What are the speed requirements for a high-speed motor stator coil winding machine? How can the machine be configured for optimal performance?

The winding process of a motor stator not only places high demands on configuration but also requires precise speed control. So, what are the speed requirements for a high-speed motor stator winding machine? How can the machine be configured for optimal performance? Vacuz will provide a brief introduction below!

I. Speed ​​Performance: Dynamic Balance of Efficiency and Precision

1. Intelligent Grading of Base Speed

Multi-station Collaborative Speed ​​Increase: The speed of a six-station internal winding machine can reach 1200 RPM, and the high-speed external winding machine can reach 5000 RPM, improving efficiency by 5 times compared to traditional single-station machines.

Adaptive Speed ​​Regulation Technology:

Fine wire (0.08-0.3mm) supports ultra-high-speed mode (≥3500 rpm), while thick wire (1.0-1.3mm) automatically switches to low-speed mode (800-1500 rpm), eliminating the risk of wire breakage through a dynamic PID algorithm.

Large-size stators (stack thickness > 200mm) employ a frequency reduction strategy (speed reduced by 25%), combined with stabilization technology to reduce wire sway.

2. Stability Enhancement Solution

Microsecond-level spindle speed correction system: Employs a magnetic encoder to monitor spindle speed in real time, compressing fluctuations to ±0.8%, ensuring turn count error ≤ 0.5 turns and wire diameter deviation ≤ ±0.008mm.

Motion trajectory optimization: Based on a fifth-order polynomial programming S-shaped acceleration/deceleration curve, the acceleration rate of change transitions smoothly, reducing mechanical shock by 40%.

II. System Configuration:

1. High-precision drive architecture

Direct drive solution:

5000RPM ultra-high-speed servo motor + zero-backlash torque motor, transmission error <0.005mm.

Nanometer-level grating ruler feedback system, achieving winding shape accuracy ±3μm.

Lightweight Transmission Components: Carbon fiber wire guide combined with magnetic levitation rails increases acceleration to 2G with a positioning error of ±0.008mm.

2. Intelligent Tension Management:

Multi-modal Tension Control:

Closed-loop tension adjustment for copper wire (5-50N), automatic 15% pressure reduction for aluminum wire, achieving ±0.5N accuracy through real-time feedback from strain gauges.

In case of sudden wire breakage, the electromagnetic brake can lock the wire reel within 10ms.

III. Process Upgrades:

1. Innovative Mold Design:

Parameterized Mold Library: Automatically matches mold type based on slot distance/stack thickness, changeover time ≤30 minutes.

Self-Cleaning Mold Nozzle:Built-in micro air blowing device automatically removes copper shavings during winding, reducing scratch rate by 90%.

2. Breakthrough in Wire Laying Algorithm:**

Path Planning: Generates a 3D wire laying trajectory through algorithms, intelligently reducing speed by 30% at corners, with a stacking rate <0.1%.

Machine vision quality inspection: AI detection of wire harness flatness (accuracy 0.02mm), real-time feedback for adjusting wiring parameters.

What are the speed requirements for a high-speed motor stator winding machine? How can the machine be configured for optimal performance? Vacuz has provided a simple explanation above; hopefully, this information will be helpful!