When discussing the requirements, process requirements and stable operation methods of brushless aircraft model motor stator winding, we need to conduct in-depth analysis from three aspects: winding core requirements, process key requirements and stable operation guarantee measures to ensure the accuracy, efficiency and stability of stator winding. Vacuz will introduce it to you!

1. Winding core requirements

‌1. Stator parameter adaptability‌:

The outer diameter and inner diameter must be strictly matched with the winding equipment model. If it exceeds the range, special equipment must be customized.

The direction of the slot determines the winding method. For example, the flying fork winding method is used when the slot is facing outward, and the needle inner winding method is used when the slot is facing inward.

The slot distance needs to be adjusted according to the wire diameter to prevent scratches and damage to the wire.

‌2. Wire material and tension control‌:

The selection of wire diameter needs to consider the motor power. Thick wire reduces the winding speed, and thin wire increases the speed but needs to prevent wire breakage.

The tension needs to be evenly controlled and adjusted in real time through sensors and control systems to avoid being too loose or too tight.

When winding multiple wires in parallel, ensure that the equipment configuration is compatible to avoid wire entanglement.

‌3. Number of turns and interlayer insulation‌:

The number of turns must be strictly wound according to the design requirements, and deviations will affect the performance of the motor.

Multi-layer winding requires the addition of insulating paper to prevent short circuits between layers.

2. Key process requirements

1.‌Pre-winding preparation‌:

The stator core needs to be cleaned on the surface to remove impurities and burrs.

The mold needs to be customized according to the stator specifications to ensure polishing and accuracy.

Parameters need to be preset through PLC or touch screen to ensure winding accuracy.

‌2. Winding operation specifications‌:

The initial fixation needs to be firm to prevent loosening during winding.

The speed needs to be adjusted according to the equipment performance and wire characteristics to avoid wire loss and wire breakage due to excessive speed.

The path needs to be optimized, and a professional algorithm is used to generate a smooth wiring path to improve the uniformity of the slot fill rate.

‌3. Finishing processing and testing‌:

The wire ends need to be connected according to the circuit design requirements to ensure stable electrical performance.

Insulation treatment requires varnishing to fill the gaps in the windings to enhance insulation performance and mechanical strength.

Quality inspection must include appearance inspection, parameter testing and salt water testing to ensure compliance with design requirements.

III. Measures to ensure stable operation

‌1. Equipment configuration optimization‌:

Use high-precision transmission components to ensure small positioning errors.

Dynamic response needs to be enhanced, and the acceleration change rate is controlled by optimizing the structure and deploying acceleration and deceleration curves.

Thermal errors need to be compensated, and the temperature distribution is monitored by infrared thermal imagers to correct position instructions in real time.

‌2. Environment and process control‌:

The production environment needs to maintain constant temperature and humidity to prevent the softening of the insulation layer of the enameled wire.

Shock absorption pads, sound insulation covers and other equipment need to be installed for shock absorption and noise reduction.

A process database needs to be established to support fast parameter matching and automatic optimization.

‌3. Real-time monitoring and maintenance‌:

Machine vision inspection requires the deployment of high-speed cameras and image processing algorithms to monitor the arrangement status of wires in real time.

Multi-source sensors need to be fused to predict equipment failures through machine learning.

Regular maintenance requires cleaning and lubrication of key equipment components, and timely replacement of worn parts.

‌4. Operator training‌:

Skill training needs to be carried out regularly to ensure that the commissioning personnel master equipment operation, parameter adjustment and troubleshooting skills.

Quality awareness education needs to be strengthened to ensure that operators have a deep understanding of key indicators and that each process meets the process requirements.

In summary, the requirements, process requirements and stable operation methods of brushless aircraft model motor stator winding involve multiple aspects, which need to be comprehensively considered and implemented from multiple angles such as equipment, process, environment, monitoring and maintenance, and personnel training. Only in this way can the accuracy, efficiency and stability of stator winding be ensured, providing a solid guarantee for the excellent performance of the motor.

Ηλεκτρονικό ταχυδρομείο: sales@vacuz.com