Brushless motor stator winding machines must meet three core conditions to achieve multi-wire parallel winding: equipment compatibility, accuracy of process parameters, and standardized operation. Furthermore, they must ensure no damage to the wires through hardware configuration, parameter control, and operational procedures. Below, Vacuz will provide a brief introduction!
I. Core Conditions for Multi-Wire Parallel Winding
1. Equipment Compatibility
Winding Machine Type Matching: Select the appropriate equipment based on the stator slot direction. For slots facing inwards, use a pin-type internal winding machine; for slots facing outwards, use a flying fork winding machine.
Tension System Accuracy: Multi-wire parallel winding requires a servo tensioner to ensure uniform tension on each wire (error ≤ ±5%), preventing wire breakage or loose winding due to tension fluctuations.
Wire Feeding Mechanism Flexibility: Employing a multi-channel wire feeding device and precision guide wheels supports synchronous wire feeding into the stator slots, preventing wire crossing or tangling.
1. Mold Design Compatibility: The mold must be customized according to the stator specifications to ensure that the wire passes through the slot without scratching and can adapt to the multi-wire winding requirements of different wire diameters (e.g., 0.1mm-0.5mm).
2. Accuracy of Process Parameters
Slot Distance Adjustment: When winding multiple wires, increasing the wire diameter requires increasing the slot distance (usually 20%-30% greater than single-wire winding) to ensure smooth passage of the wire bundle.
Winding Speed Control: The speed needs to be reduced by 10%-20% compared to single-wire winding to avoid wire damage due to excessive centrifugal force.
Wire Spacing Optimization: Adjust the wire spacing according to the wire diameter and number of turns to ensure uniform spacing between wires (error ≤ ±0.05mm) to prevent uneven magnetic field distribution or short circuits.
Interlayer Insulation Treatment: When winding multiple layers, insulating paper or film (thickness ≥ 0.1mm) must be inserted between adjacent coil layers to prevent short circuits between turns.
3. Operational Standardization
Machine Debugging Process: Before winding, parameters such as slot alignment, tension value, and winding speed must be calibrated. Accurate alignment of the stator slots and wire must be ensured through a vision system or laser calibration.
Environmental Control: The production environment must be maintained at a constant temperature and humidity to prevent damage to the enameled wire insulation layer due to moisture or high-temperature softening.
Regular Maintenance: Clean key components such as guide rollers and tension sensors weekly, and lubricate moving parts such as lead screws and guide rails monthly to reduce the risk of wire damage caused by wear.
II. Key Measures to Ensure No Wire Damage
1. Hardware Configuration Optimization
High-Accuracy Transmission Components: Servo motors and precision lead screws are selected to ensure winding path accuracy ≤ ±0.02mm, preventing wire misalignment and scraping against the slots.
Enhanced Dynamic Response: By optimizing the winding machine structure and deploying acceleration/deceleration curves, the acceleration change rate is controlled to ≤5m/s², reducing wire breakage due to inertial vibration.
Thermal Error Compensation: Temperature sensors are installed in key parts of the winding machine (such as guide pins and molds). Infrared thermal imaging monitors temperature distribution and corrects position commands in real time to prevent wire damage caused by thermal expansion.
2. Parameter Control Strategy
Tension Curve Setting: The tension curve is adjusted according to the wire material (e.g., copper wire, aluminum wire) and wire diameter.
Segmented Winding Speed Control: The winding process is divided into four stages: start-up, acceleration, stabilization, and deceleration. The speed in each stage is dynamically adjusted based on wire tension feedback to ensure the wire is always under appropriate stress.
Wire Path Optimization: A professional algorithm generates a smooth wire path, improving slot fill uniformity (error ≤ ±3%) and preventing wire breakage due to localized over-dense winding.
3. Standardized Operation Procedures
Wire End Fixing: At the start of winding, the wire end is fixed with cable ties or glue to prevent loosening during winding, which could lead to wire tangling or breakage.
Saltwater Test: After winding, the stator is immersed in a 5% salt solution. A multimeter is used to test the coil resistance and insulation to ensure there are no short circuits or leakage.
Process Database Support: A database containing stator parameters, wire specifications, and process parameters is established to support rapid parameter matching and automatic optimization, reducing manual debugging errors.
Machine Vision Monitoring: High-speed cameras and image processing algorithms are deployed to monitor the wire arrangement in real time. If any risk of wire damage is detected, the machine immediately stops and alarms.
What are the conditions for multi-wire parallel winding in a brushless motor stator winding machine? How to ensure no wire damage? Vacuz has provided a simple explanation above; we hope this information is helpful!
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