When discussing the configuration of the fully automatic stator winding machine and its guarantee of winding quality, we have to consider various factors in detail to ensure that the winding effect is both efficient and accurate. Vacuz’s in-depth and creative analysis framework for this complex process, I hope it can help everyone!

1. Customized configuration: meet various winding needs ‌

‌1. Selection of motor and drive ‌:

For stators with slots facing outward, such as brushless motor stators of aircraft models, drones, etc., if high precision is not required, the use of economical stepper motor driven flying fork winding machines is sufficient. However, for stators with slots facing inward, such as household appliances and water pumps, the accuracy of winding is higher, and the accurate control of servo motors is particularly important at this time. For the efficient production needs of multiple stations, increasing the number of servo motors is even more indispensable.

‌2. Intelligent upgrade of control system ‌:

The introduction of advanced bus-type PLC motion controllers complements professional servo systems to achieve intelligent management of winding processes. At the same time, the use of cutting-edge winding machine controller technology further improves the automation level of equipment.

‌3. Precision combination of key components‌:

High-quality guide rails, ball screws and high-precision sensors are selected to ensure that every step of winding is accurate. In addition, the addition of automatic tension control system, automatic loading and unloading system, automatic wire changing device and automatic detection function has significantly improved the overall production efficiency.

‌4. Flexibility of fixture and modular design‌:

The fast-changing fixture design allows motor stators of different specifications and models to be easily switched. At the same time, the modular design allows the winding plan to be customized according to customer needs to meet the needs of special stator winding.

‌2. All-round guarantee: ensure winding quality‌

‌1. Careful planning of winding plan‌:

Develop a detailed winding plan based on the stator structure and specifications. Every detail from wire width to stator height has been carefully considered to ensure the tightness and stability of the winding.

‌2. Accurate control of tension‌:

Tension is the core element of winding quality. According to the wire specifications and winding requirements, accurate tension control is performed to ensure that the wire is neither too tight nor too loose, thereby avoiding problems such as wire breakage or poor winding.

‌3. Reasonable speed control‌:

While pursuing efficient production, more attention is paid to the stability of winding quality. The winding speed is controlled within a reasonable range to avoid wire loss or wire breakage caused by excessive speed.

‌4. Strict management of slot fill rate‌:

As a key indicator to measure the filling degree of winding in the stator slot, the control of slot fill rate is crucial. With the help of high-precision winding machines and tension control systems, the slot fill rate is ensured to meet the standard, thereby reducing resistance increase and power loss.

‌5. Comprehensive protection against wire damage‌:

Optimize the process flow and design a reasonable wiring path to reduce the contact between the wire and sharp edges. At the same time, regularly maintain the winding equipment to ensure that it is in good condition, thereby reducing the incidence of wire damage.

‌6. Real-time monitoring and instant feedback‌:

During the winding process, sensors and monitoring equipment are used to monitor key parameters such as position, tension, and speed in real time. Make adjustments quickly through the instant feedback system to ensure the stability and efficiency of the winding process.

‌7. Continuous improvement of employee skills‌:

Provide employees with regular training and communication opportunities to improve their operating skills and safety awareness. This can not only reduce equipment failures and winding quality problems caused by improper operation, but also stimulate employees’ innovation and teamwork ability.

In summary, the configuration of the fully automatic stator winding machine and the guarantee of winding quality are a complex and delicate process. Through customized configuration and the implementation of all-round guarantee measures, we can ensure that the winding effect is both efficient and accurate, thereby meeting the high requirements and high standards of modern production for motor manufacturing.

Email: sales@vacuz.com