To achieve high-speed operation, automatic stator winding machines must meet stringent requirements in mechanical structure, electrical system, process parameter control, safety protection, and operation management. Furthermore, the machine configuration must utilize high-performance core components and be optimized in design. Below are the specific conditions and configuration requirements, which Vacuz will briefly introduce:
I. Conditions Required for High-Speed Operation
1. Mechanical Structure Stability:
The base, frame, guide rails, and other components must possess high rigidity to withstand the vibrations and inertial forces generated during high-speed operation, ensuring stable machine operation.
The transmission system needs optimization to reduce vibration and wear during high-speed operation, extending equipment lifespan. For example, using imported high-precision lead screws and guide rails, and adding dynamic balance adjustment to the transmission system.
2. Electrical System Stability:
The power supply must be stable and reliable to prevent voltage fluctuations from affecting servo motor performance. It is recommended to use a UPS regulated power supply and add power redundancy design.
Electrical components (such as servo motors and drivers) must have high-frequency start/stop capabilities and be resistant to overheating to support prolonged high-speed operation.
3. Process Parameter Adaptability:
Winding speed needs to be intelligently adjusted according to wire material, diameter, and stator parameters. For example, thin wire requires reduced speed to avoid breakage, while thick wire requires controlled acceleration to prevent coil deformation.
Tension control needs to be refined, employing a closed-loop tension control system to adjust tension in real time according to speed changes, ensuring winding stability and quality.
4. Safety Protection Measures:
Equipped with safety light curtains, emergency stop buttons, and other safety devices, meeting international safety standards.
A closed protective cover is used to prevent foreign objects from entering the equipment, ensuring operator safety.
5. Operation and Management Standardization:
Detailed operating procedures are established, and operators undergo rigorous training and assessment.
An equipment maintenance database is established to record the time, content, and results of each maintenance operation, providing data support for predictive maintenance.
II. Machine Configuration Requirements
1. Core Drive Components:
High-performance brand servo motors, such as those from Panasonic, Fuji, and Delta, are selected to ensure control accuracy and stability during high-speed operation.
1. **Servo Motors:** Servo motors must be equipped with a motor temperature monitoring system to monitor operating status in real time and prevent performance degradation due to overheating.
2. **Transmission and Guiding Components:**
Components such as lead screws and guide rails must be imported high-quality products capable of withstanding prolonged high-speed operation.
Consider using new technologies such as magnetic levitation guide rails to reduce friction and wear, and improve positioning accuracy and acceleration.
3. **Winding and Wiring Components:**
The winding head needs optimized design to meet the requirements of different coil sizes, shapes, and winding methods. Simultaneously, the winding head should be easy to replace and adjust to adapt to the production needs of different products.
The wiring mechanism must use servo drive to ensure neat wire arrangement and avoid crossing or overlapping. An automatic wire cutting device should also be configured to support automatic cutting and processing of wire ends after winding.
4. **Tension Control Components:**
An automatic tension control system should be equipped to automatically adjust the tension based on the conductor material, wire diameter, and winding speed. Real-time monitoring and control of the enameled wire tension is crucial to ensuring winding stability and quality.
5. Tensioners: High-quality products must be selected to ensure accurate tension control and stable output.
6. Molds and Fixtures:
Molds must be precision-machined according to stator parameters to ensure the guide pins can pass smoothly through the slots without wire breakage or damage.
Fixtures must have quick-change functionality to reduce changeover time and improve production efficiency.
7. Intelligent Control System:
An industrial-grade PLC and multi-axis motion controller are used to achieve coordinated control of the winding mechanism, wire laying mechanism, and loading/unloading system. Industrial bus protocols are supported to ensure high real-time performance and stability.
A touchscreen operating terminal is provided to support intuitive setting and monitoring of process parameters. Production data statistics and analysis functions are also provided, such as yield rate and production efficiency.
8. Inspection and Monitoring System:
Modules for coil turns detection, wire diameter detection, and insulation performance detection are included to monitor winding quality in real time.
Machine vision technology is introduced to detect visual defects in the wound stator, such as broken wires, skipped wires, and abnormal turns.
Adding equipment operation status monitoring functions, such as real-time monitoring and early warning of parameters like motor vibration, temperature, and current, improves equipment reliability.
What conditions are required for high-speed operation of an automatic stator winding machine? What are the machine configuration requirements? Vacuz has provided a brief explanation above; we hope this information is helpful!
English 
Spanish 
Portuguese 
Italian 
German 
French 
Russian 
Turkish 
Polish 
Ukrainian 
Japanese 
Korean 
Chinese (Taiwan) 
Chinese (China)