SDN-32ZH Commutator Hook Fusing Machine
Hot-stake resistance fusing for commutator hook terminals with constant closed-loop current feedback.
Inquire NowExplore our specialized stator winding, flat wire shaping, and automated inserting machinery configured for Tier-1 OEMs, precision pump designers, and electromechanical equipment builders across County Galway and the Western Region.
Hot-stake resistance fusing for commutator hook terminals with constant closed-loop current feedback.
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Cost-efficient spot welding machine designed for uniform contact pressure and repeatable joints.
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High-hardness guiding blades, push fingers, and precision CNC tooling kits built for zero wire scuffing.
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Simultaneous slot wedge feeding and winding insertion driven by multi-axis high-dynamic servo drives.
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Programmable lead twisting and indexing system tailored for high-speed micro-motor armatures.
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High-speed insulation taping machine for starter field coils with adjustable overlap ratio and tensioning.
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Multi-station high-speed flyer winding mechanism engineered for industrial three-phase induction stators.
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Rectangular and hairpin flat wire winding and edge-bending unit delivering maximum stator copper fill factor.
Inquire NowYears Industry Heritage (Since 1998)
Modern Manufacturing Footprint
National Invention & Utility Patents
Custom Tooling Forming Repeatability
The electromagnetic efficiency of fractional kilowatt (sub-kW) and industrial-scale alternating current (AC) or brushless direct current (BLDC) motors is fundamentally constrained by their stator slot fill factor and copper overhang profiles. For precision electromechanical manufacturers and specialized engineering facilities operating in the Galway region—such as those based in Parkmore, Ballybrit, and the Mervue Industrial Estates—optimizing stator manufacturing involves solving delicate mechanical-electrical trade-offs. Stator coil forming represents the pivotal process between primary flyer winding and subsequent varnish impregnation.
A poorly formed stator coil bundle creates severe spatial interference during insertion, elevates mechanical friction against the slot liner (leading to microscopic enamel abrasion), and causes excessive coil overhang length. Excessive end-turn extension not only wastes costly grade-2 enamel copper wire but exponentially increases parasitic resistance (I²R loss), reducing motor electrical efficiency below IE4 and IE5 Super Premium standards. As an internationally certified high-tech manufacturer, Zhejiang Rilvo Automation Equipment Co., Ltd. builds customized, servo-actuated stator coil forming machines that deliver intermediate and final 3D volumetric forming with micro-metric dimensional repeatability.
Our stator coil forming equipment leverages a synchronized dual-station or rotary table sequence incorporating internal expanding mandrels, external cuff-shaping shoes, and axial clamping headers. The process is broken into two distinct metallurgical stages:
Internal radial expanding segments gently push end turns outward while slot-exit zones are stabilized. This expands the stator bore clearance, ensuring subsequent coil group insertion passes without mechanical pinch points.
High-tensile alloy forming molds simultaneously clamp the outer boundary, inner bore clearance, and end face height. This compacts the copper bundle to guarantee tight dimensional envelope tolerances before housing assembly.
Tooling contact surfaces are finished with mirror-polished hard chrome plating or Cr12MoV vacuum hardening (>HRC60), ensuring zero scratches or stress micro-fissures in primary polyimide insulation layers.
Our modular tooling system allows rapid retrofits between varying lamination outer diameters (OD), core stack heights, and coil slot counts. Below are technical parameters for our flagship servo-driven stator coil forming equipment supplied to European OEM manufacturing lines.
| Technical Metric | Standard Series (Model SF-60/160) | Heavy-Duty Industrial (Model SF-160/260) | Custom Flat Wire / Hairpin Line |
|---|---|---|---|
| Stator Lamination O.D. | Φ30 mm – Φ160 mm | Φ140 mm – Φ280 mm | Φ80 mm – Φ350 mm (Customized) |
| Lamination Stack Height | 15 mm – 160 mm | 50 mm – 300 mm | 30 mm – 220 mm |
| Drive Actuation Method | High-Dynamic AC Servo / Hydraulic Hybrid | Proportional Electro-Hydraulic System | Multi-Axis Fully Synchronized Servo |
| End-Turn Forming Height Accuracy | ±0.15 mm | ±0.25 mm | ±0.08 mm |
| Cycle Time Per Stator | 6.0 – 9.0 seconds | 10.0 – 14.0 seconds | 8.0 – 12.0 seconds |
| Enamel Coating Breakdown Rate | 0.00% (Guaranteed <50V Surge Drop) | 0.00% (High Potential Surge Inspected) | Zero Deformation on Edge Enamel |
| Control Interface & PLC | Mitsubishi / Siemens PLC + 7" HMI | Siemens S7-1200 + Industry 4.0 Bus | Beckhoff TwinCAT / Siemens Industrial PC |
County Galway represents one of Europe's most dynamic high-technology advanced manufacturing hubs. While renowned globally as a global center of excellence for medical technology and biomedical engineering, Galway and the wider Connacht region have developed a robust, sophisticated supply chain in precision industrial automation, specialized fluid handling equipment, clean energy maritime devices, and high-spec HVAC systems.
Companies operating within industrial nodes such as Oranmore, Tuam, Loughrea, and the Galway Technology Park face strict European Union energy performance mandates, including the EU Ecodesign Directive (Directive 2009/125/EC) and Irish National Climate Action Plan decarbonization targets. To achieve the rigorous efficiency benchmarks required in micro-pumps, surgical drive motors, automated pharmaceutical handling lines, and offshore marine subsea equipment, local electromechanical manufacturers are moving decisively from manual coil forming and semi-automatic assembly toward fully integrated, turnkey coil preparation machinery.
Sub-fractional BLDC and slotless stators used in automated drug delivery systems and surgical drills require tight coil compacting without damaging ultra-fine copper wire (<0.12 mm).
Auxiliary hydraulic pumps, yaw pitch actuators, and sea-spray resistant servomotors built for West of Ireland marine deployments require heavy wire slot filling and defect-free end-turn clearances.
Ireland's nationwide residential retrofit initiatives drive surging demand for ultra-quiet, permanent magnet synchronous motor (PMSM) compressors demanding high slot fill factors and zero vibration hum.
1. Migration to Rectangular Flat Wire (Hairpin) Stators: To elevate thermal dissipation and achieve magnetic saturation advantages in smaller envelopes, precision motor builders are shifting toward flat copper wire winding. Rilvo's flat wire shaping and custom coil-forming modules ensure strict perpendicularity and bend corner consistency without insulation thinning.
2. Traceability & Cleanroom-Grade Machinery Standards: Galway's extensive regulated cleanroom engineering practices dictate that machine builders deliver equipment with oil-mist-free pneumatic actuators, stainless steel wear components, low particle generation, and Ethernet/IP or Profinet data logging capabilities.
Founded in 1998, Zhejiang Rilvo Automation Equipment Co., Ltd. (operating from our major production campus in the Shatianyang Development Zone, Sanmen, Taizhou, China) has delivered tailored motor stator and rotor manufacturing automation across over 40 countries. Our factory-direct OEM/ODM capabilities bridge high-level engineering precision with robust industrial economics.
Equipped with over 150 CNC machining centers, horizontal boring rigs, and coordinate measuring machines (CMM) to maintain in-house tooling accuracy.
Headed by our chief engineer, recipient of the national knowledge-worker model award. Mechanical, electrical, and optical programming are completely centralized.
Rigorous multi-stage quality assurance protocol: raw material metallography, dynamic balancing, dry-cycle testing, and continuous sample-stator trial runs.
Direct maritime container dispatch from Ningbo Port (2 hours from site) straight to Dublin or Cork Ports, fully compliant with CE safety directives and EUR documentation.
To assist operations directors, machine design leads, and strategic sourcing specialists in Ireland, here are direct answers addressing technical adaptation, compliance, and international logistics.
Yes. Customization is our core competency. Over 80% of the machinery we produce is built to specific OEM specifications. Our 36-member engineering department will evaluate your DWG/STEP CAD files, lamination stack height, slot cross-section, wire diameter, and insulation paper type to produce custom 3D-modeled forming mandrels and outer shoes. We run pre-delivery verification tests using your provided lamination stacks.
Every stator forming machine exported to the European Union is built in full compliance with the Machinery Directive 2006/42/EC, Low Voltage Directive 2014/35/EU, and Electromagnetic Compatibility Directive 2014/30/EU. Equipment is configured for Irish industrial three-phase 400V / 50Hz grid standards and fitted with dual-channel emergency safety circuits, optical light curtains, and CE-marked components.
Insulation integrity is maintained through three primary safeguards: First, all tooling contacting the coil is fabricated from vacuum-hardened alloy tool steel, polished to a mirror finish (Ra < 0.2 µm). Second, multi-axis servo speed profiles allow smooth acceleration curves rather than harsh impacts. Third, every machine undergo high-voltage surge and inter-turn insulation testing on sample stators prior to customer factory acceptance sign-off.
We routinely support Incoterms including FOB (Ningbo/Shanghai), CFR, CIF (Dublin or Cork Ports), and DDU/DDP arrangements. Our export logistics team coordinates vacuum-sealed barrier packaging with desiccants, secured in steel-reinforced wooden cases meeting ISPM-15 phytosanitary heat-treatment regulations for international ocean freight.
We provide comprehensive English operational and maintenance documentation, full electrical schematics with cross-referenced component tags, and comprehensive video installation manuals. Our software systems feature built-in remote diagnosis modules over secure Ethernet connections, enabling our engineering teams to assist your maintenance crews with PLC cycle parameter fine-tuning in real-time. On-site engineer dispatch is also available for integrated line installations.
Submit your stator lamination parameters, target cycle times, and wire bundle specifications today. Our engineering desk will deliver a comprehensive machine configuration proposal, tool path breakdown, and formal quotation within 24 hours.