The precision of the fully automatic brushless motor stator winding machine is inseparable from the role of various auxiliary components, such as the tensioner mechanism. So why does the fully automatic brushless motor stator winding machine use a tensioner mechanism? How to configure the tensioner more reasonably? Vacuz will introduce it to you, hoping to help you!

The core reasons for the use of tensioner mechanisms in fully automatic brushless motor stator winding machines:

‌1. Protect enameled wire and ensure stable production‌:

The tensioner mechanism effectively avoids the damage of the wire insulation layer due to excessive friction by dynamically balancing the friction between the wire and the equipment, significantly reducing the failure rate of wire breakage and wire damage, thereby improving the overall stability of the production line.

‌2. Improve winding accuracy and consistency‌:

In high-precision stator winding, such as model aircraft, drones and other fields, the tensioner can accurately control the winding tension, ensure that the coil is arranged tightly and flatly, and meet the strict requirements of the brushless motor stator for slot fullness, coil fullness and aesthetics, thereby ensuring the consistency of motor performance parameters.

‌3. Adapt to diverse wire material requirements‌:

Enameled wires of different specifications have different sensitivities to tension. The tensioner can flexibly match the physical properties of different wires through adjustable design, ensuring that the winding process is neither too tight to cause wire stretching and deformation, nor too loose to cause the coil to loosen, thereby improving the flexibility and applicability of winding.

‌4. Improve automation and production efficiency‌:

After the fully automatic winding machine is integrated with the tensioner, real-time monitoring and automatic adjustment of tension parameters are realized, reducing manual intervention. Through the sensor feedback tension changes, the controller quickly corrects the actuator action to keep the tension stable, thereby shortening the wire change and debugging time, and significantly improving production efficiency.

Reasonable configuration method of tensioner

‌1. Selection principle‌:

Preferably select tensioners with high accuracy and strong stability, such as magnetic damping tensioners, to reduce tension fluctuations.

Select a model with a tension range covering actual needs according to the wire specifications (such as wire diameter and material).

Consider the type of winding machine to ensure that the tensioner has a compact structure, adapts to small spaces or meets standard installation requirements.

‌2. Initial setting‌:

Set the initial tension according to the process specifications to ensure compliance with industry standards or manufacturer recommended values.

Perform no-load test on the equipment, adjust the output force of the tensioner, and ensure smooth operation of the actuator.

Hang the wire for trial winding, observe the situation of the wire passing through the tensioner, check the flatness of the wire arrangement, and fine-tune the tension value if necessary.

‌3. Dynamic adjustment and feedback control‌:

Integrate sensors and controllers to monitor the wire tension in real time and feed the data back to the control system.

Optimize the controller PID parameters according to the characteristics of winding speed, wire elasticity, etc. to achieve fast response and stable control.

Use the segmented control strategy to set differentiated tension values for different stages of winding to meet the needs of different working conditions.

‌4. Maintenance and calibration‌:

Regularly clean the dust on the surface of the tensioner, lubricate the moving parts, and reduce wear.

Use standard weights to calibrate the output force of the tensioner to ensure that the accuracy meets the requirements.

Stock commonly used wearing parts to ensure quick replacement in case of failure and shorten downtime.

In summary, the use of a tensioner mechanism in a fully automatic brushless motor stator winding machine has significant advantages in protecting enameled wire, improving winding accuracy and consistency, adapting to diverse wire material requirements, and improving automation and production efficiency. By properly configuring the tensioner, the winding process can be further optimized, and product quality and production efficiency can be improved.

Email: sales@vacuz.com