HOT PRODUCTS

We are growing in many areas.

Flat Wire Stator High Precision Automated Hairpin Winding Machine for Electric Motor

Fully Automatic Flat Wire Stator Motor Winding Machine Laser Paint Stripping

Flat Wire Stator Pressing Electric Motor Winding Equipment High Precision Servo Controlled

Inter Turn Insulation Widening Stator Production Line Automatic Electric Motor Winding Machine

Servo-Controlled Stator Winding Machine for Fan Motors with High-Precision Twisting

Precision Servo Winding Machine for Alternator Stators with Flat Wire Cutting Technology

about us

Suzhou Champyound Intelligent Technology Co., Ltd.

Suzhou Champyound Intelligent Technology Co., Ltd. is a manufacturer in the flat wire motor industry, we are committed to delivering efficient and precise motor solutions tailored to our clients' needs. Our business is structured around two core divisions: one that supplies a range of fully automated flat wire motor production machinery and assembly lines across various industries; and another that offers comprehensive technological development, support, and turnkey solutions to manufacturers in the flat wire motor sector. Located in Suzhou, a vibrant industrial and commercial center in the Yangtze River Delta, Champyound specializes in the R&D, manufacturing and sales of flat wire motor machines. Our machines manufactured in Suzhou are mainly designed for the production of flat wire motors, which are widely used in applications such as home appliance motors, industrial motors, compressor motors, AC motors, servo motors and generators, etc. Leveraging our seasoned engineers, skilled professionals, state-of-the-art machines, stringent manufacturing process controls, and an extensive service network, we are committed to delivering the most optimized solutions for flat wire motor manufacturing to our clients. Up to now, in addition to having a large market share in China, our machines used to be in Mexico, Spain, etc. Our machines enjoy a good reputation among our customers for their durable and reliable performance, reasonable price and good after-sales service.

No. of Employees

Annual Sales

Year Established

Export p.c

News

Streamlining Hairpin Stator Production: What Are the Key Processes and Challenges? 2025-08-20 Flat wire motor stators deliver superior power density and efficiency, but their manufacturing involves precise, multi-stage processes. Here's a breakdown of the core production steps and current industry challenges: 1. Slot Liner Insertion: Insulation between conductors and the stator core is critical. This involves forming O, C, B, or S-shaped slot liners (typically O-type; B/S offer better insulation but lower copper fill and complexity), cutting, and inserting them into the stator slots. A major automation hurdle arises when two separate liners are required between phases, reducing power density and complicating robotic insertion. Advancements focus on integrated liner designs to overcome this. 2. Hairpin Coil Fabrication: Straight copper strands undergo straightening, insulation stripping (laser stripping is precise but costly; traditional methods risk copper damage), cutting, and forming into hairpin shapes (I-PIN, Hairpin, Wave Winding). Forming techniques include stamping and gentler, higher-cost CNC spring forming, which minimizes conductor stress. 3. Automated Coil Insertion: Pre-formed hairpins are loaded into a fixture and inserted as a complete set into the stator core slots, pressed to their final position. Significant progress has been made in automated insertion complexity, moving from 2/4 layers to advanced 6/8-layer systems, now achievable by leading manufacturers. 4. Expanding, Twisting & Welding: Expanding: Fixtures position the stator. A tool grips and radially expands the ends of all but the innermost hairpin layers. Twisting (Transposing): Tools align the innermost layer ends. A twisting mechanism rotates inner and outer dies in opposite directions to bend the hairpin legs into position for welding. This repeats layer by layer. Welding: Laser or TIG welding are common, using localized high heat to melt copper and form electrical connections. Alternatives like CMT (Cold Metal Transfer) exist. Key drawbacks of laser/TIG include potential insulation damage from heat, compromising reliability, and slow point-by-point welding, hindering throughput for stators requiring hundreds of joints. Faster, cooler welding methods are a critical industry need. 5. Insulation Coating & Impregnation: This seals the winding. Processes typically involve:Coating: Stator preheating, applying powder or liquid insulation, then curing.Impregnation (Varnishing): Preheating, applying varnish via traditional dipping, Vacuum Pressure Impregnation (VPI), or drip methods, followed by gelation and full curing. VPI is often preferred for superior penetration and void elimination. Post-impregnation checks like weight comparison ensure quality. Key Industry Drivers: Automation is paramount, especially for complex slot liners and high-layer insertion. Enhancing welding speed and reliability while protecting insulation remains a top priority. Optimizing impregnation techniques ensures long-term dielectric strength and thermal performance in demanding electric vehicle and industrial applications. Continuous refinement of these processes is essential for scaling high-performance hairpin stator production efficiently. https://www.champyoundmotor.com/

When Is a Stator Cutting Machine Used, and Why is it Vital for Recycling ? 2025-08-20 In the lifecycle of electric motors and generators, there comes a point where components reach the end of their useful life, or errors occur during manufacturing. While repair and rework are options, sometimes the most efficient solution involves disassembling and recycling materials. This is where the Stator Cutting Machine plays a vital, albeit often overlooked, role. But when is a stator cutting machine used, and why is it so crucial for efficient recycling and material recovery? A Stator Cutting Machine is a specialized piece of equipment designed to cut the steel laminations of a stator core, typically to separate the valuable copper windings from the steel. Stators are composed of tightly pressed steel laminations with copper windings inserted within their slots. Separating these two materials efficiently is essential for recycling, as both copper and electrical steel are valuable commodities. The machine uses powerful cutting tools, such as hydraulic shears or specialized blades, to cleanly cut through the stator's steel frame and laminations, often in segments, making the extraction of copper much easier. When is a Stator Cutting Machine used, and why is it vital for recycling? End-of-Life Recycling: When an electric motor or generator reaches the end of its operational life, the stator cutting machine is used to dismantle it, facilitating the recovery of valuable materials. Scrapped During Manufacturing: If a stator is found to have irreparable defects during the production process (e.g., severe issues unfixable by a Varnish Stripping Machine or a Stator Pressing Machine), it can be routed to the cutting machine for material recovery. Salvaging Valuable Copper: Copper is a highly valuable non-ferrous metal. By cleanly cutting the stator, the machine allows for the efficient separation of copper windings, maximizing the amount of copper that can be recycled and reused. Recovering Electrical Steel: The laminated steel core is also a valuable ferrous scrap material. The cutting process makes it easier to extract and process this steel for recycling. Environmental Responsibility: Efficient recycling of motor components reduces the need for new raw material extraction, minimizes landfill waste, and lowers the carbon footprint associated with manufacturing, aligning with circular economy principles. Economic Viability of Recycling: By automating or streamlining the disassembly of stators, the machine makes the recycling process more economically viable, encouraging greater material recovery. Safety and Efficiency in Dismantling: Manual dismantling of stators can be time-consuming and labor-intensive. A specialized cutting machine provides a safer and much more efficient method. In conclusion, the Stator Cutting Machine is a critical tool in the recycling and material recovery chain for electric motors and generators. It provides an efficient, safe, and cost-effective method for separating valuable copper from steel laminations, making it indispensable for sustainable manufacturing and resource management. https://www.champyoundmotor.com/supplier-4569110-stator-cutting-machine

How Do Stator Widening and Twisting Machines Optimize Slot Fill and Performance ? 2025-08-20 In the quest for more powerful and efficient electric motors, especially those utilizing advanced winding techniques, the manipulation of stator slots themselves becomes critical. This is where specialized equipment like the Stator Widening Machine and Stator Twisting Machine play vital roles. But how do these machines work, and how do they optimize slot fill and ultimately enhance motor performance? Stator Widening Machine: This machine is used to precisely open or widen the slots within a stator core. After the stator laminations are stacked and pressed (often by a Stator Pressing Machine), the slot openings can sometimes be too narrow or inconsistent for efficient winding insertion, particularly for thick, pre-formed conductors like those used by a Hairpin Winding Machine. The widening process ensures that the slots are uniformly sized and optimally shaped for the subsequent winding operation. Stator Twisting Machine: This machine introduces a precise twist to the stator core. Twisting the stator (often in a skewed pattern) helps to reduce torque ripple, noise, and vibration in the final motor. It's a key technique for improving the smooth operation and acoustic performance of electric motors. How do these machines optimize slot fill and performance? Improved Slot Fill Factor (Widening): By creating wider, more consistent slot openings, the Stator Widening Machine allows for easier and denser insertion of copper conductors. This leads to a higher "slot fill factor" – packing more copper into the available space – which directly improves motor efficiency and power density. Smoother Winding Insertion (Widening): Optimal slot geometry reduces friction and stress during winding insertion, preventing damage to insulation and ensuring a smoother, faster winding process. Reduced Torque Ripple (Twisting): The Stator Twisting Machine applies a precise skew to the stator slots. This skew helps to smooth out the magnetic field interaction between the stator and rotor, significantly reducing torque ripple (fluctuations in torque output). This results in smoother, quieter motor operation. Minimized Cogging Torque (Twisting): Cogging torque is a phenomenon that causes jerky motion at low speeds. Twisting the stator helps to reduce this, improving low-speed performance and precise control. Noise and Vibration Reduction (Twisting): By smoothing out torque ripple and magnetic forces, a twisted stator contributes to a quieter motor with less overall vibration, enhancing user comfort and product longevity. Enhanced Overall Motor Performance: Both widening and twisting contribute to a more optimized magnetic circuit, leading to motors that are more efficient, more powerful, quieter, and more reliable. In essence, Stator Widening Machines and Stator Twisting Machines are specialized tools that provide the precision needed to fine-tune the stator's physical geometry. This meticulous manipulation directly enhances the efficiency of winding insertion and significantly improves the electromagnetic and acoustic performance of the finished electric motor. https://www.champyoundmotor.com/supplier-4569108-stator-widening-machine https://www.champyoundmotor.com/supplier-4569109-stator-twisting-machine

TOP selling

Video

High Precision Golf Cart Flat Wire Stator Hairpin Winding Machine Automated

Get Best Price
Video

Public Bus Flat Wire Stator Automatic Laser Varnish Stripping Machine OEM

Get Best Price
Video

ODM Needle Automatic Stator Winding Machine For Aircraft Motor

Get Best Price
Video

Servo Motor Coil Making Machine Needle Winding Machine For Aircraft Stator

Get Best Price
Aircraft Stator Coil Electric Motor Rewinding Machine Automatic Twisting

Get Best Price
Video

Aircraft Needle Stator Motor Coil Cutting Machine 6KW 380V

Get Best Price
Video

Fully Automatic Motor Stator Armature Coil Winding Machine Laser Welding

Get Best Price
Video

High Precision Flat Wire Stator Motor Assembly Line Automatic Wire Insertion

Get Best Price

Room 1 and 2, No. 95, Sanxiang Road, Kunshan Development Zone, Kunshan, China

What would you like to request?

CUSTOMERS & PARTNERS

Room 1 and 2, No. 95, Sanxiang Road, Kunshan Development Zone, Kunshan, China E-mail: sales01@cyd-auto.com Tel: +8615995673508 Tel: +8615995673508

The Largest R&D and Production Hairpin Winding Machine Supplier in China

8615995673508