The debugging optimization and stator adaptation requirements of the inner and outer winding machines of brushless motors require a comprehensive and in-depth solution, which mainly covers the debugging optimization of the no-load test, slow-speed wire debugging, acceleration test, finished product inspection and other stages, as well as the stator adaptation requirements of the inner and outer winding machines. Vacuz will briefly introduce them to you, hoping to help you!

1. Debugging optimization: accurate control in stages

1. No-load test stage

Speed verification: Under the premise of not exceeding the upper limit of the equipment by 20%, run the equipment at 10%-15% higher than the actual production speed, observe the coordination of each component, especially the synchronization of the up and down movement of the needle bar of the inner winding machine and the left and right movement of the mold, and the stability of the flying fork rotation and the wire nozzle movement of the outer winding machine.

‌Mechanical calibration‌: Use a laser rangefinder to accurately detect the mold installation position to ensure the first turn positioning accuracy; adjust the equipment base through a level to ensure the level of the equipment and reduce vibration.

2. Slow-speed wire debugging stage

‌Parameter initialization‌: Import the preset program according to the stator parameters (such as wire diameter, number of turns, and slot direction), set the initial winding speed to 30%-50% of the rated value, and gradually adjust it to a good state.

‌Wire arrangement verification‌: Manually run single-slot winding to observe whether the wire enters the slot smoothly without scratches or overlap. Use a high-power microscope to check the surface of the enameled wire to ensure that there is no damage.

‌Tension calibration‌: Real-time monitoring of wire tension through the tension sensor, combined with the PID algorithm to dynamically adjust the tensioner parameters to ensure stable tension.

3. Acceleration test stage

‌Grading speed increase‌: Gradually increase the speed by 10%-20% per gear, and observe the neatness of the wire arrangement and the stability of the equipment.

‌Dynamic compensation‌: In view of the influence of centrifugal force during high-speed operation, the wire arrangement pitch is adjusted through the servo system feedforward compensation function to ensure the accuracy of the wire arrangement.

4. Finished product inspection stage

‌Electrical performance test‌: Use LCR tester to detect winding resistance, inductance and insulation resistance to ensure that they meet the design requirements.

‌Voltage test‌: Apply 1.5 times the rated voltage for voltage test to ensure no breakdown.

‌Salt water test‌: Perform salt water immersion test on fine wire products to detect whether the leakage value meets the industry standard.

2. Stator adaptation requirements: structure and process collaborative design

1. Internal winding machine stator requirements

‌a. Slot direction‌: Slot inward structure to ensure that the wire enters the slot smoothly.

b.‌Size range‌: Outer diameter Φ50-Φ150mm, inner diameter Φ20-Φ100mm, stack thickness 10-50mm (customized equipment is required if it exceeds the range).

‌c. Slot distance‌: Slot spacing ≥2mm to avoid overlapping or scratching of wires when arranging wires.

‌d. Mold accuracy‌: mold polishing degree Ra≤0.4μm, positioning pin and stator hole matching clearance≤0.01mm.

2. External winding machine stator requirements

a.‌Notch direction‌: notch outward structure, suitable for flying fork winding technology.

‌b. Size range‌: outer diameter Φ80-Φ250mm, inner diameter Φ40-Φ180mm, stack thickness 15-60mm.

‌c. Flying fork adaptability‌: the flying fork diameter is usually 80%-90% of the stator outer diameter, ensuring that the wire evenly covers the notch.

d.‌ Wire arrangement angle‌: optimize the flying fork rotation angle, reduce the number of wire bending times, and reduce the risk of wire damage.

III. Verification of debugging optimization effect

‌1. Efficiency improvement‌: through phased debugging, the single-slot winding time of the internal winding machine is shortened to 8-12 seconds, and the external winding machine is shortened to 5-8 seconds.

‌2. Yield‌: Wire damage rate ≤ 0.2%, wire breakage rate ≤ 0.1%.

‌3. Equipment stability‌: Continuous operation for 24 hours without failure, vibration amplitude ≤ 0.05mm.

In summary, by accurately controlling the debugging process in stages and combining the stator adaptation requirements, the winding efficiency and product quality of the inner and outer winding machines of brushless motors can be significantly improved.

Email: sales@vacuz.com