The precision of the stator automatic winding machine is a key indicator. It is affected by many factors and there are also many ways to improve it. The following is a detailed discussion of these influencing factors and implementation strategies by Vacuz, hoping to help everyone!

1. Key factors affecting the precision of wire arrangement

1. Equipment accuracy
‌Accuracy of mechanical components‌: The core mechanical components of the winding machine, such as guide rails, lead screws and spindles, have processing accuracy that is the basis for ensuring accurate wire arrangement. Any problem of insufficient straightness of the guide rails or excessive lead screw gaps may cause the position of the wire arrangement to shift.

‌Stability of the electrical system‌: The accuracy and stability of electrical components such as servo motors and encoders are crucial to the accuracy of winding speed and position.

2. Control system

‌Motion control algorithm‌: The use of advanced motion control algorithms can optimize the winding trajectory, reduce speed fluctuations and position errors, and thus improve the precision of wire arrangement.

‌Accuracy of tension control‌: The stability of tension control has a direct impact on the neatness of the wire arrangement. Tension fluctuations can cause the enameled wire to be unevenly tight, which in turn affects the overall wire arrangement effect.

3. Wire arrangement mechanism

‌Wire arrangement wheel design‌: The diameter, material and surface treatment process of the wire arrangement wheel will affect the smoothness of the enameled wire sliding, and thus affect the wire arrangement effect.

‌Matching of wire arrangement speed and winding speed‌: The speeds of the two need to be accurately matched to avoid wire accumulation or breaking.

4. Mold design

‌Accuracy of slot size‌: The size accuracy of the stator core slot has a direct impact on the embedding and neatness of the enameled wire.

‌Mold rigidity‌: Insufficient mold rigidity will cause deformation during the winding process, thereby affecting the accuracy of wire arrangement.

5. Operation process

‌Quality of enameled wire‌: The uniformity of the diameter of the enameled wire, the integrity of the insulation layer and the curvature will affect the quality of the wire arrangement.

‌Accurate setting of winding parameters‌: The accurate setting of parameters such as winding speed, tension, and wire arrangement spacing needs to be accurately adjusted according to the stator specifications.

6. Environmental factors

‌Temperature and humidity‌: High temperature and high humidity environment will cause the insulation layer of enameled wire to soften, increasing the difficulty of wire arrangement.

‌Vibration and noise‌: Equipment vibration or external noise interference may have an adverse effect on winding accuracy.

2. Effective methods to improve the quality and effect of winding and arranging wires

1. Equipment optimization

‌Selection of high-precision equipment‌: Selecting a winding machine with high mechanical precision and stable electrical control is the basis for improving the precision of wire arrangement.

‌Regular maintenance‌: Regularly check and maintain the equipment, and replace worn parts in time to ensure the long-term stable operation of the equipment.

2. Control system upgrade

‌Adopt closed-loop control‌: Real-time feedback of position information through the encoder to achieve more accurate motion control.

‌Optimize tension control algorithm‌: Dynamically adjust the tension according to the diameter of the enameled wire and the winding speed to maintain the stability of the wire tension.

3. Improvement of wire arrangement mechanism

‌Design of reasonable wire arrangement wheel‌: Select a wire arrangement wheel with a smooth and wear-resistant surface, and ensure that its contact surface with the enameled wire is free of burrs.

‌Accurately match the wire arrangement speed‌: The speed of the wire arrangement motor is accurately controlled by the frequency converter to ensure that it is synchronized with the winding speed.

4. Mold design and processing optimization

‌Improve mold processing accuracy‌: Use high-precision CNC machine tools to process the stator core slots to ensure dimensional consistency.

‌Enhance mold rigidity‌: Use high-strength materials to manufacture molds to avoid deformation during the winding process.

5. Operation process optimization

‌Standardize enameled wire storage‌: Ensure that the enameled wire is stored in a dry and ventilated environment to avoid moisture or bending.

Accurately set winding parameters‌: Accurately adjust the winding parameters according to the stator specifications and enameled wire characteristics.

6. Environmental control

‌Constant temperature and humidity workshop‌: Winding operations are carried out in a constant temperature and humidity environment with a temperature of 20±2℃ and a humidity of 50±5%.

‌Vibration reduction and noise reduction measures‌: Install shock-absorbing pads and other measures at the bottom of the equipment to reduce the impact of vibration on winding accuracy.

7. Personnel training and management

‌Operation skills training‌: Regularly conduct skills training for operators to ensure that they are proficient in equipment operation and parameter adjustment methods.

‌Quality awareness training‌: Strengthen quality awareness education to ensure that each link meets the process requirements.

III. Specific implementation suggestions and prospects

1.‌Introduce an automated detection system‌: Real-time monitoring of the wire arrangement quality during the winding process, timely detection and correction of deviations.

‌2. Establish a process database‌: Record the winding parameters of different stator specifications to facilitate rapid call and optimization of the process.

‌3. Cooperation with suppliers‌: Establish a close cooperative relationship with enameled wire suppliers to jointly customize enameled wire that meets specific requirements to improve the winding quality.

In summary, by comprehensively considering multiple factors such as equipment accuracy, control system, wire arrangement mechanism, mold design, operation process and environmental factors, and taking effective improvement measures and methods, the wire arrangement precision and winding quality of the stator automatic winding machine can be significantly improved.

E-mail: sales@vacuz.com