{"id":12868,"date":"2025-09-11T02:51:04","date_gmt":"2025-09-11T02:51:04","guid":{"rendered":"https:\/\/vacuz.com\/?p=12868"},"modified":"2025-09-11T02:51:04","modified_gmt":"2025-09-11T02:51:04","slug":"what-are-the-requirements-for-winding-the-small-stator-of-a-brushless-micromotor-how-should-the-winding-machine-be-configured","status":"publish","type":"post","link":"https:\/\/vacuz.com\/es\/what-are-the-requirements-for-winding-the-small-stator-of-a-brushless-micromotor-how-should-the-winding-machine-be-configured\/","title":{"rendered":"What are the requirements for winding the small stator of a brushless micromotor? How should the winding machine be configured?"},"content":{"rendered":"

Brushless micromotor stator winding technology requires a combination of parameter adaptation, process control, and equipment selection to provide reliable implementation recommendations. Vacuz will share these solutions! We hope they are helpful!<\/p>\n

\"Aero
Aero Brushless Motor Stator<\/figcaption><\/figure>\n

I. Core Winding Process Optimization Directions<\/p>\n

1. Dynamic Tension Compensation Strategy<\/p>\n

For wire diameters between \u03a60.08 and \u03a61.3 mm, a dual closed-loop tension control system is recommended. For example, in model aircraft motor winding, this system automatically adjusts the baseline tension by monitoring wire diameter changes in real time (such as the cumulative effect of wire diameters when winding multiple strands). This prevents tension loss due to inertia during high-speed winding.<\/p>\n

2. Wire Traversing Accuracy Improvement Solution<\/p>\n

A linear encoder + servo motor directly connected to the traversing shaft is recommended, replacing traditional belt drives to eliminate mechanical backlash.<\/p>\n

Key Parameters: The servo motor response frequency must be \u22652 kHz, and the guideway positioning repeatability must be \u00b10.005 mm.<\/p>\n

3. Special-Shaped Stator Winding Technology<\/p>\n

For special-shaped stators, we recommend using a six-axis robot combined with a flexible winding head. Using offline programming to generate a spatial curved trajectory, we optimize the winding path, increasing winding efficiency by 30% while also preventing wire scratches.<\/p>\n

II. Recommended Equipment Configurations by Scenario<\/p>\n

1. Stator with Outward Slots (External Winding)<\/p>\n

Economical Solution: Flying Fork Winding Machine + Stepper Motor Wire Trapping<\/p>\n

Applicable Applications: Model Aircraft Motors, Toy Motors (Accuracy Required \u2264 0.2mm)<\/p>\n

Cost Advantage: Equipment price reduced by 40%, but winding speed must be limited to \u2264 800rpm to avoid vibration.<\/p>\n

High-Precision Solution: Flying Fork Winding Machine + Servo Motor Wire Trapping (EtherCAT Bus)<\/p>\n

Applicable Applications: Ventilator Turbine Motors, Industrial Servo Motors<\/p>\n

Performance Improvement: Wire Trapping accuracy reaches \u00b10.08mm, and slot fill rate increases by 10%-12%.<\/p>\n

2. Stator with Inward Slots (Inner Winding)<\/p>\n

Standard Solution: Needle-type inner winding machine + single servo motor<\/p>\n

Applicable Applications: Air conditioning compressor motors, water pump motors<\/p>\n

Efficiency Optimization: A four-station rotary table design reduces winding time per unit to 6-8 seconds.<\/p>\n

High-Speed \u200b\u200bSolution: Dual servo-driven inner winding machine<\/p>\n

Applicable Applications: Brushless electric drill motors, brushless angle grinder motors<\/p>\n

Key Improvement: Indexing time reduced to 0.2 seconds, supporting high-speed winding at 1200 rpm.<\/p>\n

3. Customization<\/p>\n

Modular Platform Expansion:<\/p>\n

Basic Configuration: 6-axis servo system (B&R ACOPOSmulti) + force sensor (range 0-50N).<\/p>\n

Extended Functions: Visual inspection (wire break detection), automatic loading and unloading (compatible with different stator sizes).<\/p>\n

III. Equipment Selection Pitfalls<\/p>\n

1. Servo System Selection Pitfalls<\/p>\n

Avoid selecting a driver with a response frequency less than 1kHz. Otherwise, vibration will occur during high-speed starts and stops (e.g., 1200 rpm \u2192 0 rpm), causing the wire to loosen.<\/p>\n

2. Tensioner Accuracy Verification Method<\/p>\n

Require the supplier to provide a tension fluctuation test report (must be \u2264 \u00b10.05N). Use the hanging weight method to simulate actual winding tension and verify the linearity of the magnetic powder brake.<\/p>\n

3. Key Points for Software Functionality Testing<\/p>\n

Programming Flexibility: Test the efficiency of switching between G-code and dedicated winding languages \u200b\u200bto ensure process adjustment time is \u2264 15 minutes.<\/p>\n

Data Traceability: Verify that the MES interface supports real-time upload of parameters such as tension, speed, and number of turns, and generates traceable reports.<\/p>\n

\"Automatic
Automatic winding machine for double station aero fascia gun motor<\/figcaption><\/figure>\n

What are the requirements for winding small stators for brushless micromotors? How should winding machine equipment be configured? Vacuz has provided a brief overview above. We hope this information is helpful!<\/p>\n

Email: sales@vacuz.com [fusion_form form_post_id=”431″ margin_top=”” margin_right=”” margin_bottom=”” margin_left=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=””][\/fusion_form]<\/p>\n","protected":false},"excerpt":{"rendered":"

Brushless micromotor stator winding technology requires a combination of parameter adaptation, process control, and equipment selection to provide reliable implementation recommendations. Vacuz will share these solutions! We hope they are helpful! I. Core Winding Process Optimization Directions 1. Dynamic Tension Compensation Strategy For wire diameters between \u03a60.08 and \u03a61.3 mm, a dual closed-loop tension control […]<\/p>\n","protected":false},"author":1,"featured_media":4837,"comment_status":"closed","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_gspb_post_css":"","_joinchat":[],"footnotes":""},"categories":[63],"tags":[],"class_list":["post-12868","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-technology"],"blocksy_meta":[],"_links":{"self":[{"href":"https:\/\/vacuz.com\/es\/wp-json\/wp\/v2\/posts\/12868","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/vacuz.com\/es\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/vacuz.com\/es\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/vacuz.com\/es\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/vacuz.com\/es\/wp-json\/wp\/v2\/comments?post=12868"}],"version-history":[{"count":0,"href":"https:\/\/vacuz.com\/es\/wp-json\/wp\/v2\/posts\/12868\/revisions"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/vacuz.com\/es\/wp-json\/wp\/v2\/media\/4837"}],"wp:attachment":[{"href":"https:\/\/vacuz.com\/es\/wp-json\/wp\/v2\/media?parent=12868"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/vacuz.com\/es\/wp-json\/wp\/v2\/categories?post=12868"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/vacuz.com\/es\/wp-json\/wp\/v2\/tags?post=12868"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}