In order to achieve high-speed winding of multi-station stator winding machines and ensure stability, it is necessary to coordinate and promote from multiple dimensions such as equipment hardware, control system, process optimization and environmental management. Vacuz integrates and optimizes related content, aiming to elaborate on how these measures work together to achieve the expected goals. I hope it can help everyone!

1. Optimization of equipment hardware

1. High-precision drive and transmission system

a. Servo motor and driver: Select high-performance servo motors, such as Panasonic, Delta, Fuji and other brands, to ensure excellent dynamic response and positioning accuracy during high-speed operation.

‌b. Precision transmission components: Use imported high-precision screws and guide rails, such as THK, HIWIN and other brands, to reduce vibration and wear during high-speed operation, thereby extending the service life of the equipment.

‌c. Synchronous pulleys and couplings: Optimize the transmission structure, reduce mechanical clearance, and ensure the accuracy and stability of multi-station synchronous operation.

2. High-speed tension control system

‌a.‌Digital tensioner‌: Equipped with a high-precision digital tensioner, the tension is adjusted in real time to ensure that the wire does not break or relax during high-speed winding.

‌b.‌Tension fluctuation control‌: Through a closed-loop feedback system, the tension fluctuation is controlled within ±5% to improve the uniformity and consistency of winding.

3. High-speed wire nozzle and wire arrangement mechanism

‌a.‌Ceramic or carbide wire nozzle‌: The wire nozzle made of wear-resistant materials reduces the damage to the wire caused by high-speed friction.

‌‌b. High-speed wire arrangement device‌: Use a high-precision wire arrangement mechanism to ensure that the wire is evenly arranged at high speed to avoid the occurrence of overlapping or jumper wires.

2. Upgrade of the control system

‌Distributed control system‌: Through PLC or motion controller, multi-station independent control and synchronous operation are realized to improve production efficiency.

‌High-speed communication protocol‌: Real-time communication protocols such as EtherCAT and Profinet are used to ensure the rapid response of control instructions and the accuracy of transmission.

3. Optimization of process parameters

‌Speed ​​and tension matching‌: Adjust the winding speed and tension according to the wire specifications (wire diameter, material) to ensure that the wire does not break or deform during the winding process.

‌Slot full rate control‌: By optimizing the winding procedure, ensure that the stator slot full rate is within a reasonable range (usually 70%~85%) to avoid overload.

4. Strengthening environmental management

‌Temperature and humidity control‌: Keep the workshop temperature at 20~25℃ and the humidity at 40%~60% to prevent electronic components from getting damp or overheating and ensure the stable operation of the equipment.

‌Dust and anti-static‌: Install air purification equipment to reduce the impact of dust on the equipment; use anti-static floors and tooling to avoid static electricity from damaging electronic components.

In summary, by promoting the coordinated advancement of multiple dimensions such as equipment hardware, control system, process optimization and environmental management, the high-speed winding of multi-station stator winding machines can be effectively achieved and stability can be guaranteed. The implementation of these measures not only improves production efficiency and product quality, but also injects new vitality into the development of enterprises.

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