The key to choosing a high-speed brushless stator winding machine is: first, determine the model; then, focus on the core configurations; and finally, verify the performance. High speed is not everything; stability and accuracy are prerequisites for high efficiency. So, how do you choose a high-speed brushless stator winding machine? What are the key points? Let Vacuz give you a simple introduction below!
Step 1: Choosing the Right Model
1. Inward-facing slots: Pin-type internal winding machine. A thin needle drives the enameled wire up and down reciprocatingly, accurately placing the wire into the slots inside the stator. High precision, suitable for high-speed winding requirements. Applicable to brushless motors, water pump motors, power tool motors, household appliance motors, etc.
2. Outward-facing slots: Flying fork type external winding machine. A rotating “flying fork” winds the wire around the outside of the stator. Fast speed and high efficiency, suitable for mass production. Applicable to model aircraft motors, drone motors, fan motors, fascia gun motors, etc
Step Two: Locking in the Core
After selecting the machine model, the following are the four core configurations that determine whether the equipment can “run fast and wind accurately.”
1. Winding Accuracy (The Foundation of Quality)
Requirement: Positional error must be controlled between ±0.01mm and ±0.05mm. This is a crucial indicator, directly affecting coil quality.
Tip: Pay close attention to whether the servo motor, ball screw, and linear guide used in the equipment are from reputable brands; these are the hardware guarantees of accuracy.
2. 장력 조절
Requirement: During high-speed winding, the tension must be constant and accurate. Depending on the wire diameter, the tensioner adjustment range should be between 0.1N and 5N.
Tip: Equipment with a “closed-loop tension control system” must be selected. It can monitor and fine-tune the tension in real time, which is key to ensuring that thin wires do not break and thick wires are tightly wound.
3. Winding Speed
Requirement: The speed needs to be determined based on the production scale. For small-batch production, 2000-3000 RPM is suitable, while large-scale mass production requires high-speed models with speeds exceeding 4000 RPM.
Tip: Speed must be matched to wire diameter. Fine wires (e.g., below 0.1mm) can run at high speeds, while thicker wires (e.g., above 0.8mm) must be run at lower speeds and with increased tension; otherwise, they are prone to breakage.
4. Number of Stations
Single Station: Suitable for products with larger stator dimensions (e.g., outer diameter > 120mm), higher stack thickness (> 70mm), or complex winding processes.
Multi-station (Dual/Four/Six Stations): The more stations, the higher the output per unit time for a single machine, suitable for mass production of small to medium-sized stators. However, equipment costs and mold fees also increase accordingly.
Step Three: Practical Verification
No matter how high the theoretical configuration, it’s not as good as actual testing. Before placing an order, be sure to conduct the following verifications:
1. Request on-site sampling: This is the most crucial step. 1. Bring your stator and wire, and have the manufacturer run the equipment continuously for at least 8 hours. Observe whether the winding is neat, whether there are any damaged or broken wires, and calculate the yield rate.
2. Focus on soft power: Equipment is not a one-off transaction. Confirm whether the supplier can provide 24-hour response service, as well as operation training and technical support for mold replacement.
3. Listen to the operating sound: Listen carefully when the equipment is running at high speed. High-quality equipment should have a deep, steady sound without any irregular or abnormal noises.
How to choose a high-speed brushless stator winding machine? What are the key points? The above has provided a brief explanation; hopefully, this information will be helpful!