CNC Coil Expanding & Forming Machine

• Customization: Available
• The Length Before Forming, L1: 900-3500mm
• Coil-to-Shuttle-Core Distance, L2: 800-3400mm
• Model NO.: ZHSK-2500
• Coil Nose Section ID Range, R: 15-30mm
• The Width of Coil, a: 5-20mm
• The Height of Coil, B: 20-50mm
• The Length After Forming, L3: 200-2500mm
• Total Length of Coil, L4: 300-3000mm
• Total Width of Coil, W: 200-1000mm
• Nose Section Elevation Range, H: 20-350mm
• Coil Nose Section Tilt Angle Range: 0-30°
• Angle Between Upper Layer Edge and Cente: Max. 65°
• Angle Between Lower Layer Edge and Cente: Max. 65°
• Dimensional Precision: ± 0.2mm
• Coil Nose End R: R15 R20 R25
• Arc Radius of Straight Line and Hypotenu: R25 R30
• After-sales Service: 1 Year
• Warranty: 1 Year
• Trademark: ZHENHUAN
• Origin: China
• Package Size: 6900.00cm * 1200.00cm * 2000.00cm
• Package Gross Weight: 5000.000kg

Product Description

CNC coil spreading & forming machine

I Description of the machine
This machine is specifically designed for processing medium-to-large sized coils and prismatic components, particularly those utilized in high-capacity motors requiring extended prismatic structures or oversized cross-sectional profiles. The system including: primary drive mechanism, hydraulic system, servo modules, intelligent electrical control units, and overhead arc profiling assembly. These components are synergistically coordinated through automated control architecture that ensures synchronized operation across all functional modules.
II Usage and characteristic

1. Integrated electro-hydraulic synchronization technology enables automated continuous processing from shuttle-shaped blanks to finished coils. The precision molding mechanism eliminates insulation layer damage through controlled deformation, replacing traditional manual hammering methods.
2. Continuous and single-step operation modes, suitable for both batch production and prototype manufacturing.
3. Features unique shuttle-type shaping and centering functions, ensuring excellent straight edge condition and end symmetry.
4. The machine's working pressure and stroke can be adjusted within specified ranges according to process requirements, and is capable of performing fixed-stroke operation.
5. Features a screw-driven push-pull mechanism on the worktable, for loading/unloading, positioning accuracy, balanced pressure distribution, operational reliability.

III Design and technical
          
Before forming( picture 1)               After Forming (picture 2)

Coil size before forming
The length before forming, L1	900-3500mm
Coil-to-shuttle-core distance, L2	800-3400mm
Coil nose section ID range, R	15-30mm
The width of coil, A	5-20mm
The height of coil, B	20-50mm
Coil size after forming
The length after forming, L3	200-2500mm
Total length of coil, L4	300-3000mm
Total width of coil, W	200-1000mm
Nose section elevation range, H	20-350mm
Coil nose section tilt angle range	0-30°
Angle between upper layer edge and centerline	Max. 65°
Angle between lower layer edge and centerline	Max. 65°
Dimensional precision	± 0.2mm
Coil nose end R	R15 R20 R25
Arc radius of straight line and hypotenuse	R25 R30
Arc radius of coil nose and hypotenuse	R15 R25
Clamp range:	5x20--20x65mm
Max. Coil cross-sectional area A/B	20x50mm

IV Equipment working requirement
Machine size            6900 x 1950 x 1900mm
Main driver method  Servo
Parts driven method  ball screw
Clamp method           Oil cylinder
Voltage                     380V, 3phase 4 wire, 50Hz
Cycle time                1-6 minutes; completes one coil per operation,
Total power                22kW
V Equipment composition

1. The main transmission system employs servo system, while the clamping is equipped with hydraulic cylinder and control valves, ensuring positioning of all workstations;
2. The four-arm stretching mechanism adopts servo-driven ball screw transmission system, characterized by high positioning accuracy and precision.
3. The structure is well-designed, independent adjustment of the stretching span and rotation angle, with a high degree of automation. It offers simple and convenient operation, reliable safety performance, easy maintenance, continuous working capability, and high production efficiency.
4. During the process, parameters are programmed via microcomputer. After manually loading the pre-wound coil, the operator initiates the system by pressing the start button. The equipment then automatically controls the movement of the nose clamps and straight-section clamps. The machine sequentially executes the programmed operations, including: Adjusting the length and angle of the straight sections, forming the end arches, setting the nose height. Once coil is completed, the clamps release, manual removal of the finished coil. Then resets to its initial state for the next cycle.
5. The coil (forming system) features automatic pitch control and self-centering functionality, ensuring compliance with design specifications.
6. The mechanism operates on a circular trajectory centered on the coil axis, with synchronized motion to ensure consistent span width at both ends, enabling precise insertion into motor slots.
7. The end-arc forming system adopts a multi-segment fast-plate design, allowing manual assembly of customizable arch profiles to meet requirements for coils of varying specifications.
8. The coils exhibit zero mechanical damage, with intact inter-turn insulation, ensuring fully reliable electrical performance.
9. The control system incorporates comprehensive interlocking logic and multi-layer protective measures against resistance anomalies, effectively preventing equipment failures.

VI Main parts list
6.1. One set of equipment chassis  
6.1. 1 Specification: 6900×1200×2000mm.
6.1.2 The mobile frame drives the sliding table via a lead screw to achieve horizontal movement, with an eccentric wheel mechanism providing precise locking to ensure positioning accuracy.

6.1.3 Frame's mid-section is equipped with anti-step cover plates, operators access workpieces safety.

6.1.4 All four sides feature chain-suspended zones that synchronously move with the frame.

6.1.5 Frame's four-side base is equipped with adjustable leveling plates to achieve height alignment.

6.2. Clamp device
6.2.1 Hydrualic cylinder specification Φ50×150mm;  
6.2.2 Clamp size: 7-60mm, 2 pcs at the front and back. :2-60mm,2
6.2.3 The edge radius of the clamp mouth is R15      R15
6.2.4 Pressure range: 1--12MPa (absolute pressure);    
6.2.5 The clamp can be adjusted in size and height according to the coil drawing. 
6.3. Expansion arm device 
6.3.1. Each of the four expanding arms is equipped with a curved forming device for the coil ends

6.3.2. The length of the diamond-shaped coil and straight sections is automatically positioned by the lead screw beneath the machine bed.

6.3.3. The pre-expansion left/right end lengths and the post-expansion projected end lengths are automatically positioned by the ram and hydraulic cylinder within the assembly.

6.4.4. The clamp's rotation angle is automatically adjustable within a range of 0-20°..
6.4.5. Clamp cylinder pressure 7MPA 
6.4. Control system 
6.4.1. Integrated electrical control cabinet, can automatic control and manual operation.

6.4.2, Mitsubishi PLC control. PLC
6.5. Hydraulic system 
6.5.1. Design pressure:16MPa, working pressure is ≤12MPa. 16MPa,<12Mpa
6.5.2. Hydrualic cylinder: 50*30        6 pieces           
6.5.3. Hydrualic cylinder: 50*50        6 pieces
6.5.4. Hydrualic cylinder: 63*400       2 pieces
6.5.5, Balance guide rod 40*600   8 pieces                
6.5.6, load capacity: 300KG                             
6.4.7. Hydraulic oil must be prepared by the buyer.           
6.4.8. Installed power: 5.5kw.                            
6.4.9. Cooling form: air cooling                           :
6.4.10. Solenoid valve specifications: 01H, 220v, 14 pieces     
6.4.11. Hydrualic cylinder return speed: 50                  
6.4.12 Oil pipe: Φ8                                     
6.6. Top arc device 
6.6.1. Height from center to ground: 1100mm.     
6.6.2. Max. Running length: 400mm.             
6.6.3. Max. Force of the machine head is 500kg.    :500kg
6.6.4. Max. Load of arc plate: 260kg.             
6.7. Nose clamping device 
6.7.1. The system uses dedicated hydraulic cylinder to push/pull the locking pin, fixing the coil.

6.7.2.The side clamping panels feature arc-shaped edges to prevent coil.

6.7.3.The side moving panels adjust the pressure distance according to the coil thickness.

6.7.4. Pressure is adjustable, generally 8MPA ,8MPa
VII Main parts list

No.	Name	Model	Qty.
1	Gear pump	310	1
2	Reducer	RV90	15
3	Servo motor	0.75kW	15
4	Overflow valve	02W	12
5	Electromagnetic valve	DSG-01-3C2	12
6	Cylinder	50	12
7	Level gauge	YD-UHZ	2
8	Sensor	508 series	16
9	Touch screen	10inch	1
10	Programmable controllers	FX5Useries	1
11	Screw	4010	4
12	Screw	2510	8
13	Main electrical components		1
14	Guide	HGH40	6
15	Synchronous wheel	8M	6
16	Drag chain	Z-100	4
17	Linear Bearings		12
18	Control valve
19	Screw	3210

VIII Spare parts list

No.	Name	Model	Qty.	Brand
1	Electromagnetic valve	DSG-01-3C2	2	YUKEN
2	Overflow valve	02W	2	YUKEN
3	Slider	HGH25	1	HIWIN
4	Intermediate relay		2	Schneider
5	Screw	3210	1	HIWIN