{"id":14703,"date":"2026-05-21T06:38:05","date_gmt":"2026-05-21T06:38:05","guid":{"rendered":"https:\/\/vacuz.com\/?p=14703"},"modified":"2026-05-21T06:38:05","modified_gmt":"2026-05-21T06:38:05","slug":"what-are-the-requirements-for-precision-wire-arrangement-in-a-fly-fork-stator-winding-machine-what-precautions-should-be-taken","status":"publish","type":"post","link":"https:\/\/vacuz.com\/ko\/what-are-the-requirements-for-precision-wire-arrangement-in-a-fly-fork-stator-winding-machine-what-precautions-should-be-taken\/","title":{"rendered":"What are the requirements for precision wire arrangement in a fly fork stator winding machine? What precautions should be taken?"},"content":{"rendered":"

The fly fork winding machine is the primary equipment for winding the stators of external rotors in drone motors, model aircraft motors, and other similar products. Its working principle is that the stator remains stationary, while the winding arm (fly fork) rotates at high speed around the stator teeth, and simultaneously, the wire guide shaft reciprocates up and down to complete the winding.<\/p>\n

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Due to the large centrifugal force and inertia experienced by the copper wire during high-speed rotation of the fly fork, achieving precise wire arrangement (neat, tight, non-overlapping, and non-crossing) places high and demanding requirements on equipment control, molds, and wire materials.<\/p>\n

I. Core Requirements for Precision Wire Arrangement in Fly Fork Winding Machines<\/p>\n

To achieve a precise wire arrangement, the equipment must meet the following key performance indicators:<\/p>\n

1. High-Precision Synchronous Control of Multiple Axes<\/p>\n

Precision wire arrangement is not simply a matter of “fly fork rotating, wire guide shaft moving,” but rather the rotation angle of the fly fork (main shaft) and the vertical position of the wire guide shaft (servo translation axis) must be synchronized by electronic gears.<\/p>\n

For each rotation of the fly fork, the wire guide spool must move precisely to a distance within micrometers (typically equal to the actual outer diameter of the enameled wire plus a tiny manufacturing clearance).<\/p>\n

When the wire is wound to the stator ends for a “return,” the servo system must have dynamic acceleration and deceleration compensation; otherwise, wire bridging can easily occur at the ends.<\/p>\n

2. Dynamic Adaptive Tension Control<\/p>\n

Constant Tension at High Speeds: The fly fork speed is typically 2000-4500 RPM. When the fly fork rotates to the side of the stator and to the ends, the speed at which the copper wire is pulled out fluctuates violently. Precision wire guide requires the tensioner (often an active servo tensioner) to follow this fluctuation in real time, controlling the tension fluctuation within a suitable range.<\/p>\n

Appropriate Tension Values: If the tension is too low, the copper wire cannot adhere tightly to the stator teeth, resulting in wire breakage and bulging; if the tension is too high, the wire will be thinned (resistance increases) or even broken, damaging the insulation.<\/p>\n

3. Seamless Fit Between Tooling and Core-Protecting Mold<\/p>\n

During the flying fork winding process, the copper wire slides into the stator slot through the core-protecting plate (lead mold). The slope design and surface roughness of the core-protecting plate directly determine whether the wire can slide smoothly to the predetermined winding position. If the mold dimensions are slightly off, the wire will fall out of place.<\/p>\n

II. Important Considerations for Precision Winding with Flying Forks<\/p>\n

In actual production or equipment debugging, the following details are crucial to success and are also areas prone to pitfalls:<\/p>\n

1. The “Actual Tolerance” of the Enamelled Wire’s Outer Diameter Must Be Considered<\/p>\n

Don’t blindly trust the nominal wire diameter: For example, a copper wire nominally 0.5mm might have an actual outer diameter of 0.54mm after adding the insulating enamel film, and the tolerance may also vary between different batches of wire.<\/p>\n

Note: When setting the winding step distance in the PLC program, the nominal value cannot be directly entered. The actual outer diameter of the current batch of copper wire must be measured with a micrometer, and the winding step distance must be fine-tuned online. 1. If the step distance is too small, the wire will climb onto the previous layer; if it’s too large, gaps will appear in the middle, causing the second layer to collapse.<\/p>\n

2. Strictly prevent “twisting” and “flipping” during multi-wire winding.<\/p>\n

Drone motors often involve double-wire external winding or multi-wire parallel winding processes. Under the centrifugal force of the high-speed rotation of the fly fork, several copper wires can easily become tangled and overlap in the air, causing them to stack vertically when entering the stator slot, instantly damaging the precision wiring.<\/p>\n

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Multi-hole wire guides or special flat wiring nozzles must be used to ensure that several copper wires are parallel and side by side at the exit point.<\/p>\n

From the tensioner to the fly fork spindle inlet, each guide wheel must be designed with an independent isolation groove to prevent the wires from twisting together before entering the machine.<\/p>\n

3. The wiring of the first layer (base layer) is crucial.<\/p>\n

Precision wiring follows the “foundation effect”. If the first layer of wiring is uneven, has gaps, or is misaligned, the second and third layers will amplify this defect, causing the slot fill factor to fall short of design requirements and potentially even jamming the fly fork.<\/p>\n

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During commissioning, the first layer should be closely observed. Typically, when winding the first turn at the stator root, the fly fork speed should be appropriately slowed down, using tension to ensure the first turn firmly grips the root edge of the stator insulation frame.<\/p>\n

Check the neatness of the stator core laminations. If the core itself has burrs or misaligned laminations, the first layer of wires will not align.<\/p>\n

4. Deformation of the frame and stator geometry<\/p>\n

Frame expansion: As the number of winding layers increases, the accumulated compressive force of the copper wire becomes enormous, easily causing the plastic insulation frame at both ends of the stator to “push” outwards and deform. Once the frame deforms, the wiring boundary widens, and the original wiring trajectory becomes misaligned.<\/p>\n

5. Dynamic Balancing and High-Speed \u200b\u200bVibration of the Flying Fork<\/p>\n

The flying fork is an asymmetrical structure with a winding arm on one side. Although it has a balanced weight, even a slight imbalance in dynamic balance during high-speed operation can cause minute vibrations in the machine body. This vibration is transmitted to the output nozzle, causing irregular oscillations of the copper wire, thus damaging the precision wiring.<\/p>\n

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\u00a0<\/figcaption><\/figure>\n

What are the requirements for precision wiring in a flying fork stator winding machine? What precautions should be taken? A brief description has been provided above; hopefully, this information will be helpful!<\/p>","protected":false},"excerpt":{"rendered":"

The fly fork winding machine is the primary equipment for winding the stators of external rotors in drone motors, model aircraft motors, and other similar products. Its working principle is that the stator remains stationary, while the winding arm (fly fork) rotates at high speed around the stator teeth, and simultaneously, the wire guide shaft […]<\/p>\n","protected":false},"author":1,"featured_media":11978,"comment_status":"closed","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_gspb_post_css":"","_joinchat":[],"footnotes":""},"categories":[63],"tags":[],"class_list":["post-14703","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-technology"],"blocksy_meta":[],"_links":{"self":[{"href":"https:\/\/vacuz.com\/ko\/wp-json\/wp\/v2\/posts\/14703","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/vacuz.com\/ko\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/vacuz.com\/ko\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/vacuz.com\/ko\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/vacuz.com\/ko\/wp-json\/wp\/v2\/comments?post=14703"}],"version-history":[{"count":1,"href":"https:\/\/vacuz.com\/ko\/wp-json\/wp\/v2\/posts\/14703\/revisions"}],"predecessor-version":[{"id":14704,"href":"https:\/\/vacuz.com\/ko\/wp-json\/wp\/v2\/posts\/14703\/revisions\/14704"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/vacuz.com\/ko\/wp-json\/wp\/v2\/media\/11978"}],"wp:attachment":[{"href":"https:\/\/vacuz.com\/ko\/wp-json\/wp\/v2\/media?parent=14703"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/vacuz.com\/ko\/wp-json\/wp\/v2\/categories?post=14703"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/vacuz.com\/ko\/wp-json\/wp\/v2\/tags?post=14703"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}