In the process of exploring how the motor stator automatic winding machine can accurately control the wire arrangement, we deeply analyzed a series of skills and methods, aiming to provide everyone with a comprehensive and efficient solution. The following is a detailed explanation of these key points by Vacuz:

I. Optimization and upgrade of core hardware configuration

‌1. High-precision transmission components‌: In order to ensure the positioning accuracy of the wire arrangement device when moving at high speed, we use a combination of ball screw and linear guide rail to strictly control the positioning error within ±0.01mm. At the same time, a servo motor with a rated speed of not less than 3000RPM is selected, and direct drive technology is introduced to effectively eliminate mechanical transmission errors, so that the spindle speed can easily break through the 5000RPM mark.

‌2. Strengthening of dynamic response‌: The structure of the wire arrangement device is optimized through finite element analysis, which greatly reduces the inertial mass, thereby achieving a significant increase in acceleration, easily reaching more than 1.5G, and adapting to the needs of high-speed start and stop.

3. Adaptive adjustment of the wire nozzle: The wire nozzle is made of high-performance materials such as ceramic or tungsten carbide, and is equipped with a pneumatic/electric fine-tuning mechanism to compensate for slight changes in the wire diameter in real time. At the same time, the wire diameter-speed-tension mapping table database is integrated to automatically match the appropriate speed and tension combination according to the wire diameter to ensure the stability and excellence of the wire arrangement effect.

2. Innovative application of precision wire arrangement algorithm and control

1. Optimization of path planning: An accurate three-dimensional mathematical model is established based on the stator slot type, and a professional algorithm is used to generate a smooth wire arrangement path, which effectively reduces the bending stress of the wire. For different slot types (such as trapezoidal and rectangular), the wire arrangement spacing and the number of winding layers are dynamically adjusted to make the slot full rate more uniform.

2. Introduction of speed control: Slow down in advance at the corners of the path to effectively avoid the phenomenon of wire being thrown out or overlapped due to excessive centrifugal force. At the same time, the vibration suppression algorithm is integrated to inject a notch filter at the key frequency point, which significantly reduces the impact of resonance on speed stability.

‌3. Implementation of thermal error compensation‌: The temperature distribution of the motor and the lead screw is monitored in real time by an infrared thermal imager, and a thermal deformation model is established to correct the position command in real time. For example, when the temperature rises by 10°C, the system will automatically compensate for the positioning error of 0.005mm to ensure the continuous stability of the wiring accuracy.

III. Intelligent upgrade of tension and wire management

‌1. Implementation of intelligent tension control‌: Equip a tension sensor to monitor and adjust the winding tension in real time to ensure that the copper wire tension range is between 0.5-5N and the aluminum wire tension range is between 0.3-3N, effectively preventing the occurrence of wire breakage or looseness. At the same time, a closed-loop feedback system is used to automatically optimize the tension curve according to the wire material, wire diameter and winding speed to achieve accurate tension control.

‌2. Simplification of wire path‌: Optimize the winding and wire passing process, reduce the number of wire bending times, and reduce friction loss. For example, the single-layer winding + short path design can save 5%-10% of enameled wire. At the same time, auxiliary devices such as wire wheels and wool felt are used to ensure smooth wire transportation and avoid entanglement or crossing.

IV. Continuous improvement of mold and device precision

‌1. Design of high-rigidity molds: Use high-strength materials (such as alloy steel) to manufacture molds to ensure that no deformation occurs during the winding process. At the same time, high-precision CNC machine tools are used to process the stator core slots to ensure dimensional consistency, such as the slot width tolerance is strictly controlled within ±0.02mm.

‌2. Strengthening the positioning and calibration of the wire arrangement device: Regularly check the verticality and coaxiality of the wire arrangement wheel and wire clamp to ensure the consistency of the wire arrangement direction. At the same time, use a laser calibrator to detect the movement trajectory of the wire arrangement device. Once the deviation exceeds ±0.05mm, adjust it immediately to ensure the continuous stability of the wire arrangement accuracy.

V. Refined management of environment and process control

1. Creation of a constant temperature and humidity production environment: Working in a workshop with a temperature of 20±2℃ and a humidity of 50±5% effectively prevents the softening of the insulation layer of the enameled wire. At the same time, shock-absorbing pads, soundproof covers and other equipment are installed to reduce the interference of vibration and noise. For example, when the vibration amplitude is controlled at ≤0.02mm, the wiring accuracy is significantly improved.

2. Establishment of process database and adaptive optimization: Establish a process database including stator models, wire specifications, and winding parameters to support fast parameter matching. At the same time, a reinforcement learning algorithm is introduced to automatically adjust parameters according to real-time production data (such as tension fluctuations and speed changes) to achieve adaptive optimization and continuously improve production efficiency and product quality.

VI. Comprehensive layout of real-time monitoring and fault prevention

1. Deployment of machine vision inspection system: Deploy high-speed cameras and image processing algorithms to monitor the arrangement status of wires in real time, with a defect detection accuracy of more than 99.5%. At the same time, multi-source sensors (such as tension, temperature, and vibration sensors) are integrated to predict equipment failures through machine learning, such as 24-hour advance warning of potential problems such as tensioner wear.

‌2. Strengthening of operator skill training‌: Regularly organize debugging personnel to conduct skill training in equipment operation, parameter adjustment, and troubleshooting. At the same time, strengthen quality awareness education to ensure that each link meets the process requirements, such as strictly controlling the wire spacing tolerance within ±0.03mm, and continuously improving product quality and production efficiency.

In summary, through the optimization and upgrading of core hardware configuration, the innovative application of precision wire arrangement algorithms and controls, the intelligent upgrading of tension and wire management, the continuous improvement of mold and device accuracy, the refined management of environmental and process control, and the comprehensive layout of real-time monitoring and fault prevention, we have successfully achieved accurate control of the wire arrangement accuracy of the motor stator automatic winding machine. This achievement not only improves production efficiency and product quality, but also brings users more reliable and efficient solutions.

이메일: sales@vacuz.com