In the operation of high-speed, fully automatic stator winding machines, the nozzle and tensioner play a crucial role. They not only impact winding accuracy and efficiency, but also directly impact product quality and production costs. Therefore, the correct selection and configuration of the nozzle and tensioner, as well as their coordinated optimization, are key to improving winding machine performance. Vacuz will explain!

I. Core Requirements and Selection Strategies for Nozzles

1. Material and Wear Resistance

Requirements: The nozzle must possess high hardness and excellent wear resistance to withstand high-speed friction and constant scraping from the wire.

Selection Strategy: Prefer nozzles made of high-hardness materials such as carbide or ceramic coatings to extend their service life and reduce downtime and replacement.

2. Dimensions and Precision

Requirements: The nozzle’s inner diameter must precisely match the wire diameter to ensure tight and uniform winding.

Selection Strategy: Select the appropriate nozzle shape and inner diameter based on the stator slot size and winding density. Generally speaking, the inner diameter of the nozzle should be 1.1-1.3 times the wire diameter.

3. Dynamic Stability

Requirement: The nozzle must have sufficient rigidity to prevent vibration during high-speed operation, which could affect the alignment of the coils.

Selection Strategy: Choose a nozzle with a lightweight design (such as titanium alloy) to reduce inertia and improve dynamic response speed.

II. Core Requirements and Selection Strategy for Tensioners

1. Tension Control Accuracy

Requirement: Tension fluctuations must be kept within a small range to ensure consistent coil tightness.

Selection Strategy: Prefer closed-loop control tensioners (such as magnetic powder tensioners and servo tensioners) for their fast response and high control accuracy.

2. Tension Range and Adjustability

Requirement: The tensioner must cover the required tension range of the wire and support fine-tuning.

Selection Strategy: Select an appropriate tensioner range based on the wire diameter and winding speed, and ensure it has sufficient fine-tuning accuracy.

3. Real-Time Monitoring and Feedback

Requirement: The tensioner must be equipped with a sensor to monitor tension changes in real time and automatically compensate.

Selection Strategy: Choose an intelligent tensioner that supports data logging and remote monitoring to facilitate process analysis and fault tracing.

III. Collaborative Optimization Strategy for Nozzle and Tensioner

1. Compatibility Test

Steps: In no-load mode, gradually adjust the tensioner parameters and observe the wire jitter at the nozzle exit.

Purpose: Ensure proper matching between the nozzle and tensioner to prevent jitter from degrading winding quality.

2. Dynamic Compensation Algorithm

Principle: Combine nozzle motion trajectory and tension fluctuation data to adjust tension output in real time via a PLC or motion controller.

Effect: Significantly improve tension stability during high-speed winding and enhance coil consistency.

3. Preventive Maintenance

Period: Regularly check nozzle wear and tensioner accuracy.

Tools: Use specialized tools (such as laser rangefinders and tensiometers) for inspection and calibration.

Purpose: Extend the service life of the nozzle and tensioner and reduce maintenance costs.

IV. Summary

The nozzle and tensioner of a high-speed, fully automatic stator winding machine must meet three core requirements: high accuracy, high stability, and high interoperability. Proper selection and configuration of these key components, as well as their coordinated optimization, can significantly improve winding quality, production efficiency, and equipment utilization, while reducing maintenance costs. Therefore, in practical applications, comprehensive consideration and selection should be made based on the wire material characteristics, winding speed, and process requirements.

E-mail: sales@vacuz.com