Break the Wire Gauge Limit | Xingte Segmented Stator Layer Winding Machine: Solving High-Precision Manufacturing Challen

With the rapid advancement of vehicle electrification and intelligent driving, the EPS (Electric Power Steering) motor serves as a critical actuator component. Its performance and reliability directly determine the vehicle’s handling experience and safety level. Nevertheless, traditional winding equipment struggles to meet requirements for large wire gauges, high precision and multi-group winding. Pain points including limited applicable wire size, low yield, rough wire-end treatment and lengthy changeover have become industry bottlenecks restricting quality improvement and cost reduction for EPS motors.

Leveraging profound technical expertise and in-depth industry insights, Xingte Technology has launched the segmented stator layer winding machine. This groundbreaking solution sets a new benchmark for EPS motor winding and delivers a high-precision, high-efficiency and highly stable winding system for manufacturers.

Constrained by tension control and mechanical structures, traditional winding machines are prone to wire breakage and loose winding when processing large-diameter wires. Most equipment on the market can only handle wires below 1.6 mm, failing to satisfy the demand for large-gauge coils in high-performance EPS motors.

Xingte’s segmented stator layer winding machine achieves a key breakthrough, supporting a maximum wire diameter of 2.5 mm, well above the industry average. To accommodate large wire gauges, the machine is equipped with Xingte’s self-developed dedicated tensioner. Combined with precise mechanical calculations for the XYZ axes of the winding spindle, wire clamping cylinder, workpiece hold-down cylinder and associated mechanisms, it ensures stable winding of large-diameter wires without insulation damage or winding deformation, delivering core equipment support for manufacturing high-performance EPS motors.

EPS motor coils impose stringent requirements on varnish-stripping position accuracy and wire-end flatness. Due to insufficient length detection and wire arrangement control, conventional equipment often suffers from excessive varnish-stripping deviation and wrinkled wire ends, which push up defect rates, material waste and rework costs.

Adopting three-tier precision assurance, Xingte’s segmented stator layer winding machine enables zero-defect winding:

• An encoder wheel for real-time winding length detection, paired with precision spindle wire arranging technology, controls varnish stripping position tolerance within 1 mm;
• Workpiece wire clamp with 180° flipping function, physically eliminating wire-end wrinkling, a long-standing defect of traditional winding processes;
• No extra wire tails generated during winding to cut material loss. The stable production yield reaches more than 99%, significantly lowering manufacturing costs.

Current EPS motor production covers single-piece, 2-up, 3-up and 4-up winding specifications. Traditional machines feature limited program storage, complicated changeover procedures and poor capacity for seamless multi-group winding. Manual intervention is frequently required, dragging down throughput and introducing consistency risks from misalignment and tension fluctuation.

Designed for high compatibility and seamless operation, Xingte’s segmented stator layer winding machine addresses flexible manufacturing needs:

• Compatible with single, 2-up, 3-up and 4-up winding tasks. One machine covers mainstream EPS stator coil specifications and removes the need for multiple separate devices;
• Optimized mechanical transmission and software coordination algorithms enable seamless 2-up, 3-up and 4-up winding without manual adjustment, preventing wire offset and tension variation at joint sections to guarantee consistent product quality;
• Supports fast mold change, large-capacity program storage and reserved automation ports for convenient parameter configuration;
• Multiple units can be interconnected to form automatic production lines. Reserved automation interfaces facilitate unmanned full-process operation from winding to finished coils, greatly boosting productivity.

Backed by years of R&D accumulation in motor winding, Xingte Technology takes “resolving real industry pain points” as its core R&D philosophy. The segmented stator layer winding machine represents more than an equipment upgrade — it is an innovation for segmented stator winding technology. It overcomes core difficulties in large-gauge winding, precise varnish-stripping control and seamless multi-group winding, offering EPS motor manufacturers an integrated high-efficiency, high-quality and cost-effective solution.

The launch of this segmented stator layer winding machine will further help the EPS motor sector overcome manufacturing hurdles and fuel the development of automotive electrification.

For more technical details or customized solutions, please contact: Ms. Ren Tel: +86 181 2995 6796 Email: lisa@xingtekj.com

Samples of Xingte automated solutions on display.