Fully automatic brushless motor stator winding machines are primarily used for stator winding. Their workflow is standardized. So, what are the workflows for fully automatic brushless stator winding machines? How can the winding process be optimized? Vacuz will explain!

I. Core Workflow

1. Stator Positioning and Mold Installation

Secure the motor stator to ensure stability. Select and install the winding mold according to specifications.

2. Parameter Configuration and Program Calling

Enter key parameters such as wire diameter, winding speed, and tension. Call preset programs to accommodate production of multiple models.

3. Winding Start and Process Control

The electric main drive rotates the turntable. The winding head guides the wire into the stator slots, and the clamping device secures and cuts the wire tail. The inter-wire tension is adjusted in real time to prevent wire breakage or loosening.

4. Automatic Shutdown and Quality Inspection

Automatically stops after reaching the preset number of turns. Sensors monitor parameters, and combined with electrical testing, ensure winding performance.

II. Winding Process Optimization Strategies

1. Equipment Selection and Maintenance

Select high-precision equipment to improve winding accuracy and equipment lifespan. Establish a maintenance database to predict failures and replace worn parts.

2. Dynamic Parameter Adjustment

Adjust tension in real time based on wire specifications. Reduce speed when winding thicker wires or multiple strands to minimize wire loss and breakage.

3. Improved Wire Arrangement Precision

Introducing machine vision technology enables precise wire arrangement. Using 3D-printed molds shortens development cycles and reduces costs.

4. Intelligent and Automated Upgrades

An intelligent parameter setting system automatically generates winding plans and optimizes historical data. Remote monitoring and fault warnings enable rapid response to abnormalities.

5. Process Innovation

A wear-resistant process reduces wear during winding. Multi-strand winding solutions balance efficiency and quality.

Fully automatic brushless stator winding machines achieve efficient and stable winding production through precise positioning, dynamic parameter control, and intelligent technology. Optimizing the process requires coordinated advancement in four aspects: equipment precision, parameter adjustment, wiring technology upgrade, and intelligent management. Developing targeted plans based on specific application scenarios can significantly improve winding quality and production efficiency.

E-mail: sales@vacuz.com