The motor stator of the drone usually uses a special winding machine to complete the winding process. For the winding machine, it is necessary not only to understand the common winding schemes and measures, but also to understand how to automatically arrange the wires and other functions. Vacuz combines the relevant content to further refine and add some innovative ideas, hoping to help everyone!

1. Refinement and innovation of schemes and measures

1. Equipment selection and configuration

‌Flying fork winding machine upgrade‌: Select a new generation of flying fork winding machine, whose flying fork design is more sophisticated and rotates faster, which can more effectively drive the wire nozzle to clamp the enameled wire into the stator slot. For the demand for precision wiring, consider customizing servo motors and high-precision drive controllers.

‌Workstation configuration optimization‌: In addition to selecting the number of workstations according to production scale and efficiency requirements, you can also consider introducing modular design so that the workstations can be flexibly increased or decreased according to production needs to improve equipment utilization.

‌Core component reinforcement‌: Select core components such as high-quality motors, screws, guide rails and cylinders from internationally renowned brands to ensure the stability and durability of the equipment under long-term high-speed operation. At the same time, consider adopting redundant design, such as dual motor drive, spare screw, etc., to improve the reliability and fault tolerance of the equipment.

2. Process optimization

‌Intelligent winding mold‌: Introduce intelligent mold recognition system, automatically select the appropriate mold according to the input stator parameters, and reduce manual operation errors. At the same time, the mold device adopts a quick clamping mechanism to improve the efficiency of mold replacement.

‌Refined tension control‌: Adopt a closed-loop tension control system, combined with high-precision tension sensors and intelligent algorithms, to achieve real-time monitoring and accurate adjustment of wire tension. The system can automatically adjust the tension range according to the wire type and wire diameter to ensure that the tension is always maintained in a suitable state.

‌Intelligent setting of winding parameters‌: Introduce artificial intelligence algorithm to automatically set parameters such as program number, coil turns, winding speed, etc. according to stator parameters and wire characteristics. At the same time, the system can monitor the winding effect in real time, and automatically adjust parameters according to feedback to achieve the optimal winding effect.

3. Automation control

‌PLC and motion controller integration‌: Adopt a system that integrates high-performance PLC and motion controller to achieve accurate linkage between the spindle motor and the winding system. The system supports multiple programming languages, which is convenient for users to customize and develop according to actual needs.

‌Human-machine interface upgrade‌: Equipped with a high-resolution touch screen human-machine interface, it supports graphical operation and real-time data display. The interface design is simple and intuitive, and operators can easily complete the flexible setting of parameters such as automatic winding, multi-line winding, thick wire winding, automatic indexing, automatic cross-slot and winding speed.

‌Real-time monitoring and intelligent adjustment‌: Introduce Internet of Things technology to realize remote monitoring and intelligent adjustment of equipment. The system can monitor the winding parameters and effects in real time, send alarm information in time when abnormalities are found, and automatically adjust the parameters to restore the stable state. At the same time, the system can record historical data to provide data support for subsequent process optimization.

4. Quality inspection and maintenance

‌Automation of salt water test‌: Introduce automated salt water test equipment to realize automatic salt water immersion, inspection and recording after the winding is completed. The system can automatically determine whether the stator meets the requirements according to the preset standards to reduce manual inspection errors.

‌Intelligent equipment maintenance‌: Establish an equipment maintenance management system to realize intelligent and automated equipment maintenance. The system can automatically remind maintenance tasks according to the equipment operation time and status, and record maintenance status and replacement parts information. At the same time, the system can predict the risk of equipment failure and take measures in advance to avoid failure.

2. Automatic winding and arranging measures

‌1. Innovation of arranging device‌: Adopt new arranging device design, such as laser-guided arranging, magnetic suspension arranging, etc., to improve the accuracy and stability of arranging. At the same time, consider introducing adaptive arranging algorithm to automatically adjust the arranging strategy according to wire characteristics and stator parameters.

2.‌Intelligent setting of harness length and spacing‌: Introduce intelligent measurement system to automatically set harness length and spacing according to product requirements and wire characteristics. The system can monitor the harness status in real time and automatically adjust parameters according to feedback to ensure that the harness length and spacing are always kept in a suitable state.

‌3. Intelligent control of harness direction‌: Use visual recognition technology to realize intelligent control of harness direction. The system can monitor the harness direction in real time, find deviations and correct them in time to avoid entanglement or crossing. At the same time, the system can automatically adjust the harness closing processing strategy according to product requirements to ensure tightness and aesthetics.

‌4. Speed ​​and tension coordinated control optimization‌: Introduce advanced control algorithms to achieve coordinated control of motor speed and tensioner. The system can automatically adjust the motor speed and tension value according to the actual winding effect, keep the wire tension stable and increase the winding speed. At the same time, consider introducing a predictive control algorithm to predict the future winding state based on historical data and adjust the parameters in advance to achieve the control effect.

I hope these detailed and innovative ideas can provide more inspiration and help for your solution. Do you have any other needs or questions?

Sähköposti: sales@vacuz.com