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1. Coil Looping Machine

Precision Engineering for Efficient Coil Production

The Coil Looping Machine from Radius Engineering Solutions is designed for high torque and precise control, ensuring consistent and accurate coil loops for stator manufacturing.

Achieve Perfect Coil Formation with Precision Control: 

a) Coil Loop Lengths: 300 mm to 3500 mm

b) Conductor Width: 2.5 mm to 12 mm

c) Conductor Thickness: 1.5 mm to 10 mm

d) Multiple Bobbin Support: 2, 4, up to 12-16 bobbins for simultaneous drawing

e) High-Torque Motor for smooth and consistent operation

Key Features : 

a) High Torque Capability: Delivers a maximum torque of 6000 Nm, accommodating various coil sizes and materials.

b) Adjustable Speed: Operates at speeds up to 10 rpm for precise control.

c) Versatile Loop Lengths: Handles 350 mm to 3000 mm loop lengths.

d) Wide Conductor Width Range: Supports conductors from 3 mm to 50 mm wide.

e) Digital Turns Counter: Ensures accurate monitoring of coil turns.

f) Variable Speed Geared Motor: Provides high torque with a soft start feature, enhancing safety.

Technical Specifications :

a)Torque: Up to 6000 Nm

b)Speed Range: Up to 10 rpm

c)Loop Length: 350 mm to 3000 mm

d)Conductor Width: 3 mm to 50 mm

e)Torque: Up to 6000 Nm

Applications : 

Ideal for manufacturers of stator coils, enhancing productivity and ensuring high-quality coil formation.

1. Coil Spreading / Forming Machine

Ensuring Uniform Spreading for Consistent Coil Formation

The Coil Spreading / Forming Machine ensures accurate shaping and spreading of looped coils, allowing for precise stator coil formation. Available in hydraulic and pneumatic variants, it ensures efficiency and repeatability.

Precision Engineering for High-Quality Coil Manufacturing: 

a)Versatile Coil Handling: Capable of managing coil loops from 500 mm to 3000 mm and accommodating coil sections up to 20 x 60 mm

b) User-Friendly Interface: Equipped with an intuitive HMI and PLC system for easy machine setup and operation.

c) Precision Adjustment: Reference scales facilitate accurate machine settings tailored to specific coil data.

d) Secure Clamping Mechanism: Robust knuckle holders ensure firm clamping and effortless coil removal

Key Features : 

a) Coil Loop Lengths: 300 mm to 3500 mm. 

b) Coil Section Width: 7 mm to 20 mm.

c) Coil Section Height: 12 mm to 60 mm.

d) SCADA-Integrated PLC: Automatic span and spread adjustment.

e) Hydraulic, Pneumatic & Servo Variants: Available for different production needs.

f) User-Friendly Interface: HMI & PLC system for easy setup and operation.

Technical Specifications :

a) Coil Loop Length: 500 mm to 3000 mm

b)Coil Section Capacity: Up to 20 x 60 mm

c)Operation Modes: Hydraulic and Pneumatic

d)Control System: HMI and PLC integration

Applications : 

Perfect for electrical coil and bar manufacturers, ensuring high-quality production.

1. Advanced NC-based system for high-precision coil forming and spreading

a) NC-Based Automation with SCADA integration for precise and repeatable coil forming

b) Servo-Driven Accuracy for consistent and damage-free coil spreading

c) Quick Setup & Program Storage for efficient batch processing

d) Available in Hydraulic & Servo Configurations for greater flexibility.

e) User-Friendly HMI + PLC + SCADA system for real-time monitoring and easy operation

f) Designed for a wide range of coil sizes with high repeatability and smooth operation

1. Coil Taping Machine

Versatile Models for Precision Taping on Small to Large Coils

Our Coil Taping Machines provide precision insulation taping solutions for small, medium, and large stator coils. They ensure consistent tape application to enhance coil longevity and insulation quality.

Variants & Features :

a) Suspended Coil Taping Machine :

1. Coil Loop Length: 300 mm to 3500 mm. 

2. Ideal for medium-sized coils.

3. Semi-automatic machine with a taping head suspended from an overhead track, ensuring consistent taping guided by an operator.

4. Ergonomic design for operator comfort.

5. Suitable for various coil sizes with uniform tape application.

b) Robotic Coil Taping Machine:

1. Equipped with a 7-axis ABB robot for automated high-precision taping.

2. High-speed, precise taping with SCADA integration.

3. Electric taping head allows bobbin angle and tape tension adjustments.

4. SCADA Integration for programmable pitch control.

5. Ideal for high-volume production.

c) Bench-Mounted Taping Machine:

1. Compact, bench-mounted configuration for small to medium-sized coils.

2. User-friendly operation and space-saving design.

3. Cost-effective solution for workshops.

Technical Specifications :

a) Taping Speed: Adjustable, based on machine model

b) Coil Size Compatibility: Varies by model

c) Control System: PLC with HMI interface.

d) Small Coils (RES-15-30): Handles up to 15 mm width, 30 mm height (belt-driven system)

e) Medium Coils (RES-20-50): Handles up to 20 mm width, 50 mm height (suspended taping system)

f) Large Coils (RES-35-100): Handles up to 35 mm width, 100 mm height (robotic system for coils up to 6m).

g) 6-Axis Robotic System for precision tape application.

h) Automatic Tension Control and bobbin angle adjustment for consistent quality.

Applications : 

a) Generator and motor coil manufacturers

b) Repair workshops

1. Coil Moulding / Curing / Consolidation Press

Efficient Moulding, Curing & Pressing for High-Throughput Production

The Coil Moulding and Consolidation Press ensures precise compaction of stator coils, enhancing electrical and mechanical properties.

a) Accommodates Coil Lengths: Up to 6000 mm

b)Vertical Pressing Force: Up to 8 Tons

c)Horizontal Pressing Force: Up to 15 Tons

d) SCADA-Based Process Monitoring for real-time pressure & temperature control

e) PID Temperature Control for uniform curing and quality assurance

Key Features :

a) PLC Controlled Operation: Ensures consistent pressing.

b) Multiple Head Configurations: 4 to 16 heads for different coil sizes.

c) Accommodates Large Coils: Up to 6000 mm in length.

d) High Pressing Force: 

e) Vertical Force: Up to 8 tons.

f) Horizontal Force: Up to 15 tons.

g) PID Temperature Control: Uniform curing and process reliability.

Technical Specifications :

a) Taping Speed: Adjustable, based on machine model

b) Coil Size Compatibility: Varies by model

c) Control System: PLC with HMI interface

Applications : 

For manufacturers needing precision coil consolidation for enhanced coil durability and insulation performance.

1. Conductor Cutting, Buffing & Straightening Machine

Comprehensive Solutions for Conductor Preparation

The Conductor Cutting, Buffing, and Straightening Machine is a multi-functional system designed for precision conductor preparation before coil manufacturing.

Precision Cutting and Finishing for Quality Coil Preparation

a) NC-Based System with PLC & HMI Control for high-precision operations.

b) Conductor Thickness: 1 mm to 4 mm

c) Conductor Width: 2.5 mm to 18 mm

d) Precision Buffing & Clean Edge Finishing for superior conductor preparation.

Key Features :

a) Integrated Cutting, Buffing & Straightening: Reduces handling time.

b) Precision Cutting: Accurate length measurements.

c) Surface Buffing: Enhances conductor surface quality.

d) Straightening Mechanism: Ensures deformity-free conductors.

e) User-Friendly Design: Simplifies operation and maintenance.

Technical Specifications :

a) Conductor Size Range: Available upon request

b) Cutting Accuracy: High-precision cutting mechanism

c) Buffing Speed: Adjustable settings for desired finish.

d) Straightening Capability: Meets stringent manufacturing tolerances.

Applications : 

Ideal for stator coil manufacturers, enhancing efficiency in conductor preparation.

Lead stripping machine is used to remove the enamel using the concept of induction heating. By doing this process there is localised, constant and precise heating which can be set. to ensure that only the enamel is removed and underlying conductor is not damaged. There is Excellent temperature control and energy saving achieved in this process. The conventional process of buffing which leads to pollution can be eliminated and the working environment can be improved.