Brushless fully automatic stator winding machines play a vital role in the motor manufacturing industry. During use, some minor faults may occur. Vacuz provides a detailed analysis of these faults, their causes, solutions, and some practical suggestions for equipment maintenance.

Common faults and solutions

I. Wire breakage

Phenomenon: The wire breaks suddenly during the winding process.

Cause: Improper tension setting, excessive acceleration, too fast winding speed, friction or foreign matter in the wire path, incorrect placement of the wire barrel, etc.

Solution:

1. Check and adjust the tensioner setting to ensure reasonable tension.

2. Reduce acceleration and winding speed to reduce the tension on the wire.

3. Clean foreign matter on the wire path to ensure a smooth and unobstructed path.

4. Place the wire barrel correctly to avoid unnecessary pressure or wear on the wire.

II. Strike needle

Phenomenon: The wire nozzle hits the skeleton during winding.

‌Cause‌: The mold positioning is inaccurate, and the wire nozzle and the skeleton are not in the same straight line.

‌Solution‌:

1. Adjust the position of the mold and the needle bar wire nozzle to ensure that they are in the same straight line.

2. Use manual mode for debugging to ensure that the wire nozzle can be smoothly inserted into the gap of the skeleton.

‌III. Abnormal jumper‌

‌Phenomenon‌: The wire jumps out of the mold or skeleton during the winding process.

‌Cause‌: Inaccurate mold positioning, insufficient winding machine accuracy, poor wire quality, etc.

‌Solution‌:

1. Check and adjust the mold positioning accuracy to ensure the matching degree between the mold and the skeleton.

2. Improve the overall accuracy of the winding machine to reduce errors.

3. Choose reliable quality enameled wire to ensure the strength and stability of the wire.

‌IV. Machine shaking‌

‌Phenomenon‌: The machine shakes significantly during the winding process.

‌Cause‌: Poor machine configuration, non-standard overall frame, use of inferior spare parts, unstable installation ground, etc.

‌Solution‌:

1. Check and replace substandard parts to ensure the overall performance of the machine.

2. Ensure that the frame is stable and reliable without looseness or deformation.

3. Install the machine on a stable ground to reduce vibration.

4. If the problem is serious, you may need to replace a winding machine with a higher configuration.

‌V. Uneven Wire Arrangement‌

‌Phenomenon‌: The wires are not arranged neatly after winding.

‌Cause‌: Improper controller settings, wire arrangement device failure, insufficient mold accuracy, improper operation of the commissioning personnel, etc.

‌Solution‌:

1. Check and adjust the controller settings to ensure that the wire arrangement parameters are correct.

2. Check and repair the wire arrangement device to ensure its normal operation.

3. Replace a higher precision mold to improve the accuracy of the wire arrangement.

4. Strengthen the training and management of the commissioning personnel to ensure standardized operation.

Maintenance measures:

‌1. Clean the winding machine‌

Regularly clean the waste thread ends, foreign objects and flying dust on the working table of the winding machine.

Check whether there are foreign objects or sharp objects on the bobbin, wool felt, wire wheel, wire mouth, etc., and clean them in time.

‌2. Lubricate the transmission part‌

Regularly lubricate the transmission parts such as motors, rolling bearings, screws, guide rails, etc.

If it is a flying fork winding machine, you also need to pay attention to the lubrication of the die tongue.

‌3. Check the tensioner‌

Regularly check whether the tensioner components are operating normally and whether the tension range is offset.

Remove the flying dust on the surface of the tensioner and do daily maintenance of precision parts.

‌4. Check the electrical part‌

Regularly check whether the power supply voltage, circuit, relay, etc. are in good condition.

Check whether each cylinder is operating normally and whether each circuit is damaged or leaking.

‌5. Check the stability of the whole machine‌
Regularly check the stability of the whole machine of the winding machine to ensure that the screws are tightened and not loose.

If there is obvious shaking during operation, it may be that the universal wheel or the bottom screw is loose, and the screws should be tightened in time.

‌6. Regular maintenance‌

Develop a detailed maintenance plan, including cleaning, lubrication, inspection, adjustment and other steps.

Perform a comprehensive inspection every month and a major overhaul every year.

If the machine is aging or seriously faulty, you can consider returning it to the factory for repair or modification.

In short, the brushless fully automatic stator winding machine may encounter a variety of minor faults during use. For these faults, we need to take corresponding solutions to troubleshoot and repair them. At the same time, in order to extend the service life of the winding machine and improve production efficiency, we also need to perform regular maintenance work on it.

Email: sales@vacuz.com