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Views: 35 Author: Site Editor Publish Time: 2025-11-11 Origin: Site
In motor manufacturing, the forming process is one of the final and most crucial steps in shaping the stator coil after winding and lacing. A precise forming machine ensures that the stator end coils meet strict dimensional tolerances and insulation requirements, directly influencing the motor's performance, efficiency, and service life. Choosing the right forming machine for different motor specifications is not simply about matching the size—it's about ensuring compatibility with production needs, automation levels, and long-term consistency.
A forming machine (also known as a shaping machine) is designed to reshape and compress the stator coil ends after the winding and tying process. During forming, the copper wires and insulation are adjusted into their final positions, giving the stator its finished internal and external diameters and end height.
This process:
Improves coil compactness and uniformity
Prevents wire damage or insulation deformation
Ensures smooth assembly with the rotor and housing
Enhances the electrical and mechanical stability of the motor
In modern motor production, especially in high-efficiency motors and automotive drive systems, precision forming has become essential to meet increasingly tight performance standards.
Selecting a forming machine depends on several interconnected parameters. Below are the major factors to consider:
| Selection Factor | Description | Typical Range or Consideration |
|---|---|---|
| Stator Outer Diameter | Determines the forming mold size | 40–200 mm (small motors); 200–400 mm (industrial) |
| Stack Height | Impacts mold depth and pressing force | 20–300 mm |
| Wire Type and Size | Influences pressure setting and mold surface material | Round or flat copper wire, enameled or insulated |
| Coil Density | Affects the required shaping pressure and time | High-density coils need slower, controlled forming |
| End Coil Height | Determines forming stroke | Adjustable via hydraulic or servo system |
| Production Volume | Decides whether to choose single-station or multi-station systems | Manual (low volume) or automatic double-station (mass production) |
| Automation Integration | Compatibility with robotic arms, transfer lines, or PLC systems | Essential for modern production lines |
Forming machines are classified based on their driving system and control method. Each type has specific strengths suited for different production needs.
| Machine Type | Transmission / Control | Advantages | Typical Application |
|---|---|---|---|
| Mechanical Forming Machine | Cam or crank-driven | Simple structure, low cost | Small or general-purpose motors |
| Hydraulic Forming Machine | Hydraulic cylinders + PLC control | High pressure, stable force, adjustable stroke | Medium-to-large stators, industrial motors |
| Servo-Electric Forming Machine | Servo motor control with precision feedback | Precise, programmable, environmentally friendly (no oil) | EV motors, high-end appliance motors |
Hydraulic forming machines remain the most widely used in heavy-duty or large stator production because of their high pressure capacity and durability. Servo-driven systems, however, are increasingly popular in precision applications such as electric vehicle (EV) or high-efficiency home appliance motors.
To select the most suitable forming machine, manufacturers should evaluate both motor type and production requirements. Below is a simplified matching guide:
| Motor Type | Typical Stator Diameter | Recommended Forming System | Remarks |
|---|---|---|---|
| Small home appliance motor | 50–120 mm | Mechanical or hydraulic single-station | Simple forming cycle, low setup cost |
| Industrial AC motor | 150–300 mm | Hydraulic double-station system | High efficiency, consistent pressure |
| Automotive motor (EV/HEV) | 100–250 mm | Servo-electric or PLC hydraulic system | Requires precision control and repeatability |
| Fan / Pump motor | 120–200 mm | Hydraulic forming with adjustable stroke | Adaptable for multiple stator types |
| Compressor / High-voltage motor | 250–400 mm | Heavy-duty hydraulic or customized forming line | Focus on strength and dimensional accuracy |
A well-matched forming machine not only ensures dimensional accuracy but also prevents production issues such as wire damage, coil rebound, or inconsistent forming height.
Modern forming machines are often integrated with PLC (Programmable Logic Controller) systems and HMI (Human-Machine Interface) panels. These allow:
Real-time monitoring of forming pressure, stroke, and temperature
Easy switching between different motor models
Automated safety interlocks and fault detection
Data recording for traceability and quality control
For example, a hydraulic forming machine with dual-station rotary table can handle two stators alternately, improving output efficiency by over 30% compared with traditional single-station models.
When producing stators for industrial or automotive motors, manufacturers often face a trade-off between throughput and precision.
Take, for instance, a hydraulic automatic shaper like the Z4L6-4010 — it uses a combination of hydraulic transmission and PLC control. With an internal expanding and external collecting mechanism, it shapes the stator's inner and outer diameters and end height in one cycle. The machine's vertical double-station turntable improves operation efficiency while maintaining consistent shaping accuracy, making it ideal for medium to large motor production lines.
While this model serves as an example, the core principle applies broadly: multi-station, automated forming systems can dramatically enhance productivity without compromising on coil integrity.
When evaluating a supplier or model, keep these practical guidelines in mind:
Define Your Production Range: Know the minimum and maximum stator diameters you'll produce.
Assess Flexibility: If your factory handles multiple motor models, ensure the forming system supports quick mold changes.
Check Repeatability: Verify that pressure and height tolerances remain stable across long runs.
Review Automation Potential: Look for systems compatible with upstream coil insertion and downstream testing machines.
Confirm After-Sales Support: Proper maintenance and technical support are vital for long-term stability.
Choosing a forming machine suitable for different motor specifications is a strategic decision that affects both production efficiency and product quality. By understanding your stator parameters, wire characteristics, and automation goals, you can narrow down the right system—mechanical for simplicity, hydraulic for power, or servo-electric for precision.
For manufacturers looking to optimize both shaping accuracy and output, advanced PLC-controlled hydraulic systems—such as dual-station automatic models—represent a balanced and cost-effective choice.
If you're exploring which configuration best suits your production line, consulting with an experienced forming machine supplier like ZHONGJI INTELLIGENT can ensure that your equipment investment translates directly into higher motor performance and manufacturing efficiency.
