CE Certified Stator Coil Insertion Line Manufacturers & Exporter

Under conventional single-phase or three-phase distributed winding topologies, Nakro automated servo coil inserting machines comfortably achieve between 78% to 82% slot fill factor (total bare copper area relative to net slot area after accounting for slot insulation paper). This is accomplished via multi-stage profile guide blades and high-precision CNC pre-winding grouping that organizes parallel wire bundles linearly, eliminating random crossovers prior to insertion.

Enamel scratch prevention is achieved through three engineering barriers: First, the insertion guide blades are manufactured from vacuum-hardened Vanadis powder metallurgy steel with mirror hand-lapping to Ra ≤ 0.05μm, coated with TiCN for extreme lubricity. Second, the blade tips feature lead-in tapers that physically shield the stator tooth edges from contact with the entering conductors. Third, a pneumatic micro-lubrication system applies an atomized, residue-free vanishing lubricant to the wire bundle immediately prior to insertion, which evaporates completely during curing/varnishing.

Yes. If the internal stator bore diameter and the slot count remain constant, accommodating different stack heights (e.g., from 40mm to 160mm) is completely digital: the operator simply inputs the new stack height on the HMI touchscreen, and the servo pusher stroke dynamically re-indexes without changing mechanical tooling. If the stator bore diameter or lamination slot geometry changes, a complete modular tooling cartridge changeover (including guide blades, pusher foot, and wedge guides) is required, which takes approximately 20 to 30 minutes via quick-release locating pins.

The integrated automatic wedge cutting and feeding module processes a broad array of roll-fed electrical insulation materials, including DMD (Dacron-Mylar-Dacron), NMN (Nomex-Mylar-Nomex), pure Nomex 410, Polyimide film, and electrical-grade presspaper with thicknesses ranging from 0.15mm to 0.38mm. The station features precision servo feeding, heating/creasing wheels for profile shaping, and hardened tungsten carbide guillotine blades that ensure clean, burr-free wedge edges.

Our CE certification adheres fully to European Harmonized Standards including EN ISO 12100 (Risk Assessment & Reduction), EN 60204-1 (Electrical Safety of Machinery), and EN ISO 13849-1 (Safety-Related Parts of Control Systems, Category 4 / Performance Level e). The work envelope is guarded by Category 4 infrared safety light curtains, dual-channel emergency stop circuits with monitoring relays, pneumatic pressure decay dump valves, and interlocked transparent polycarbonate shields.

Every machine undergoes a strict factory acceptance protocol: First, a continuous dry run of 50,000 cycles to confirm thermal stability of servo motors and mechanical linkages. Second, actual production hot-testing using 200 to 500 sets of customer-supplied stator laminations, slot paper, and magnet wire. We verify slot fill, end-turn height consistency, surge test withstand (≥ 3000V), insulation resistance (> 500MΩ), and ground hipot breakdown voltage. FAT video records and physical stator samples are dispatched to the client for final sign-off before seaworthy fumigated wooden crating.

Nakro provides comprehensive overseas commissioning and technical assistance. Our factory-certified field engineers conduct on-site installation, line integration, and operator training covering routine calibration, recipe setup, and preventive maintenance. Furthermore, all control panels include an industrial VPN gateway enabling remote telemetry, PLC diagnosis, and software updates over secure cloud connections, ensuring instant troubleshooting regardless of geographical time zones.