Explore our industrial-grade automated equipment designed for induction motors, automotive alternators, brushless DC units, and precision starter motors. Built to integrate seamlessly into modern automated lines across Greater Manchester.
Years Manufacturing Stator Machinery
Industrial Plant Infrastructure
National Engineering Patents
Dedicated R&D Automation Engineers
Manchester and the broader North West manufacturing belt are experiencing a resurgence in precision electromechanical engineering. Automated stator coil insertion systems form the backbone of local operational transformations across several strategic sectors.
Tier-1 automotive sub-assembly plants and EV retrofitters around Trafford Park and Stockport rely on high-fill-factor insertion equipment. Handling both round and shaped enameled wire, our machines ensure that high slot fill rates (reaching up to 82%) are achieved without scraping thin dielectric enamel, guaranteeing insulation resistance required for 400V/800V automotive drivetrains.
Facility infrastructure and compressor builders situated throughout Cheshire and Lancashire require robust induction motor winding and insertion. Our multi-axis servo-driven coil and wedge inserters (such as the DQ-2 platform) feed enameled coils and insulating wedges simultaneously into the stator core slots, streamlining pump motor stator assembly while eliminating manual coil wedging bottlenecks.
Advanced tech manufacturers in aerospace corridors around Salford and Rochdale demand tight electromagnetic tolerances. By utilizing computer-calibrated tooth blades and adjustable wedge pushers, our machines insert windings into high-slot-density, small-bore stators for brushless permanent magnet synchronous motors (PMSM) with repeatable geometric uniformity.
The UK manufacturing landscape is pivoting toward high-efficiency standards (IE3, IE4, and Super Premium IE5) driven by national net-zero commitments and volatile industrial energy tariffs. In electric motor construction, mechanical coil insertion is the critical pivot where electrical design turns into physical hardware. For plant managers in Manchester and Liverpool, optimizing this stage defines competitive edge.
Historically, manual and semi-pneumatic inserting methods presented major drawbacks: excessive operator intervention, high scrap rates from damaged wire coatings, and uneven end-turn heights that complicate subsequent lacing and trickle impregnation. Contemporary automated stator insertion operates on dual-action servo kinematics. In this architecture, insertion pushers and wedge blades advance synchronously via high-precision ballscrews driven by Mitsubishi or Siemens servo controls.
| Performance Dimension | Traditional Mechanical Insertion | Automated Servo-Driven System (Rilvo Standards) | Operational Impact for Manchester Plants |
|---|---|---|---|
| Slot Fill Factor Capability | 65% – 72% Max | 75% – 85% Precision Fill | Enables IE4/IE5 high-density designs with lower copper volume. |
| Insertion Cycle Time | 45 – 70 seconds / cycle | 12 – 25 seconds / cycle (depending on stack length) | Over 200% capacity increase per operating shift. |
| Enamel Scrape Risk | Moderate to High (mechanical friction) | Near Zero (guided blade clearance control <0.03mm) | Eliminates inter-turn short circuits and insulation breakdowns. |
| Tooling Changeover | 3 – 5 hours per stator frame | 20 – 40 minutes (modular cassette tooling) | Facilitates high-mix, low-to-medium-volume batch runs common in the UK. |
Operating as a certified High and New Technology Enterprise since 1998, Zhejiang Rilvo Automation Equipment Co., Ltd. delivers direct factory capabilities, robust intellectual property, and bespoke tooling design to global industrial users.
With an expansive 60,000 m² modern manufacturing campus and over 150 in-house CNC machining centers, grinding machines, and wire-EDM units, we do not subcontract our core tooling. Stator tooth blades, wedge guides, and pushing fingers are heat-treated and ground in-house, ensuring mechanical tolerances within microns.
Led by senior chief engineers recognized with national technical awards, our multidisciplinary team handles electrical, optical, and mechanical design. We construct turnkey lines—from slot insulation (DFC-1) and coil winding (XB-1GZ) to inserting (DQ-2), intermediate forming, end-lacing, and trickle varnishing (SZD-376).
We maintain full ISO9001 quality management, 3C safety credentials, and 17 proprietary national patents covering high-speed wire embedding and automatic indexing tooling. Every machine destined for export undergoes extensive trial runs using the customer’s actual stator cores and magnet wire before dispatch.
Clear, direct technical and commercial answers tailored for British procurement managers, production engineers, and machinery importers.
We work directly from your stator iron core DXF/DWG drawings, stack length specifications, slot cross-sectional profiles, and wire winding schematics. Our engineers customize the inserting blades, pushers, and wedge guides specifically to your geometry, testing fit-up with physical core samples before full dispatch.
Equipment for British and European plants is manufactured for 415V / 3-phase / 50Hz electrical supply. Control architectures incorporate internationally recognized components (such as Schneider, Omron, Mitsubishi, or Siemens PLCs and touchscreen HMIs) that fully comply with CE and UK machinery safety directives.
We provide FOB Ningbo, CIF Liverpool/Felixstowe, and door-to-door DDU/DDP arrangements. Standard machine builds require 30 to 45 business days including custom tooling machining and FAT (Factory Acceptance Test) trial runs. Transit times to UK ports typically range between 28 and 35 days.
Every machine is delivered with comprehensive electrical schematics, PLC backup parameters, high-definition video operating manuals, and an essential wear-parts package (blades, pushers, cutter guides). We provide remote video setup and troubleshooting assistance, with on-site engineering dispatch available for complete turnkey line projects.
Submit your stator core drawings, stack height, slot dimensions, and wire gauge details. Our engineering desk will deliver a comprehensive proposal complete with cycle-time estimates and tooling layout within 24 hours.
Get a Quote
