The fully automatic winding and arranging process of the brushless stator winding machine covers many aspects, including technical processes, precision requirements, technical challenges and solutions, as well as industry applications and standards. Vacuz will briefly analyze the relevant content of the fully automatic winding machine winding and arranging!

The fully automatic winding and arranging process of the brushless stator winding machine is a key technology in modern motor manufacturing. This process involves precise mechanical control, automated programming, and the collaborative work of multi-dimensional parameters. Its precision requirements directly determine the performance and reliability of the motor.

‌1. Core technical process of fully automatic winding and arranging ‌

‌1. Intelligent programming and path planning ‌

Use CAD software or a dedicated programming system to input stator structural parameters, such as the number of slots, slot type, number of winding layers, etc., to generate a three-dimensional winding path model.

The system automatically calculates and optimizes the winding sequence to avoid crossing, overlapping or sudden changes in tension, ensuring that the copper wire can fill the slot evenly and accurately.

‌2. Dynamic control of tension and speed‌

A closed-loop tension control system is used to monitor the copper wire tension in real time and adjust it dynamically to ensure that the tension fluctuation range is within a small range (such as ±0.5N).

The winding speed and tension are linked to each other. The tension is automatically reduced during high-speed winding to prevent wire breakage, and the tension is increased during low-speed winding to ensure tight wire arrangement.

3.‌High-precision mechanical execution‌

The wire arrangement mechanism uses precision ball screws and linear guides with high repeatability to ensure that the copper wire is arranged in layers in the slot without deviation.

The tension control uses hysteresis or servo tensioners with short dynamic response time and a tension fluctuation range controlled within a small range (≤±2%).

The wire trimmer and reversing mechanism are driven by a high-precision servo motor to achieve accurate wire trimming and reversing operations, and the wire trimming error and reversing angle error are controlled within a small range.

4. Online detection and feedback compensation‌

The laser displacement sensor monitors the position of the copper wire in real time. Once the deviation exceeds the set threshold (such as ±0.05mm), the system automatically adjusts the position of the wire arrangement mechanism immediately.

The visual inspection system scans the winding surface, identifies and processes defects such as missing wires and overlaps to ensure winding quality.

‌Second, core indicators of precision requirements‌

‌Winding position accuracy‌: The copper wire must be arranged strictly according to the slot contour, and the error must be controlled within a small range (within ±0.02mm) to avoid magnetic circuit asymmetry due to offset.

‌Tension consistency‌: The tension fluctuation throughout the process must be controlled within a small range (≤±3%) to prevent wire breakage or coil loosening due to sudden tension changes, affecting motor efficiency and life.

‌Interlayer insulation and filling rate‌: The interlayer insulation paper must be accurately positioned, and the error must be controlled within a small range (≤±0.1mm).

‌Repeat positioning accuracy‌: When winding multiple slots, the error of the winding starting point of adjacent slots must be controlled within a small range (≤±0.05mm) to ensure the consistency of the electromagnetic performance of the motor.

‌Third, technical challenges and solutions‌

‌Challenge 1‌: The copper wire is prone to shaking during high-speed winding, resulting in disordered wiring.

‌Solution‌: Use high-rigidity guide rails and closed-loop servo systems, combined with active vibration suppression algorithms, to reduce the jitter amplitude to a small range (within ±0.01mm).

‌Challenge 2‌: Interference between wires during multi-wire winding.

‌Solution‌: Optimize wire diameter and spacing through electromagnetic field simulation, combined with real-time tension compensation technology, to reduce the risk of short circuit between wires to a low level (below 0.1%).

The fully automatic winding and arranging technology of brushless stator winding machines is an important development direction in the field of modern motor manufacturing. By continuously optimizing hardware accuracy and software algorithms to achieve efficient and reliable automated production, it will be able to meet the stringent standards of high-end motor manufacturing and inject new vitality into the sustainable development of the motor industry.

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