In the field of motor manufacturing, the fully automatic brushless winding machine has become the core equipment for the production of multiple models of stators with its excellent equipment configuration flexibility, mold versatility, parameter adjustability and standardized changeover process. Through a series of innovative designs and technical applications, these winding machines can efficiently and accurately meet the production needs of stators of different specifications. Let Vacuz introduce them to you!

1. Modular design: equipment flexibility

‌1. Multi-axis motion control‌: Using advanced X/Y/Z three-axis or more degrees of freedom motion system, the servo motor accurately drives the needle nozzle to achieve accurate positioning of the stator slot. This design not only improves the winding accuracy, but also greatly broadens the scope of application of the equipment.

‌2. Dynamic tension adjustment‌: Equipped with a high-precision tension controller, the tension is automatically adjusted according to the wire diameter and material of the wire to ensure the tightness and consistency of the wire during the winding process. This feature is particularly critical when winding thick wires, which can effectively prevent wire damage.

‌3. Optimization of the wire arrangement mechanism‌: Using precision wire arrangement guides or visual positioning systems to ensure that the wires are parallel and the spacing is uniform when multiple wires are wound. The application of laser calibration technology controls the error within a very small range, improving the quality and efficiency of winding.

‌2. Mold versatility: standardization and adjustability

‌1. Mold quick change system‌: The standardized mold interface design makes mold replacement fast and simple. This not only shortens the changeover time, but also improves the utilization rate of the equipment.

‌2. Adjustable mold design‌: By adding gaskets or adjusting screws, the mold can be reused between different types of stators. This design reduces mold costs and improves production flexibility.

‌3. Multi-station layout‌: The application of four-station or six-station winding machines enables the equipment to process multiple different types of stators at the same time. This layout greatly reduces the downtime of the equipment and improves production efficiency.

‌3. Parameter adjustability: intelligent control

‌1. Programmed parameter management‌: Pre-store winding programs for different types of stators and call them with one click through the touch screen. This function simplifies the debugging process and improves the efficiency of production preparation.

‌2. Adaptive winding algorithm‌: Dynamically adjust the winding trajectory according to the stator slot type to avoid wire scratches or overlap. This intelligent winding method not only improves product quality, but also reduces production costs.

‌3. Real-time monitoring and feedback‌: Integrated sensors monitor key parameters such as winding tension, number of turns, and wiring neatness in real time, and automatically shut down and alarm when abnormal. This function ensures the stability and safety of the production process.

‌IV. Standardization of the changeover process: a guarantee to reduce human errors‌

‌1. Standardized operating procedures‌: Develop detailed changeover steps and operating procedures to ensure that each changeover can be carried out according to the established process. This greatly reduces the probability of human errors.

‌2. Visual auxiliary tools‌: The application of visual auxiliary tools such as laser locators or AR glasses makes mold installation more accurate and efficient. This technology not only improves positioning accuracy, but also shortens changeover time.

‌3. Employee training and assessment‌: Regularly train operators to master multi-model stator changeover skills and verify proficiency through simulation tests. This measure ensures that operators can master the skills of changing models and improve production efficiency and product quality.

With its innovative features such as modular design, intelligent parameter adjustment, and fast changing technology, the fully automatic brushless winding machine has become an efficient tool for the production of multiple models of stators. Enterprises should choose appropriate strategies according to their own product characteristics and production needs to ensure the production efficiency and flexibility of the equipment, realize “one machine for multiple uses”, and reduce production costs and improve market competitiveness while ensuring product quality.

Email: sales@vacuz.com