In the manufacturing process of brushless motors, stator winding is a crucial link. However, some difficulties are often encountered in the winding process. These difficulties may come from equipment configuration, operating technology, material properties and other aspects. Vacuz will analyze these difficulties in detail and propose corresponding solutions to improve winding quality and production efficiency. I hope it can help everyone!

1. Analysis of winding difficulties

‌1. Wire arrangement problem‌

Difficulty: The wire arrangement is not tight and bloated, and precise wire arrangement cannot be achieved.

Reason: The winding machine equipment configuration is low or the debugging is not in place, resulting in poor wire arrangement effect.

2.‌Multi-wire parallel winding‌

Difficulty: When the wire diameter is thicker, multi-wire parallel winding is difficult to achieve.

Reason: Due to space limitations, it is easy to cause uneven tension between wires, thereby affecting the winding quality.

‌3. Wire damage problem‌

Difficulty: It is easy to damage the wire when winding thick wire.

Reason: The thick wire has a large wire diameter, and the friction force during winding is large, which is easy to wear or break.

‌4. Wire breakage problem‌

Difficulty: Wire breakage is easy when winding thin wire.

Reason: Thin wire has a small diameter and is prone to breakage due to excessive tension when winding at a fast speed.

‌5. Equipment stability‌

Difficulty: Unstable machine operation leads to reduced winding quality.

Reason: Aging, wear or improper configuration of equipment affects winding accuracy and stability.

‌6. Mold and stator frame problem‌

Difficulty: The processing of mold and stator frame does not meet the requirements, resulting in problems such as scraping wire and hitting needles during winding.

Reason: The processing accuracy of mold and stator frame is not enough or the installation positioning is inaccurate.

2. Solution

1. ‌Improve equipment configuration and debugging‌

Use better-configured winding machine equipment, such as high-precision wire winding machine, to improve wire arrangement accuracy and efficiency.

Professionally debug the equipment to ensure that the wire arrangement is neat and tight to meet production requirements.

‌2. Optimize multi-wire parallel winding technology‌

Choose the appropriate number of parallel windings according to the wire diameter to avoid the problem of multi-wire parallel winding caused by excessive wire diameter.

Use advanced winding processes and technologies, such as multi-station winding machines, to improve winding efficiency and accuracy.

‌3. Prevent wire damage‌

Specially treat thick wires, such as using wear-resistant materials or increasing lubrication to reduce friction during winding.

Debug the machine to ensure that the tension is moderate during winding to avoid excessive wear and tear.

‌4. Prevent wire breakage‌

Reduce the winding speed when winding thin wires to reduce excessive tension.

Regularly check and maintain the equipment to ensure that there are no impurities or foreign matter in the wire wheel, wire nozzle and other parts to maintain a smooth winding environment.

‌5. Improve equipment stability‌

Maintain and maintain the equipment regularly to ensure that the equipment is in good condition.

Use advanced control systems and sensor technology to monitor the operating status of the equipment in real time and detect and solve problems in a timely manner.

‌6. Ensure the quality of molds and stator frames‌

Strictly produce molds and stator frames according to the drawings to ensure processing accuracy and accurate installation positioning.

Polish and grind the molds and stator frames to avoid problems such as scraping and hitting the needle, and improve the winding quality and production efficiency.

In summary, there are indeed many difficulties in the winding process of the brushless motor stator winding machine. However, by improving equipment configuration, optimizing winding process, preventing wire damage and wire breakage, improving equipment stability, and ensuring the quality of molds and stator frames, we can effectively solve these problems and improve winding quality and production efficiency. This will provide better protection for the manufacture of brushless motors and help the sustainable development of the motor manufacturing industry.

E-mail: sales@vacuz.com