What should I do if the winding method of my brushless stator winding machine is incorrect? How do I adjust the winding method to the correct one?

When the brushless stator winding machine’s winding method is incorrect, adjustments need to be made based on the stator slot direction, the manifestation of winding problems, and aspects such as equipment debugging, parameter settings, and hardware configuration. Below is a detailed analysis and adjustment method, which Vacuz will briefly introduce!

I. Selecting the Winding Method Based on the Stator Slot Direction

1. Stator with Slots Facing Outwards:
Winding Method: Typically uses a flying fork winding method.

Debugging Points:

Adjust the positions of the die head, die tongue, stator rod, and guard plate to ensure accurate positioning and no offset.

Avoid skipped wires, broken wires, and damaged wires.

2. Stator with Slots Facing Inwards:

Winding Method: Typically uses a needle winding method.

Debugging Points:

Adjust the positions and positioning of the wire feeding device, needle rod, wire nozzle, stator frame, and die to prevent needle collisions.

Ensure the wire feeding method is reasonable and simple, the wire feeding meets requirements, and there are no broken or damaged wires.

II. Specific Adjustment Methods for Winding Problems

1. Disorganized or Uneven Winding:

Check Power Supply and Voltage: Ensure the power supply voltage is stable and meets the equipment’s stable production requirements.

Verify Winding Parameters: Check if the enameled wire diameter, number of turns, winding direction, and other parameters are set correctly.

Check the Wire Laying Device: Ensure the wire laying device is normal and undamaged or loose.

Adjust the Tensioner: Adjust the tensioner parameters according to the tension setting table to avoid excessively loose or tight tension.

Control Winding Speed: Ensure a normal winding speed based on stator parameters and product requirements to avoid uneven wire laying due to excessive speed.

Stable Control System: Update the control system software to ensure system stability and reliability.

2. Broken or Damaged Wire:

Check Die and Auxiliary Accessories: Ensure the die design is reasonable, the machining is careful, and there are no burrs, protrusions, etc. Check that auxiliary accessories such as the wire guide roller, wire nozzle, and felt are clean and free of impurities and foreign objects.

Adjust the Tensioner: Avoid excessive tension that could lead to wire breakage.

Control winding speed: Avoid excessive winding speed, which can damage the wire.

Inspect the spool: Ensure the spool is free of defects and the wire quality is up to standard.

3. Unstable machine operation:

Check machine configuration: Ensure the servo motor, driver, controller, and other key components are reliable and meet precision wiring requirements.

Stabilize the machine chassis and frame: Check the chassis, frame, and worktable for good material quality and sufficient stability to prevent shaking during machine operation that could cause winding deviation.

III. General debugging steps and suggestions

1. No-load operation test:

Before production, conduct a no-load operation test on the winding machine, at a speed as high as possible compared to the actual production speed (but not exceeding the upper limit by 20%).

Observe the changes in various parameters and the coordination of each component, noting any abnormal sounds.

Only after confirming stable machine operation can production commence.

2. Wire-loaded debugging:

After placing the mold fixture, input the corresponding program and perform debugging with wire.

Using a slow winding adjustment method, after winding the wire a few times to confirm normal operation, try winding one slot at a time.

If problems such as uneven wire arrangement, wire breakage, or skipped wires occur, adjust the tension, wire arrangement device, or mold position promptly.

3. Repeated testing and adjustment:

After confirming that winding one slot is successful, continue winding the next slot until the sample is fully wound.

Repeated testing can be performed several times to observe various parameters and winding effects.

Once no problems are confirmed, gradually increase the speed until the desired speed is reached.

What if the brushless stator winding machine’s winding method is incorrect? How to adjust to the correct winding method? Vacuz has provided a simple explanation above; we hope this information is helpful!