Custom-built, reliable electric motor windings for railway and naval applications
The railway and naval industries demand electrical components that ensure uninterrupted operation, maximum safety, and resistance to extreme environmental conditions. Electric motors installed on trains and ships must continue working reliably under strong vibrations, temperature fluctuations, high humidity, and potentially explosive atmospheres.
That’s why electric motor windings in these sectors cannot rely on off-the-shelf solutions. They require technical expertise, carefully selected materials, and a tightly controlled manufacturing process.
At Zampolli, we specialize in producing electric motor windings for the railway and naval sectors, delivering tailor-made solutions engineered to meet the exact technical specifications of each application.
The specific demands of railway and marine electric motor windings
In the railway sector, electric motors are used in critical systems such as traction, forced ventilation, and cooling or air conditioning units. These motors must maintain peak efficiency even after thousands of kilometers of variable operation, without frequent maintenance or performance loss. The quality of the winding directly impacts system longevity and reliability.
In the naval sector, challenges are different but equally complex: constant humidity, saltwater corrosion, thermal and mechanical oscillations from wave motion, and in some cases operation in explosion-risk zones. In such environments, every electrical component must meet strict protection and insulation requirements.
Motor windings must therefore be built with corrosion-resistant materials, properly insulated, and able to ensure continuous operation even under aggressive environmental conditions.
Advanced manufacturing techniques for railway and naval windings
To ensure maximum reliability, every Zampolli winding for the railway and naval sectors is produced using a combination of cutting-edge technologies and high-precision manual techniques. Copper distribution in the stator slots is meticulously calibrated to deliver a uniform magnetic field and minimize electrical losses.We use only certified materials compliant with international standards such as ATEX and IECEx, ideal for use in explosive or corrosive environments.
One critical element is phase-to-phase insulation, which is handled with the utmost care to prevent internal short circuits. The entire manufacturing process undergoes strict quality control, culminating in final testing with high-precision instruments. Each winding is electrically tested with tolerances below 2%, ensuring optimal performance under all conditions.
Common applications of our windings in railway and naval sectors
Zampolli windings are used in a wide range of railway systems, including electric traction motors that power trains, as well as motors for HVAC systems that ensure onboard comfort and safety.
In the naval industry, they are found in electric propulsion motors, onboard pumps, cargo handling and lifting systems, and ventilation units.
Thanks to our flexible manufacturing and fully customizable approach, each winding can be tailored to meet specific requirements for voltage, power, size, and operating conditions.
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How Zampolli meets the demands of railway and marine applications
For both railway and marine projects, Zampolli exclusively produces hand-inserted windings, a method that provides full control over every stage of the process and guarantees precise conductor placement within each slot. All solder joints are flame-welded and protected by double insulation: an initial layer of insulating tape, followed by a secondary coating in fiberglass-reinforced silicone tubing.
Every material used is certified according to industry standards, and final electrical testing is carried out using rigorous procedures that verify each individual parameter.
With over 50 years of experience, an evolved artisanal approach, and a constant focus on innovation, Avvolgimenti Zampolli delivers custom electric motor windings for the railway and marine sectors that are both reliable and precisely engineered.
The quality of our windings reflects the perfect balance of technical expertise, production control, and the ability to listen and respond to each client’s unique needs.
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We can produce a very wide range of asynchronous windings thanks to dedicated but flexible equipment.