The application of the fully automatic flying fork winding machine brings many benefits to the winding of the stator. It can not only improve production efficiency, but also improve product consistency. So how does the fully automatic flying fork winding machine wind and arrange wires in multiple stations? What are the requirements for winding machine customization? Vacuz will introduce it to you, hoping to help you!

The principle and implementation method of multi-station winding and arranging wires of the fully automatic flying fork winding machine:

1. The core principle of multi-station winding and arranging wires

The fully automatic flying fork winding machine achieves efficient and accurate wire arrangement through multi-station collaborative operation. Its core principle is mainly reflected in the following three aspects:

‌1. Mechanical structure coordination ‌:

‌ Dynamic coordination between flying fork and die head ‌: The high-speed rotation of the flying fork drives the enameled wire to be wound, and the die head is accurately stuck into the stator slot and pressed into the coil layer by layer. The multi-station equipment quickly switches the slot through the indexing system to achieve continuous operation.

‌ Multi-station independent drive ‌: Each station is equipped with an independent flying fork, die head and guard plate mechanism, which ensures the consistency of action through synchronous transmission and shortens the die change time.

‌2. Control system hierarchical control:

‌Main control system: PLC or industrial computer is used for unified scheduling, real-time synchronization of winding parameters, and coordination of each workstation.

‌Workstation subsystem: Each workstation is equipped with an independent servo driver, which is responsible for the execution of specific actions to achieve seamless connection.

‌3. Wire arrangement path optimization:

‌Three-dimensional space wire arrangement: The guard plate and the die head work together to control the distribution of coil layers and avoid insulation damage.

‌Dynamic tension compensation: The tensioner adjusts the output force in real time according to the change of wire diameter to ensure the tightness of the wire arrangement.

2. Technical implementation case of multi-station winding and arranging wires

‌Four-station high-speed wire arrangement (model aircraft motor application):

Equipment configuration: four sets of independent flying forks, high-precision die heads and servo indexing systems.

Wire arrangement effect: The winding time of a single slot is shortened to 8 seconds, and the overall efficiency is increased by 300%.

‌Double-station thick wire arranging‌:

Equipment configuration: large torque flying fork, thickened die tongue and wear-resistant guard plate.

Wire arrangement effect: 30 wires can be wound in parallel without wire breakage, with a daily output of 2,000 stators and a stable yield rate of more than 99.5%.

3. Customization requirements of fully automatic flying fork winding machine

In order to meet the winding requirements of different stators, the fully automatic flying fork winding machine needs to be customized. The core customization parameters include:

‌1. Stator parameter matching‌:

Number and size of slots: determine the flying fork indexing angle and die head stroke.

Wire diameter range: configure the tensioner range and the flying fork wire nozzle aperture.

‌2. Process demand customization‌:

Winding speed: set the maximum speed and acceleration time of the flying fork.

Wire arrangement accuracy: determine the guard plate design parameters and die head pressure.

3. Key component customization requirements include:

‌Mold system‌: made of high-precision, high-strength alloy steel to ensure the life of the mold.

‌Tensioner configuration‌: Select the appropriate type according to the wire diameter and speed requirements to ensure dynamic response.

‌Division system‌: Use servo motor or stepper motor to ensure division accuracy and stability.

4. Customization process and verification standards

The customization process includes three stages: demand confirmation, scheme design and review, prototype testing and acceptance. The verification standards cover no-load testing, load testing and document delivery to ensure that the equipment performance meets the requirements.

In summary, the fully automatic flying fork winding machine achieves efficient and accurate wiring through multi-station collaborative operation, control system hierarchical control and wiring path optimization. At the same time, customization is carried out according to stator parameters and process requirements to ensure the applicability and stability of the equipment.

E-mail: sales@vacuz.com