Eliminate Downtime in High-Speed Stator/Rotor Continuous Punching Lines
Traditional methods for manufacturing electric motor stators and rotors relied heavily on punching individual laminations using formed dies and then stacking them. This process was material-intensive and inefficient. As the stamping industry evolves towards high-efficiency automation, this single-stroke method is increasingly being replaced by continuous punching using coil material. However, a bottleneck remained: the decoiling process typically used single-head decoilers. While enabling continuous production, these machines caused significant downtime when a coil was exhausted, requiring lengthy changeover and re-threading periods, severely impacting overall productivity.
To overcome the challenge of low efficiency in the “strip steel punch-coil-wrap-stack” process for forming stator and rotor cores, our high-speed stamping line design incorporates a Double-Head Decoiler instead of the traditional single-head unit. This innovative solution features two operational stations. While one station is actively feeding and decoiling material into the punching line, the other station can be simultaneously loaded with a new coil. When the active coil is depleted, the decoiler simply rotates 180 degrees to instantly switch to the pre-loaded station. This rapid exchange dramatically improves single-machine efficiency, enabling the high-speed punching line to operate without interruption, delivering significant advantages in material savings and boosted production output.
Application in Stator/Rotor Lamination Production:
In operation, pre-punched strip material (with teeth oriented outwards) is fed into an entry guide formed by the decoiler’s upper side plate, material support plate, and lower side plate. Crucially, the precisely selected thickness of the material support plate ensures the strip remains flat after passing through this guide. As the strip enters the coiling stage, a drive pin is first inserted into a pre-punched slot in the strip ahead of the tangent point. The decoiler motor then engages, pulling the strip forward. Subsequent drive pins sequentially engage with the strip under the action of cam profiles, driving the toothed strip forward in its forming motion. When the coiled material reaches the exit of the winding mechanism, a guide cam’s spiral surface ejects it, allowing it to wind onto the decoiler’s core shaft, forming the laminated core. Simultaneously, the drive pins retract under the combined action of the guide cam and springs, enabling continuous coiling operation. This process significantly enhances workflow efficiency.
The Double-Head Decoiler offers reliable forming, ensures the toothed strip remains flat, and guarantees smooth material movement. Furthermore, the diameter of the material support plate is larger than the inner diameter of the core forming structure, effectively preventing interference between the drive pins and the toothed strip during the coiling process. It stands as a practical and essential decoiling solution for modern, high-volume stator and rotor lamination manufacturing.
