Multi-wire inner and outer winding are common winding methods for brushless motor stators. They can solve many problems and are often used across various industries. So, what are the advantages of using multi-wire inner and outer winding machines for brushless motor stators? What are the differences between the two? Vacuz will explain.

I. Technical Principles and Structural Differences

1. Multi-wire inner winding

Improving winding accuracy: Exploring the use of laser navigation or visual recognition technology, combined with high-precision servo motors, to achieve accurate positioning during multi-wire winding and reduce winding errors.

Optimizing coil structure: Researching the effects of different slot types on coil arrangement and heat dissipation performance, optimizing coil structure, and improving motor efficiency.

2. Multi-wire outer winding

Reducing high-frequency losses: Using enameled wire made of special materials (such as low-loss copper alloy wire) combined with optimized winding processes further reduces losses during high-frequency operation.

Improving heat dissipation: Exploring the addition of heat dissipation channels within the stator slots or employing heat pipe technology to improve heat dissipation efficiency and extend motor life.

II. Expanding Application Scenario Adaptability

1. Typical Applications of Multi-Wire Inner Winding

New Energy Vehicle Drive Motors: Combining high slot fill rate and compact structure, they improve the range and power performance of new energy vehicles.

Medical Equipment Motors: Leveraging the low noise and stable operation of inner-wound motors, they meet the precise control and low-interference requirements of medical equipment.

2. Typical Applications of Outer Winding

Precision Machining Equipment Motors: For CNC machine tools and laser cutting machines, the low torque ripple and high-precision control of outer-wound motors ensure machining accuracy and surface quality.

Rail Transit Motors: Combining the heat dissipation performance and reliability of outer-wound motors, they meet the long-term, high-load operation requirements of rail transit.

III. Process Challenges and Solution Innovation

1. Difficulties of Multi-Wire Inner Winding

Wire Insertion Damage Prevention: Developing a new self-lubricating enameled wire material to reduce friction damage during the wire inserting process.

Improving Slot Fill Consistency: Using intelligent algorithms to simulate and optimize the wire insertion process improves slot fill consistency and production efficiency.

2. Difficulties in External Winding

Improving Winding Efficiency: Researching high-speed winding technology and automated tooling to reduce winding time and labor costs.

Optimizing End Shaping: Utilizing advanced welding technology and tooling design to achieve accurate end shaping and fixation, improving assembly precision and reliability.

IV. Deepening Technological Trends and Integrated Innovation

1. Hybrid Winding Process

Structural Design Optimization: Exploring suitable structural designs for hybrid winding motors, balancing the advantages of internal and external winding, and improving the motor’s overall performance.

Manufacturing Process Innovation: Researching the manufacturing processes for hybrid winding motors, such as using advanced technologies such as laser welding and ultrasonic welding, to improve production efficiency and product quality.

2. Flat Wire Technology

Material and Process Research: Exploring the effects of flat wires of different materials (e.g., copper alloy, aluminum alloy) and cross-sectional shapes (e.g., rectangular, trapezoidal) on motor performance.

Heat Dissipation and Efficiency Improvement: Combining flat wire technology with optimized heat dissipation design further enhances the motor’s heat dissipation performance and efficiency.

3. AI-Optimized Design

Algorithm Model Optimization: Employing more advanced machine learning algorithms and models, such as deep learning and reinforcement learning, improves the accuracy and efficiency of winding parameter generation.

Smart Manufacturing Integration: Combining AI-optimized design with smart manufacturing technologies enables intelligent and automated motor design and manufacturing.

What are the advantages and differences between multi-wire internal and external winding methods for brushless motor stator winding machines? Vacuz has provided a brief analysis and explanation. We hope this information is helpful!

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