Configured specifically to support UK Tier-1 motor developers and niche low-to-high volume electric vehicle powertrain assembly lines, ensuring repeatability, micron-level concentricity, and CE/UKCA compliance.
The United Kingdom’s automotive sector is undergoing its most radical transformation since the inception of internal combustion mass manufacturing. Driven by the Advanced Propulsion Centre (APC UK) directives, the Automotive Transformation Fund (ATF), and stringent Zero Emission Vehicle (ZEV) mandates requiring 80% zero-emission new cars by 2030 and 100% by 2035, the demand for localized electric machine (e-machine) production infrastructure has surpassed critical mass.
For British powertrain developers, tier-1 sub-system assemblers, and niche performance e-drive manufacturers—ranging from the high-volume corridors in Sunderland and the West Midlands to specialized motorsport and boutique hypercar workshops in Oxfordshire’s Motorsport Valley—the bottleneck is no longer electromagnetic simulation. The core commercial and technical challenge lies in industrialization: migrating from lab-scale prototypes to high-speed, repeatable, zero-defect automated stator and rotor line production.
Zhejiang Rilvo Automation Equipment Co., Ltd. (Rilvo Automation) acts as the end-to-end turn-key manufacturing partner for British industrial buyers. We engineer fully integrated custom OEM production lines covering every discrete step: automated slot liner insertion, precision multi-axis needle and flyer winding, flat-wire roll forming and stripping, automated coil insertion, CNC hydraulic multi-stage wire expanding and end-turn shaping, intermediate hot-staking commutator and lead welding, and state-of-the-art horizontal trickling and continuous roll-dip varnishing stations.
Our stator and rotor production systems integrate seamlessly into the varied manufacturing regimes operating across England, Wales, and Scotland.
Tailored for high-throughput passenger car BEVs requiring automated hairpin or wave-wound stators. Incorporating fully synchronized inline stations that achieve cycle times under 45 seconds per completed stator pack, including laser decoating, multi-die bending, and servo-assisted slot embedding.
For high-power-density axial and radial flux e-motors deployed in Formula E, Le Mans hypercars, and bespoke high-performance EV platforms. The lines provide flexible batch tooling changes (< 25 minutes) with multi-strand Litz wire and specialized resin trickling to withstand extreme continuous thermal classes (Class H & 220°C).
Supporting UK bus retrofits, municipal electric commercial vehicles, and agricultural machinery built across the North West and Midlands. Capable of handling massive lamination stack heights (up to 400 mm) and wire diameters exceeding 2.2 mm with robust hydraulic coil spreading and deep-slot insertion forces.
British electrical machine manufacturers operate under stringent scrutiny regarding capital allocation, Overall Equipment Effectiveness (OEE), and carbon-footprint reduction. In dialogue with UK factory managers, five prominent engineering trends dictate stator machine specification:
1. Transition from Distributed Random-Wound to Continuous Hairpin / Wave Stators: Distributed winding lines using equipment like our XB-1GZ and High Speed Induction Motor Coil Winding Machines remain indispensable for micro-mobility, auxiliary actuators, and commercial vehicle drives. However, traction drive programs demand hairpin manufacturing cells capable of 2D/3D wire bending without tearing outer PAI/PI enamel coatings.
2. Vacuum Pressure Impregnation (VPI) vs Automated Trickle Varnishing: Traditional dip tanks are being phased out in modern UK plants due to solvent VOC emission regulations and excessive energy consumption. Horizontal trickle impregnators—such as our SZD-376/63.5 Model—apply catalyzed epoxy resin directly onto pre-heated end turns using resistance heating. The capillary action draws the resin through slot interstices within minutes, cutting electrical curing consumption by 65% and eliminating post-machining varnish scraping.
3. Comprehensive Traceability and Industry 4.0 Compliance: UK industrial contracts require per-part serialized data logging. Every automated machine in our line integrates Ethernet/IP, Profinet, or OPC UA gateways, recording crimp force, winding tension, insertion pressure profiles, and dielectric hipot leakage directly into central MES systems.
| Process Step | Standard Distributed Round Wire Line | Rilvo Custom OEM Automated Line | Validation / Traceability Standard |
|---|---|---|---|
| Slot Insulation | Single-index mechanical paper cutter | Servo-driven programmable B-stage DMD/Nomex insertion (0.8s/slot) | Optical wedge presence check |
| Coil Winding | Single-spindle manual flyer winder | Multi-spindle synchronous servo winding with closed-loop tensioners | Dynamic load-cell gram-force log |
| Coil Embedding | Pneumatic push / manual guide blade | Hydraulic-servo simultaneous coil & wedge pusher (Model 5 DQ-1) | Peak stroke displacement & force plot |
| End-Turn Shaping | Manual wooden mallet / pneumatic clamp | Two-stage radial expanding & axial pressing CNC dies | Laser coordinate profile scanning |
| Varnish Application | Batch solvent-dip tank & gas oven | Automated horizontal trickle varnishing with Joule effect curing | Resin weight verification (±0.5g) |
| Electrical Testing | Off-line bench tester (Sampling) | Integrated 4-in-1 end-of-line: Surge, Hipot (5kV), Resistance, PDIV | Per-part QR serialization export |
Founded in 1998, Zhejiang Rilvo Automation Equipment Co., Ltd. has spent over 27 years engineering high-precision micro-motor and automotive stator/rotor manufacturing equipment.
Unlike trading entities or low-tier integrators who outsource machine frames and precision fixtures to third parties, Rilvo Automation retains 100% internal control over the machining, grinding, heat treatment, and programming of critical machine components. Located in the Shatianyang Development Zone of Sanmen, Taizhou, our 60,000 m² modern manufacturing hub houses over 150 internal precision CNC lathes, five-axis machining centers, and wire EDM stations.
Led by our President and Chief Engineer—a decorated national knowledge-worker model honoree of the All-China Federation of Trade Unions—our 36-member technical R&D division bridges electrical, mechanical, and optical machine vision systems. Every machine designated for the United Kingdom undergoes a complete pre-shipment Factory Acceptance Test (FAT) running real customer lamination stacks and copper magnet wire. Full high-speed video verification, slot-fill cross-section micro-sections, and dielectric test logs are signed off prior to Ningbo port dispatch.
We hold active ISO9001 Quality Management System accreditation, China Compulsory Certification (3C), National High and New Technology Enterprise credentials, and engineer all European/UK-bound equipment to strictly align with the UK Supply of Machinery (Safety) Regulations 2008 and BS EN 60204-1 safety standards.
Addressing essential technical, contractual, regulatory, and logistics inquiries for UK-based equipment installations.
All machinery exported to England, Scotland, and Wales is certified to the relevant UKCA statutory instruments and CE Directives (Machinery Directive 2006/42/EC, Low Voltage Directive 2014/35/EU, EMC Directive 2014/30/EU). We utilize dual-channel safety circuits, Pilz/SICK light curtains, Pilz safety relays, and emergency stop interlocks in full compliance with BS EN ISO 13849-1 (Category 4, PL e) and BS EN 60204-1 electrical codes with 400V 50Hz 3-phase industrial power supply standards.
Yes. Our winding, inserting, and shaping systems are built with modular quick-change cassettes. For instance, our DQ-2 coil inserter or 5 DQ-1 embedding machine can transition between different stator outer diameters (e.g., from Φ110 mm passenger car e-pumps to Φ220 mm traction motors) in under 45 minutes through tool-less mechanical clamps and digital program recipe selection on the HMI.
Prior to dispatch, the buyer delivers 50–200 sets of blank lamination cores, slot paper, and designated enameled wire to our Sanmen factory. We run continuous batch trials at design speed, verifying Cpk ≥ 1.67 across dimensions, checking slot enamel leakage via 5kV surge/hipot testing, and generating detailed dimensional inspection reports. UK teams can attend onsite or perform virtual multi-angle high-resolution video buy-offs.
We regularly quote FOB Ningbo/Shanghai, CFR/CIF Felixstowe, Southampton, London Gateway, or Liverpool, as well as DDP directly to your facility gate in the UK. Machinery is treated with high-grade VCI rust-preventative barriers, vacuum shrink-wrapped, and crated in heavy-duty fumigated wooden cases built for deep-sea container voyages.
We provide two commissioning pathways: First, direct deployment of our senior automation engineers to your UK plant for mechanical anchor validation, line integration, and operator training. Second, all machine control panels feature integrated secure VPN remote gateways (eWON/Secomea) allowing our lead PLC engineers in Zhejiang to troubleshoot code, update cycle profiles, and inspect sensor signals in real time.
We deliberately engineer our electrical architectures around globally available standard tier-1 industrial brands. Servo motors, drives, and PLCs use Siemens, Mitsubishi, or Schneider Electric; pneumatic valves and cylinders rely on SMC or Festo; electrical switchgear features Schneider or ABB. UK maintenance engineers can source routine consumables locally within 24 hours.
Submit your stator/rotor lamination CAD drawings (.STEP / .DXF), slot dimensions, wire gauge specifications, and target annual cycle takt times. Our chief automation engineering team will formulate a full turnkey machine proposal within 48 hours.
Official Sales & Engineering Office · Zhejiang Rilvo Automation Equipment Co., Ltd.
