Engineered to satisfy demanding slot fill factors, strict dimensional concentricity, and dielectric insulation standards required by Kharkiv's heavy electrical machinery builders and electro-technical maintenance centers.
Programmable CNC multi-axis flyer winder tailored for single- and three-phase induction stators, delivering high wire layering regularity and zero enamel scuffing.
High-frequency inverter spot welder featuring closed-loop current feedback for hot-stake fusing and copper/copper-clad aluminum commutator hook terminations.
Rigid double-flyer rotor winding station configured for fast tooling turnover, precise slot hook indexation, and balanced tension control on power tool armatures.
Heavy-duty rectangular and flat wire bending and winding platform engineered for large-section traction coils, auxiliary generators, and low-loss magnet systems.
Fully integrated cell linking stack feeding, slot insulation, high-speed winding, commutator welding, and intermediate dynamic balance validation.
Automatic overlap taping apparatus applying mica, Kapton, and polyester insulation tapes to field coils and heavy starter stator groups with adjustable pitch.
Continuous thermal-trickle resin impregnation machine delivering void-free encapsulation, superior moisture resistance, and rapid radiant gel curing.
Heavy industrial multi-pole winding system built with strengthened spindle assemblies to handle thick magnet wire diameters without rotational deflection.
Achieving optimal magnetic flux and thermal conduction inside laminated steel cores requires precision mechanical expansion without micro-cracking copper conductors.
In modern industrial electric motors—especially high-output induction machines and traction drives—the stator coil expanding and forming operation bridges the critical gap between loose winding insertion and mechanical retention. When coils are inserted into stator core slots via pneumatic or servo-driven pusher bars, the end-turns remain flared, asymmetric, and prone to phase-to-phase contact or casing interference.
Rilvo Automation’s multi-stage coil expanding systems integrate an internal expansion mandrel with segmented outer forming dies. As the internal core expands radially outward, it compacts the conductor bundles deep into the core slots while creating precise clearance for rotor insertion. Simultaneously, axial push blocks calibrate end-turn height, ensuring uniform copper volume distribution around the circumference.
This mechanical precision directly reduces leakage reactance, mitigates localized hotspot formation, and eliminates partial discharge inception voltages (PDIV) under variable frequency drive (VFD) switching stresses.
| Engineering Parameter | Standard Automated System | Rilvo Heavy-Duty Specification |
|---|---|---|
| Applicable Stator OD | Φ40 mm – Φ180 mm | Φ30 mm – Φ320 mm (Custom to Φ500 mm) |
| Lamination Stack Height | 20 mm – 220 mm | Up to 380 mm continuous stroke |
| Expanding Actuation | Standard Hydraulic | High-Response Hydraulic / AC Servo Hybrid |
| Radial Positioning Tolerance | ±0.10 mm | ±0.025 mm with linear optical encoder |
| Slot Wedge Material | Nomex / DMD / Polyester | Reinforced Epoxy Glass, Nomex, & Pressboard |
| Cycle Index Time | 14 – 22 sec/piece | 8 – 15 sec/piece (model dependent) |
Kharkiv remains one of Central and Eastern Europe's foremost engineering capitals, renowned for turbogenerators, heavy traction systems, agricultural machinery, and municipal energy infrastructure.
Serving Kharkiv's transport machinery enterprises, railway repair hubs, and specialized sub-assembly contractors producing heavy DC/AC traction stators. Our machines provide the necessary mechanical tonnage to expand heavy-gauge rectangular copper bars without tearing primary slot cell insulation.
Auxiliary boiler pumps, forced-draft ventilation blowers, and municipal heating circulatory pumps in the Kharkiv regional grid require continuous S1-duty electric motors. Machine precision ensures that rewound or newly manufactured stators handle aggressive start-stop cycles.
Kharkiv repair workshops restoring electric motors for agricultural processing, metallurgical complexes, and municipal water treatment plants need fast changeover capability across diverse frame standards (IEC and legacy GOST frame heights 71 to 280).
Ukraine's industrial alignment with European energy efficiency norms is fundamentally reshaping equipment procurement requirements in Kharkiv.
| Technological Driver | Legacy Kharkiv Base Practice | Next-Gen Requirement Implemented |
|---|---|---|
| Motor Efficiency Regulation | GOST standard IE1 / IE2 equivalence | Mandatory IEC 60034-30-1 IE3 & IE4 Premium Efficiency |
| Copper Slot Utilization | 60% – 66% loose manual winding | 74% – 82% mechanical expanding & auto-insertion |
| Impregnation Method | Dip-and-bake solvent tanks (high VOC) | Continuous trickling & vacuum-assisted UV/thermal curing |
| Control Systems | Relay-logic manual operation | Multi-axis servo CNC with programmable recipe memory |
As Kharkiv manufacturers target export markets within the European Union and modernize domestic water, heat, and transport infrastructure, the demand for IE3 Premium and IE4 Super Premium efficiency motors has accelerated exponentially.
Achieving IE4 standards cannot be done through manual coil insertion; human workers cannot pack the requisite volume of magnet wire into compact lamination slots without damaging thin enamel films. Rilvo's stator coil expanding machines apply progressive, synchronized hydrostatic expansion forces. This pushes the copper strands outward symmetrically against the slot tooth walls, maximizing conductive copper cross-section while maintaining air gap roundness.
Furthermore, local procurement specialists in Kharkiv are prioritizing dual-frequency tooling (50Hz standard grid / 60Hz export ready) and control hardware capable of remote telemetry for predictive maintenance.
Combining 27 years of dedicated electro-mechanical equipment engineering, extensive in-house machining infrastructure, and comprehensive export compliance.
Decades of continuous R&D dedicated specifically to electric motor automation: stator inserting, expanding, armature spot-welding, flat wire forming, and resin trickling plants.
Located in the Shatianyang Development Zone of Sanmen, Taizhou, featuring over 150 internal CNC turning, milling, and precision grinding machines for complete tooling concentricity control.
Our engineering laboratory—staffed by 36 specialized R&D engineers—holds 17 authorized patents covering servo lead tensioning, wave coil shaping, and multi-segment expansion dies.
Every structural frame, guide bush, and electronic sub-assembly undergoes verified staging inspections before dynamic mechanical burn-in and customer-sample trial sign-offs.
Over a decade of customized tooling manufacture. We configure slot wedges, expanding mandrels, and flyer guides strictly to your lamination drawings and stack heights.
Direct shipments dispatched from Ningbo Port under FOB, CFR, CIF, and EXW terms, accompanied by comprehensive electrical schematics and multilingual instruction sets.
Direct technical and commercial clarifications addressing import procedures, electrical compatibility, tooling customization, and post-delivery engineering support.
Submit your stator core geometry, slot configuration, and target production cycle time. Our senior engineering team will calculate optimal mechanical expansion forces and provide a complete line quotation.
