How to achieve uniform winding force in a fully automatic motor stator winding machine? How to control the force and speed?

When operating a fully automatic stator winding machine, the control of force and speed is crucial. Poor control can easily damage or break the wire, resulting in unsatisfactory winding quality. So, how can a fully automatic stator winding machine achieve uniform winding force? How can the force and speed be controlled? Below, Vacuz will give you a simple introduction!

I. Methods for Achieving Uniform Winding Force

1. High-Precision Tension Control System

Core Function: Tension is a key factor affecting winding uniformity. It requires a high-sensitivity tension sensor and closed-loop control technology to monitor and adjust the wire tension in real time to ensure constancy.

Adjustment Strategy: Set the tension range according to the wire material (e.g., copper wire, aluminum wire) and diameter. Aluminum wire tension needs to be lower than copper wire to avoid thinning the wire diameter or damaging the insulation layer; thin wires require reduced tension to prevent breakage, while thick wires require sufficient low-to-medium speed torque.

Maintenance Points: Regularly check the tensioner’s condition to ensure there is no wear or malfunction, and avoid wire overlap or skipping due to tension fluctuations.

2. Precision Transmission System

Hardware Configuration: Employs high-precision servo motors, encoders, and lead screws or cams to drive the wire laying mechanism, reducing mechanical vibration and backlash, and ensuring accurate speed and position control.

Structural Optimization: Simplifies the frame design, reduces moving components, improves overall stability, and prevents equipment vibration from affecting winding accuracy.

3. Mold and Wire Laying Mechanism Matching

Mold Accuracy: Select molds that match stator parameters (such as slot direction and size) to ensure correct wire diameter, number of turns, and layout. Mold processing must be performed according to drawing accuracy to avoid uneven winding due to mold deviations.

Wire Laying Trajectory: The movement trajectory of the wire laying mechanism must be synchronized with the winding shaft. Lead screws or cams are used to achieve uniform arrangement, preventing wire accumulation or excessive gaps.

4. Wire Quality Control

Material Selection: Select wires with suitable elastic modulus and tensile strength according to process requirements to avoid winding deformation due to unstable material properties.

Diameter Uniformity: Use wires with small diameter fluctuations to reduce tension changes caused by differences in wire diameter.

Surface Treatment: Ensures a smooth and lubricated wire surface, reducing winding resistance and improving uniformity.

II. Force and Speed ​​Control Strategies

1. Speed ​​Adjustment Methods

Motor Drive: Directly controls winding speed through servo motor or stepper motor speed adjustment. Servo motors are suitable for precision winding, while stepper motors are suitable for general applications.

Inverter Control: For AC motor winding machines, the operating frequency is adjusted via an inverter to achieve a wide speed range and good stability.

PLC or CNC System: Parameters are set using a human-machine interface, and the control system automatically adjusts the motor speed, supporting segmented speed adjustment (e.g., slowing down at the beginning/end of winding and speeding up in the middle).

Mechanical Transmission Adjustment: Speed ​​is changed by replacing pulleys, gears, and other transmission components, but transmission stability must be ensured.

2. Coordinated Control of Force and Speed

Dynamic Adjustment: Adjusts speed in real time according to changes in wire tension. For example, reducing speed when tension increases to prevent wire breakage; increasing speed when tension decreases to improve efficiency.

Parameter Optimization: Record the optimal speed-tension combination for different wire materials and processes, and establish a database for subsequent production use, reducing debugging time.

Start-up and Stop Control: For thin wires, a slow, gradual start-up is required to prevent breakage; when stopping, set a slow speed to avoid wire slack or misalignment.

3. Operation and Maintenance Specifications

Debugging Phase: Ensure all parameters (such as tension, speed, number of turns) are set correctly, and perform manual tests to verify component alignment and smooth operation.

Production Monitoring: Observe the winding density, shape, and tension in real time; immediately stop the machine and adjust if any abnormalities are found.

Regular Maintenance: Clean the equipment surface and internal parts (such as the wire laying mechanism and tension control system), inspect and replace worn parts (such as lead screws and guide rails), and lubricate the transmission system to reduce friction.

How to achieve uniform winding force on a fully automatic stator winding machine? How to control the force and speed? Vacuz has provided a simple explanation above; hopefully, this information will be helpful!