The fully automatic brushless motor winding machine is mainly used to wind the stator. Different stator products have different wire diameter designs. There are also single wire and multiple wire winding methods. So how does the fully automatic brushless motor winding machine wind multi-wire thick wire stator? Is there any good solution? Vacuz will introduce it to you!

1. Winding difficulties and innovative solutions

1. Tension control of multi-wire winding

‌Difficulty‌: When winding multiple wires, the wire diameter is thicker and the tension between wires is uneven.

‌Innovative solution‌: In addition to selecting the appropriate number of windings and reducing the winding speed, you can also consider introducing a tension control system to ensure the stability of the winding quality by real-time monitoring and adjusting the tension between wires. At the same time, the use of high-precision tension sensors can control the tension more accurately and reduce the winding problems caused by uneven tension.

2. The problem of wire damage in thick wire winding

‌Difficulty‌: Thick wire is easy to wear or break when winding.

‌Innovative solutions‌: In addition to reducing the winding speed and adopting an enhanced pendulum needle process, you can also consider using a more wear-resistant nozzle material, such as ceramic or carbide, to reduce the friction between the nozzle and the thick wire. At the same time, pre-treating the thick wire, such as applying a layer of protective agent, can also effectively improve its wear resistance.

3. The problem of loose wiring

‌Difficulty‌: The wiring is not tight and bloated.

‌Innovative solutions‌: In addition to using high-precision winding machines and professional debugging, you can also consider introducing machine vision technology to accurately control the wiring position and density through real-time image recognition. This will not only improve the accuracy and efficiency of wiring, but also achieve a tighter wiring effect.

2. Precautions and innovative ideas in the winding process

1. Equipment debugging and maintenance

‌Innovative ideas‌: Establish an equipment maintenance database to record detailed data for each maintenance and debugging, so as to analyze the performance change trend of the equipment and predict and prevent potential failures in advance. At the same time, use remote monitoring technology to monitor the operating status of the equipment in real time to achieve fault warning and rapid response.

2. Quality of mold and stator frame

‌Innovative ideas‌: Introducing 3D printing technology to manufacture molds and stator frames can achieve higher processing accuracy and more complex structural design. At the same time, 3D printing technology can also shorten the mold manufacturing cycle and reduce production costs. In addition, surface hardening of the mold and stator frame can also effectively improve their wear resistance and service life.

3. Winding parameter setting

‌Innovative ideas‌: Adopt an intelligent winding parameter setting system to automatically adjust the appropriate winding scheme according to parameters such as wire diameter and winding speed. At the same time, through big data analysis technology, historical winding data is mined and analyzed, and winding parameter settings are continuously optimized to improve winding quality and production efficiency.

I hope these innovative ideas can provide you with new inspiration and help in the use of the fully automatic brushless motor winding machine.

Имейл: sales@vacuz.com