Manufacturing
Large Scale Manufacturing
Marelli Motori operates one of Europe’s most advanced alternators and motors manufacturing facilities at its Arzignano headquarters, where specialist workers support the fully integrated production of industrial-grade machines up to 13 MW, 15kV, and 50 tons.
The site combines large-scale manufacturing, R&D, and vertically integrated processes to deliver high-output alternators and motors for demanding energy and industrial applications.
The manufacturing of Marelli Motori is a meticulously detailed engineering process, combining unparalleled technical expertise with the most advanced automation and technologies.
From the processing of raw materials to the final testing, every single stage is managed to guarantee micrometric precision, and the utmost reliability of the finished product.
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In-house Vacuum Pressure Impregnation system (VPI)
The Vacuum Pressure Impregnation (VPI) technique provides optimum machine protection and extended operational life. This superior performance is achieved by utilising a precisely engineered combination of high-grade impregnating resin, advanced insulation systems, and stringent process parameters.
Technical features:
- maximum impregnable diameter: 3150 mm
- maximum stator weight: 20 ton
- minimum pressure: 2mbar
- maximum pressure: 6bar
Core Component Manufacturing: Shaft, Rotor & Winding Excellence
Shaft Manufacturing
We maintain complete vertical control over the production of our shafts, starting from the raw material. The maximum initial weight of the unprocessed bar is 4.5 tons. This raw stock is fully processed in-house, utilising high-precision technologies including turning, milling, and grinding. Once complete, the shaft is ready for seamless integration into the rotor assembly.
Winding and Rotor Production
Our commitment to advanced technology is demonstrated through our winding capabilities. We have recently acquired a new, state-of-the-art winding machine which significantly expands our production envelope. This machine can handle rotors up to 20 tons and 22 poles, with a maximum shaft length of 6 meters. These advanced capabilities allow us to produce highly specialised rotors for the most demanding applications.
Precision Balancing
After the rotor is fully assembled and wound, it undergoes a critical step in the balancing machine. The balancer precisely measures any residual imbalance. This identified unbalance is corrected to ensure that the machine’s vibration levels strictly adhere to all relevant industry standards, specifically IEC 60034-14. This guarantees smooth, reliable, and compliant operation across its entire speed range.
Technical features:
- Maximum Rotor Weight Capacity: up to 50 tons
- Transmission Solution: Cardan Shift Integration
- Maximum Rotor Diameter: up to 2400 mm
- Maximum Rotor Length: up to 6000 mm
- Maximum Balancing Speed: up to 4200rpm
In-Process Quality Control
Quality is always Marelli Motori’s top priority. Our robust In-Process Control strategy ensures precision at every step of manufacturing, guaranteeing a best-in-class, reliable product.
1. Mechanical Measurement:
We perform meticulous mechanical measurements on large-scale components using a suite of high-precision instruments for unparalleled dimensional accuracy and precision. these advanced technologies verify that every structural part adheres strictly to the required tolerances, ensuring the foundation of our motors is built for zero-defect assembly and long-term reliability.
2. Electrical Validation:
Comprehensive electrical checks are conducted on all electrical components (stator and rotors windings, etc.). This continuous validation process is key to ensuring the maximum operational reliability and the superior performance of the final machine.
Stringent Testing
A key strength of the Arzignano facility is its state-of-the-art test infrastructure, enabling full validation of generators and motors in both horizontal and vertical configurations. This ensures every machine meets stringent global standards (IEC, IEEE, ATEX, UL) and complies with the requirements of the main certified marine bodies, such as DNV, ABS, BV, LR and many others. This guarantees reliable performance across mission-critical sectors, including AI data centres, power generation, marine, hydropower, and oil & gas.
Furthermore, alongside traditional on-site witnessing, Marelli Motori offers the Online Factory Acceptance Test (FAT) as a value-added service, allowing customers to attend tests remotely with the highest quality assurance, saving time and costs.
Service
Our products have been specifically designed for ease-of-maintenance, offering quick access to key components to facilitate maintenance, repair and operation activities to reduce service costs.
Crucially, our service offering is fully integrated with our manufacturing capabilities. This guarantees rapid response times and ensures that every repaired or overhauled machine strictly adheres to original production standards, effectively restoring it to “like-new” quality and reliability.
Power Solutions Division
Our independent power solution pairs Bergen Engines AS gas engines with Marelli Motori large-frame alternators to deliver scalable, utility-grade power for high-density AI workloads. Engineered for continuous duty, fast load response and long-duration stability, this combination provides truly grid-free, always-on power for next-generation AI data-centre operations.
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