Brushless micromotors are increasingly used, and the winding of their stators is also an important link. How to wind the wire well and how to wind it correctly are common problems that need to be paid attention to. Vacuz will introduce it to you, hoping to help you!

Correct winding method for brushless micromotor stator and requirements for fully automatic winding machines ‌

‌1. Correct winding method for brushless micromotor stator ‌

‌1. Clarify the winding direction and rules ‌:

When winding, it is necessary to strictly distinguish the head and tail of the wire to ensure that different winding methods can produce symmetrical magnetic pole distribution.

The winding methods of two adjacent slots should be opposite to produce different magnetic poles after the current is passed, and ensure that the magnetic pole distribution is symmetrical to avoid the central axis of the stator being affected by eccentric force.

‌2. Winding according to the stator structure ‌:

‌ Stator with slot facing outward ‌: It is recommended to use flying fork winding equipment. During debugging, the position between the die head, die tongue, stator rod, and guard plate must be accurately adjusted to ensure that the winding process is stable and correct.

‌Stator with slot facing inward‌: Suitable for needle winding equipment. During debugging, attention should be paid to the position and positioning between the wire arrangement device, needle bar, wire nozzle, stator frame, and mold to ensure that the wiring is reasonable and meets the wire arrangement requirements.

‌3. Consider the details of winding‌:

‌Ordinary stator wire arrangement‌: For ordinary wire arrangement with low requirements, general equipment can be used, but the configuration needs to be matched according to actual needs. After the winding is completed, salt water test is required to ensure quality.

‌Precision stator wire arrangement‌: The requirements are higher, and higher-configuration equipment needs to be selected. Careful during debugging to ensure that the wire is not messy and meets the precision requirements.

‌Stator thick wire winding‌: Thick wire winding is more difficult. The speed should be as slow as possible during debugging. The winding method should be as simple as possible, and the machine configuration should be good to ensure the winding quality.

‌Multi-wire winding‌: Choose the appropriate winding method according to the wire diameter and the number of strands. The configuration and winding method should be reasonable, and the speed should not be too fast to avoid damaging the wire.

‌II. Requirements for fully automatic winding machines‌

‌1. Customized configuration‌:

‌Motor and drive selection‌: Select the appropriate motor and drive according to the stator type and winding requirements. For stators with notches facing outward, stepper motors can be used to drive the flying fork winding machine; for stators with notches facing inward, servo motors should be used for accurate control; for the efficient production needs of multiple stations, the number of servo motors needs to be increased.

‌2. Introduce advanced controllers‌:

Combining bus-type PLC motion controllers with professional servo systems to achieve intelligent management of the winding process.

Introduce cutting-edge winding machine controller technology to improve the automation level and production efficiency of the equipment.

‌3. Select high-quality components‌:

Select high-quality guide rails, ball screws and high-precision sensors to ensure the accuracy and stability of the winding process.

‌4. Equipped with auxiliary function systems‌:

The addition of automatic tension control systems, automatic loading and unloading systems, automatic wire changing devices and automatic detection functions can significantly improve overall production efficiency and quality.

‌5. Adopt fast-changing fixture design‌:

It enables motor stators of different specifications and models to be easily switched to meet the needs of special stator winding. The modular design enables the winding scheme to be customized according to customer needs.

‌6. Comprehensive guarantee of winding quality‌:

‌a. Carefully plan the winding scheme‌: Develop a detailed winding scheme based on the stator structure and specifications to ensure the tightness and stability of the winding.

‌b, Accurately control the tension‌: Accurately control the tension according to the wire specifications and winding requirements to avoid problems such as wire breakage or poor winding.

‌c. Reasonably control the winding speed‌: While pursuing efficient production, control the winding speed within a reasonable range to avoid wire loss or wire breakage caused by excessive speed.

‌d. Control the slot full rate‌: With the help of high-precision winding machines and tension control systems, ensure that the slot full rate meets the standard and reduce resistance increase and power loss.

‌e. Optimize the process‌: Optimize the process and design a reasonable wiring path to reduce the contact between the wire and the sharp edge and reduce the incidence of wire damage.

‌f. Real-time monitoring of key parameters‌: Use sensors and monitoring equipment to monitor key parameters such as position, tension, speed, etc. in real time, and make rapid adjustments through the instant feedback system to ensure the stability and efficiency of the winding process.

‌g. Improve employee skills and awareness‌: Provide employees with regular training and communication opportunities to improve their operating skills and safety awareness to ensure the safety and quality of the winding process.

Vacuz hopes that these suggestions can provide you with useful references in the selection of brushless micromotor stator winding and fully automatic winding machines.

Email: sales@vacuz.com