3 and IE4 induction motors requires slot fill rates exceeding 78%, which is physically unachievable with manual insertion. Rilvo's automatic servo-driven stators achieve dense conductor packing without wire strand crossing.
With massive investments reviving the Camaçari automotive manufacturing footprint for electric and hybrid vehicles, demand for hairpin stator lines and BLDC auxiliary motor assembly (steering pumps, HVAC blowers, brake actuators) is skyrocketing. Our CJL-7 flat wire and SW-130G welding systems directly fulfill these e-powertrain targets.
Imported capital machinery in Brazil must strictly conform to Portaria No. 3.214 NR-12 (Machinery Safety). Every Rilvo system is certified under European CE Machinery Directive 2006/42/EC and can be configured with dual safety-circuit relays, Cat-4 light curtains, and emergency shutoff topologies aligned with local Brazilian labor safety norms.
| Motor Production Metric | Legacy Manual / Semi-Auto Method | Rilvo CE-Certified Automated Line | Impact on Salvador Manufacturing Plants |
|---|---|---|---|
| Slot Fill Factor | 55% – 62% | 78% – 85% | Enables immediate IE3 / IE4 energy compliance under Brazilian laws |
| Stator Insertion Cycle Time | 180 – 240 seconds | 18 – 32 seconds | Increases single-shift daily throughput by up to 450% |
| Dielectric Breakdown Reject Rate | 3.5% – 5.8% | < 0.15% | Dramatically reduces wasted enameled copper and unrecoverable scrap |
| Safety & NR-12 Interlocking | Retrofit required upon import | Built-in CE Cat-4 / Dual Redundant | Bypasses costly on-site safety rewiring and certification delays in Bahia |
Since 1998, Zhejiang Rilvo Automation Equipment Co., Ltd. has delivered turnkey motor manufacturing systems worldwide from our modern 60,000 m² campus.
Tooling heads, winding needles, and wedge guides are machined in-house across 150+ machining units to preserve sub-micron concentricity and hardened steel endurance.
Over a decade of customized engineering. Our design engineers optimize machine geometries around your exact stator and armature CAD drawings, stack heights, and wire gauges.
Every electrical cabinet and mechanical link operates under stringent ISO9001 quality frameworks, verified on-site by international inspection bodies for complete provenance.
Routine shipping from Ningbo port directly to the Port of Salvador or Port of Aratu under FOB, CIF, or CFR incoterms, supported by Portuguese-language manuals and documentation.
Addressing essential technical, regulatory, and logistics queries for engineering and purchasing managers importing into Brazil.
Every motor assembly line for the Brazilian market is custom-wired for 380V or 220V three-phase at 60Hz. We employ top-tier industrial automation brands (Siemens, Schneider, or Mitsubishi) with integrated surge filters and harmonic suppression suitable for regional grid variances.
Yes. Our machines are built to European CE standard EN ISO 12100 / EN 60204-1. We supply dual-channel safety relays, physical perimeter guards, safety optoelectronic barriers (light curtains), and translated electrical circuit schematics to streamline certification by registered Brazilian engineers (ART/CREA).
You provide your bare stator lamination stacks, rotor shafts, and magnet wire specifications. We build and calibrate the tooling, run 500+ uninterrupted test cycles, record high-definition video data, verify slot fill and dielectric resistance, and deliver an exhaustive FAT report prior to balance payment release.
Ocean freight transit from Ningbo / Shanghai to the Port of Salvador (BRSSA) or Port of Aratu averages 32 to 42 days. Machines are hermetically sealed in vacuum anti-corrosion barrier foil, packaged with industrial desiccants, and crated in fumigated export-grade solid wooden cases to withstand maritime equatorial moisture.
Yes. Our stator inserting and winding machines are designed around quick-change modular tooling. Stator outer diameters, inner diameters, and stack heights can be altered by swapping the insertion wedge guide and setting servo parameters via the touchscreen HMI in less than 20 minutes.
Each unit ships with a 2-year consumable wear-part kit (blades, needles, pneumatic seals). We provide remote diagnostics via industrial VPN router connections, interactive commissioning video guidance, and Portuguese-annotated operational manuals, alongside fast-track DHL/FedEx spare delivery.
Connect directly with Rilvo's industrial automation engineering team. Send your stator/rotor specifications, lamination drawings, and desired shift output to receive a customized line layout and quotation.