What are the precision requirements for a multi-station internal motor stator coil winding machine for motor stators? How can the winding quality be improved?

Motor stator internal winding machines are typically used to wind inner stator products. They employ a pin-type winding method, moving up and down to quickly wind enameled wire into the stator slots. To improve efficiency, four-station or six-station machines are often used. So, what are the precision requirements for multi-station internal winding machines for motor stators? How can winding quality be improved? Vacuz will explain!

I. Precision Requirements: Multi-dimensional Indicators to Establish Quality Benchmarks

1. Core Parameter Precision

Coil Turns Error: Must be strictly controlled within ±1 turn to avoid motor performance instability due to turns deviation.

Wire Diameter Deviation: Requires a wire diameter error ≤ ±0.01mm to ensure the wire’s compatibility with the stator slot shape and prevent damage due to excessively thick wire or breakage due to excessively thin wire.

Wire Arrangement Neatness: Wires must be arranged tightly without crossing, with an interlayer gap error ≤ ±0.05mm to reduce coil resistance fluctuations and electromagnetic interference.

2. Stator Adaptability Accuracy

Slot Parameter Adaptation: The slot width needs to be dynamically adjusted according to the wire diameter and the number of parallel strands.

Layer Thickness Control Accuracy: The stator layer thickness error ≤ ±0.1mm, avoiding changes in winding curvature due to layer thickness deviation, which could lead to wire damage or uneven wire arrangement.

Outer Diameter and Height Adaptation: The outer diameter error ≤ ±0.2mm, and the height error ≤ ±0.5mm, ensuring that the winding machine station and stator dimensions match, reducing mechanical interference.

3. Multi-Station Coordination Accuracy

Positioning Error Between Stations: For multi-station equipment (e.g., four-station, six-station), the positioning error between each station ≤ ±0.05mm, avoiding inconsistent coil shapes due to station deviations.

Speed ​​Synchronization: The winding speed of each station must be synchronized, with an error ≤ ±2%, preventing wire tension fluctuations caused by speed differences.

II. Measures to Improve Winding Quality: End-to-End Optimization from Hardware to Process

1. Hardware Configuration Upgrade

Servo Drive System:

Utilizing a high-precision servo motor paired with a bus-type PLC motion controller, accurate programming control of winding trajectory, angle, and speed is achieved.

Equipped with a closed-loop tension control system, combined with a tension sensor to monitor wire tension in real time, controlling tension fluctuations within ±5%, preventing wire slack or breakage due to unstable tension.

Mold and Fixture Design:

Dedicated winding molds are designed for different stator models, with mold positioning accuracy ≤±0.02mm, ensuring coil shape and size meet requirements.

The fixture adopts a quick-change structure, with changeover time ≤5 minutes, improving production flexibility.

Wire Laying Mechanism Optimization:

A servo-driven wire laying device is used, combined with a ball screw and linear guide, achieving a wire laying device positioning error ≤±0.01mm, supporting high-speed movement requirements.

1. Optimized Wiring Path:A special algorithm generates a smooth path, reducing wire bending stress and preventing wire crossing.

2. Refined Control of Process Parameters:

Winding Speed ​​Adjustment:

Dynamically adjust the winding speed based on wire diameter and stator parameters.

Decelerate in advance in complex wiring areas (such as corners) to ensure a smooth wire transition.

Tension Management:

Set differentiated tensions for different wire materials (e.g., copper, aluminum). Aluminum wire tension should be 10%-20% lower than copper wire tension to prevent paint peeling.

Use dynamic tension compensation technology to adjust tension in real time to counteract wire elastic deformation and ensure tight wiring.

Multi-Wire Parallel Winding Optimization:

For multi-wire parallel winding processes, optimize the wire bundle arrangement sequence to avoid inter-wire interference.

Configure a multi-channel tensioner to independently control the tension of each wire, ensuring uniform parallel winding.

What are the precision requirements for multi-station internal winding machines for motor stators? How to improve winding quality? Vacuz has been explained in simple terms above. I hope this information can be helpful to everyone!