In the process of selecting and matching brushless motor outer rotor winding machines, it is crucial to fully consider motor specifications, winding technology, machine performance and actual production needs. Vacuz provides you with a detailed purchase guide from multiple dimensions such as winding machine categories, core configurations, technical points and performance standards:

I. Selection of winding machine categories

1. Flying fork winding machine

‌Application scenario‌: Designed for outer rotor stators with slots facing outward, commonly used in aircraft model motors, drone motors and gimbal motors.

‌Advantage‌: Known for high-speed winding, excellent efficiency, very suitable for large-scale production environments.

‌Configuration recommendation‌:

‌Ordinary type‌: Using stepper motors, suitable for scenarios with low requirements for wire arrangement accuracy.

‌Precision type‌: Equipped with servo motors to ensure constant winding tension and regular wire arrangement to meet high accuracy requirements.

2. Needle winding machine

‌Application scenario‌: Although not a typical application for outer rotors, it is suitable for some specially designed stators with slots facing inward.

‌Features‌: High winding accuracy, but relatively slow speed, suitable for small batch or high-precision product production.

2. Core configuration and detail control

‌1. Drive system‌:

‌Stepper motor‌: High cost-effectiveness, suitable for low-speed and low-precision operations.

‌Servo motor‌: Provides high accuracy and high response performance, suitable for high-speed and high-precision winding needs.

‌Direct drive motor‌: No need for a deceleration mechanism, high transmission efficiency, suitable for high-speed winding (such as speed requirements exceeding 5000 RPM).

‌2. Control system‌:

‌PLC control‌: Stable and reliable, supports multi-axis linkage, suitable for complex winding processes.

‌Motion controller‌: Realizes high-precision trajectory control, suitable for difficult processes such as multi-line winding and special-shaped winding.

‌Human-machine interface)‌: Intuitive operation, supports parameter setting, fault diagnosis and production data recording.

‌3. Mechanical structure‌:

‌Spindle accuracy‌: The spindle runout is required to be less than 0.01mm to ensure the concentricity of the winding.

‌4. Wire nozzle design‌:

‌Ceramic or diamond wire nozzle‌: wear-resistant, high temperature resistant, suitable for high-speed winding.

‌Adjustable wire nozzle angle‌: adapt to different slot types and winding directions.

‌5. Tension control system‌:

‌Magnetic powder brake‌: stable tension, suitable for thin wire diameter (such as below 0.05mm).

‌Servo tensioner‌: provides high-precision tension control, suitable for thick wire diameter (such as above 1.0mm).

‌6. Wire arrangement mechanism‌:

‌Precision guide rail‌: ensure stable wire arrangement, avoid wire jump and overlap.

‌Synchronous belt drive‌: low noise, high precision, suitable for high-speed wire arrangement.

‌Wire arrangement algorithm‌: supports a variety of wire arrangement methods, such as spiral wire, cross wire, etc., to optimize the coil filling rate.

3. Technical points and performance standards

‌1. Winding speed and accuracy:

‌Speed: Select according to wire diameter and slot type, such as 0.2mm wire diameter can reach more than 1500 RPM.

‌Accuracy: Winding position error is less than ±0.05mm, and turn error is less than ±1 turn.

‌2. Applicable wire diameter range:

‌Fine wire diameter: 0.03mm~0.2mm, high-precision wire nozzle and tension control system are required.

‌Thick wire diameter: 0.2mm~2.0mm, high-torque spindle and wear-resistant wire nozzle are required.

‌3. Multi-wire parallel winding capability:

‌Number of wires: Supports 2~16 wires parallel winding, requiring independent tension control and synchronous wire arrangement.

‌Insulation treatment: When winding, insulating paper or insulating paint should be added between the wires to prevent short circuit.

‌4. Automation level:

‌Automatic loading and unloading: Improve production efficiency and reduce manual intervention.

‌Automatic mold change‌: Quickly switch between stators of different specifications to adapt to the production of multiple varieties.

‌Quality inspection‌: Integrated functions such as number of turns detection and wire break detection to ensure product consistency.

IV. Production demand matching

1.‌Capacity demand‌:

‌Small batch‌: Select a single-station or double-station winding machine to flexibly adjust the process.

‌Large batch‌: Select a multi-station (such as 4-station, 6-station) or a fully automatic production line to improve efficiency.

‌2. Product diversity‌:

‌General winding machine‌: Suitable for products with little change in slot type and wire diameter.

‌Special winding machine‌: Customized for specific products, such as high-speed motors, micro motors, etc.

‌3. Cost budget‌:

‌Economical type‌: Stepper motor + PLC control, suitable for start-ups or low-cost needs.

‌High-end type‌: Servo motor + motion controller, suitable for high-precision, high-value-added products.

V. Brand and supplier recommendations

‌1. International brands‌: leading technology, suitable for high-end markets.

‌2. Domestic brands‌: high cost-effectiveness, perfect after-sales service.

VI. Common problems and solutions

‌1. Wire damage and wire breakage‌: check the wear of the wire nozzle, adjust the tension parameters, and optimize the winding speed.

‌2. Untidy wire arrangement‌: calibrate the wire arrangement mechanism, adjust the wire nozzle angle, and check the spindle runout.

‌3. Low winding efficiency‌: upgrade the drive system, optimize the winding algorithm, and reduce non-productive time.

When selecting a brushless motor outer rotor winding machine, it is necessary to comprehensively consider the motor specifications (slot type, wire diameter, number of turns), production requirements (capacity, precision) and budget. It is preferred to have equipment with high-precision drive, stable control system and flexible wire arrangement mechanism, and pay attention to the supplier’s technical support and after-sales service capabilities.

E-mail: sales@vacuz.com