What type of winding machine is used for the external rotor of a brushless motor? What are the key features of this equipment?

Brushless motors typically use either fly fork winding machines or pin winding machines for winding the external rotor. These two types of equipment offer significant advantages in automation, winding efficiency, precision control, and adaptability, meeting the demands of complex external rotor structures and winding processes. Below is a brief explanation of the specific equipment types and their key features.

I. Fly Fork Winding Machine: A Classic Choice for External Rotor Winding

Applicable Scenarios:

The fly fork winding machine is the traditional and mainstream equipment for external rotor winding, especially suitable for stator structures with outward-facing slots (i.e., the stator of an external rotor motor). Its working principle involves the high-speed rotation of the fly fork driving the wire nozzle, which, in conjunction with a mold and guard plate, accurately inserts the enameled wire into the stator slots, achieving layered winding.

Key Features:

1. High Speed ​​and High Efficiency:

The fly fork speed can reach 2000-5000 RPM, far exceeding the winding speed of manual or semi-automatic equipment, significantly improving production efficiency.

For example, the Vacuz brushless motor pin winding machine adopts a dual-station design, winding two brushless rotors per cycle, significantly improving production efficiency.

2. Precision Wire Arrangement:

For example, the Vacuz winding machine uses a programmable control system (such as PLC + servo motor) to accurately control the trajectory of the fly fork, ensuring that the enameled wire is wound evenly and tightly into the slot, avoiding overlap or excessive gaps.

Accurate mold positioning and a sophisticated wire arrangement device enable multi-layer automatic wire arrangement, meeting high-precision winding requirements.

3. Automation Integration:

The Vacuz winding machine integrates automatic loading and unloading, clamping, winding, wire arrangement, and wire cutting functions, reducing manual intervention and lowering operational difficulty and labor intensity.

The Human-Machine Interface (HMI) supports fault diagnosis, production recording, and parameter storage (such as winding turns, wire diameter, slot skipping method, etc.), facilitating production management and quality control.

4. Stable Structure:

The frame utilizes a combination of sheet metal and aluminum profiles, providing strong shock absorption and maintaining low vibration even at high speeds, ensuring winding accuracy.

Precision guide rails, lead screws, cylinders, and other high-quality components further enhance the stability of equipment operation.

II. Pin-Type Winding Machine: A High-Efficiency Solution for Multi-Pole External Rotors

Applicable Scenarios:

The pin-type winding machine uses a servo motor to drive the pin bar in high-speed up-and-down motion, coordinating with the left-and-right movement of the die and the forward-and-backward movement of the pin bar to wind enameled wire into the stator slots. Its dual-station design is particularly suitable for mass production of brushless motor external rotors.

Key Features:

1. Dual-Station Design, Doubled Capacity:

Each cycle can simultaneously wind two brushless rotors, doubling the production efficiency compared to single-station equipment, making it suitable for large-scale production.

For example, the Vacuz winding machine is specifically designed for brushless external rotors, supporting multi-diameter winding, automatic indexing, automatic slot crossing, and other functions, offering simple operation and high efficiency.

2. Modular Fixtures for Quick Changeover:

The fixtures feature a modular design, ensuring accurate positioning and easy replacement, quickly adapting to the production needs of different product models.

Supports complex winding methods such as multi-strand parallel winding and serial winding, meeting diverse product requirements.

3. Accurate Tension Control to Prevent Wire Damage:

Equipped with a tension sensor and control system, it monitors and adjusts wire tension in real time, ensuring appropriate wire tension during winding and preventing wire breakage due to excessive tension or detachment due to insufficient tension.

For example, the Vacuz winding machine effectively solves the problem of wire damage when winding thicker wires (e.g., 0.7mm and above) by optimizing the winding process and tension management.

4. Low-Noise Design for Improved Working Environment:

The equipment operates with low noise; even several machines operating simultaneously will not produce significant noise, providing a more comfortable working environment for operators.

III. Equipment Selection Recommendations: Matching Functions to Needs

1. Basic Requirements:

For smaller production scales or a single product model, a single-station flying fork winding machine can be selected, balancing cost and efficiency.

For example, the Vacuz high-speed winding machine is affordable and meets basic functional requirements.

2. High-efficiency production:

For mass production of external rotors, a dual-station pin-type winding machine, such as the Vacuz, is the preferred choice. Its high degree of automation and quick changeover significantly increase production capacity.

3. Customization needs:

For products with special dimensions (e.g., rotor outer diameter exceeding 120mm, stack thickness exceeding 80mm), it is necessary to choose equipment manufacturers that support non-standard customization, such as Vacuz, which can customize equipment parameters according to customer requirements.

What kind of winding machine equipment is used for the external rotor of a brushless motor? What are the significant features of this equipment? Vacuz has provided a brief explanation above; we hope this information is helpful!