Manufactures special-purpose machines and complete systems for stator, rotor and motor production – from winding technology to impregnation.
Alliance Winding Equipment, Inc.
Fort Wayne, USA · Newark, UK · Mestrino, Italy · Suzhou, China · Pune, India · Nelahozeves-Lešany, Czech Republic · Guadalupe, Mexico · Stuttgart (Partners)New on Amplifa
About us
Alliance Winding Equipment, Inc. (AWE) has been developing and manufacturing production machines and automation systems for the electric motor and generator industry since 1986. The product portfolio includes Wind & Insert machines for round-wire stators, hairpin stator systems (population, twist, welding), Needle Wind and Direct Wind machines, rotor and motor assembly lines, connection technology under the Joyal brand (diffusion bonding, resistance staking, brazing) as well as resin impregnation systems under the Newtech brand. Systems are custom-designed for the specific stator and rotor design – from flexible lab units to high-performance automation lines with MES integration, RFID traceability and test stations. Materials processed include copper/magnet wire, aluminium, electrical steel laminations, permanent magnets, insulating resins and epoxy powder. Customers come from the electric motor and generator industry, the automotive sector and general industry; delivery is worldwide to more than 25 countries. Headquarters are in Fort Wayne, Indiana (USA); further locations for sales, service and manufacturing exist in Newark (UK), Mestrino (Italy), Suzhou (China), Pune (India), the Czech Republic and Mexico, among others. Since 2014, AWE has been a wholly owned subsidiary of Khorporate Holdings, Inc. (location list according to the company's own website).
- Site
- Fort Wayne, IN, USA
- Processes
- Wind & Insert (round-wire stator winding and insertion, shed/kicker/no-twist), Core build / cleating / lamination stacking (welded or cleated, straight or skewed), Welding MIG / TIG / plasma / laser (stator cores, hairpin pins), Slot insulation (stator/rotor slot insulation), Insertion / drift / forming (vertical/horizontal, pre-form, final form), Lacing (single/double end, looper tube / arbor style), Connection technology: Joyal fusing (hot connection, hot crimp, commutator soldering/brazing), Diffusion bonding / resistance staking / solid-state brazing for magnet wire
- Materials
- Copper, Aluminium, Litz wire, Magnet wire, Lamination stacks (laminations, electrical steel), Permanent magnets, Insulating resins and varnishes (resins/varnishes), Epoxy powder (powder coat)
- Certificates
- ISO 9001:2015
- Founded
- 1986
- Industries
- Electric motor and generator industry, Automotive, General industry, Aerospace, Power generation, Compressors
- 01
Application-specific machine and system design (engineering)
- 02
Tooling design and tooling manufacture
- 03
Machine building and system integration (winding, insertion, welding,
- 04
Assembly and commissioning
- 05
Installation, training and on-site/remote service
- 06
Refurbishing, retooling and relocation
Processes and Technologies
Copper / magnet wire
Base material for windings, hairpins and the connection processes of Joyal fusing technology.
Aluminium
Processed by Joyal fusing technology for electrical connections just like copper.
Litz wire
Can be processed in the hot-connection and fusing processes without manual stripping.
Lamination stacks (electrical steel/laminations)
Raw material for stator and rotor cores, stacked and welded or cleated.
Permanent magnets
Processed in rotor assembly lines including magnet placement, magnetization and balancing.
Insulating resins and varnishes
Applied by Newtech trickle/roll-dip impregnation systems with energy-assisted curing.
Epoxy powder / powder coating
Coating of hairpin pins and stators in hairpin systems.
Locations
Fort Wayne
USHeadquarters with manufacturing, sales, service (also Joyal brand)
- Wind & Insert machines
- Joyal fusing machines
- Hairpin stator systems
Newark
GBAWE Newtech Ltd. – sales and service location, impregnation technology
- Materials
- Insulating resins, varnishes
- Resin impregnation systems
- Robotic dispensing systems
Mestrino (PD)
ITAlliance Winding Europe S.r.l. – sales and service location
Suzhou
CNAlliance Automation Suzhou Ltd. – sales, service and manufacturing
Pune
INAlliance Winding Equipment India Pvt. Ltd. – sales, service and manufacturing
Nelahozeves - Lešany
CZRESC S.r.o. – sales, service and manufacturing partner
Guadalupe, Nuevo León
MXSales and service
Stuttgart
DEIndustria Oberlander Ingenieur GmbH & Co. KG – business development partner
Machinery and Technology Areas
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Wind & Insert (round-wire stator winding and insertion, shed/kicker/no-twist)Assembly | – | – | – | – | Magnet wire, Copper, Lamination stacks (laminations) |
| Core build / cleating / lamination stacking (welded or cleated, straight or skewed)Joining | – | – | – | – | Lamination stacks (laminations) |
| Welding MIG / TIG / plasma / laser (stator cores, hairpin pins)Joining | – | – | – | – | Copper, Lamination stacks |
| Slot insulation (stator/rotor slot insulation)Assembly | – | – | – | – | – |
| Insertion / drift / forming (vertical/horizontal, pre-form, final form)Assembly | – | – | – | – | Magnet wire |
| Lacing (single/double end, looper tube / arbor style)Assembly | – | – | – | – | – |
| Connection technology: Joyal fusing (hot connection, hot crimp, commutator soldering/brazing)Joining | – | – | – | – | Copper, Aluminium, Litz wire, Magnet wire |
| Diffusion bonding / resistance staking / solid-state brazing for magnet wireJoining | – | – | – | – | Magnet wire, Copper |
| Resin impregnation / varnish (trickle, roll dip; shortwave IR, resistance and induction heating)Surface | – | – | – | – | Insulating resins, Varnishes |
| Powder coating and paint for pins/statorsSurface | – | – | – | – | Epoxy powder, Paint |
| Hairpin stator equipment: population, bending, laser ablation (enamel removal), insertionAssembly | – | – | – | – | Copper |
| Needle winding / in-slot winding / direct pole winding (internal, external, segment, linear stripAssembly | – | – | – | – | Copper, Magnet wire |
| Rotor assembly (magnet placement, shaft insertion shrink/interference fit, magnetization)Assembly | – | – | – | – | Copper, Permanent magnets |
| Full motor assembly (pressing stator into housing, rotor into stator, end bells/seals)Assembly | – | – | – | – | – |
| Robotic dispensing (gluing, sealants, gasketing, encapsulants, potting)Assembly | – | – | – | – | Adhesives, Sealants, Encapsulants, Potting compounds, Gasketing materials |
| Testing station integrationTesting | – | – | – | – | – |
| Machining/tooling (tool design and manufacture, machine building for corporate customers)Engineering | – | – | – | – | – |
9 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Wind & Insert machines and complete systems (round wire stator) | Alliance Winding Equipment | – | – | – | – |
| Robotic wind & insert system (kicker-pin-style winder, 15-second cycle time) | Alliance Winding Equipment | – | – | – | – |
| Wind & Insert cell (three-phase insertion, integrated) | Alliance Winding Equipment | – | – | – | – |
| Hairpin stator systems (population, twisting, welding) | Alliance Winding Equipment | – | – | – | – |
| Needle wind / direct wind machines | Alliance Winding Equipment | – | – | – | – |
| Joyal fusing machines (stand-alone, rotary, bowl-fed) | Joyal (Alliance Winding Equipment) | – | – | – | – |
| Newtech resin impregnation systems and robotic dispensing systems | AWE Newtech | – | – | – | – |
| Rotor assembly and motor assembly machines | Alliance Winding Equipment | – | – | – | – |
| Large-frame vertical no-twist winding / NEMA 400F / IEC 250F automatic vertical insertion | Alliance Winding Equipment Nema 400F / IEC 250F | – | – | 2020 | – |
Additional services
Quality
Alliance Winding Equipment is certified to ISO 9001:2015 (scope of certification: design and manufacture of stator and rotor production machines and systems for electric motors and generators). Systems are equipped with integrated test stations, laser engraving/barcode and RFID traceability as well as MES integration.
| Evidence | Fort Wayne |
|---|---|
| ISO 9001:2015 |
History
- 1986
Foundation of Alliance Winding Equipment, Inc.
- 1987
First Wind & Insert machine
- 2003
First Needle Wind machine
- 2004
Acquisition of Joyal Products, Inc. (founded 1947) and Newtech Ltd. (founded 1980)
- 2010
Alliance Automation Ltd. starts manufacturing in Suzhou, China
- 2011
Alliance Winding Europe S.r.l. starts in Mestrino, Italy
- 2014
AWE Group acquired 100% by Khorporate Holdings, Inc. as of September 1
- 2015
First hairpin technology machine
- 2016
Newtech develops powerful, precise resin systems
- 2019
AWE redefines the limits of large-frame automation systems
- 2020
First large-frame vertical no-twist winding; NEMA 400F / IEC 250F automatic vertical insertion
- 2023
First kicker-pin-style winder