The fully automatic flying fork stator winding machine is a high-end piece of equipment in the motor production industry. Its operating principle, technical features, and stability control strategy reflect modern industry’s pursuit of precision manufacturing and intelligent manufacturing. Vacuz’s systematic analysis of its core features and optimization suggestions are highly recommended.

I. Operating Principle: Precision Coordination of Mechanics and Control

1. Flying Fork Rotation System

The flying fork rotates at a high speed exceeding 2500 rpm, with a ceramic nozzle guiding the enameled wire. A spring mechanism enables back-and-forth movement, ensuring tight alignment of each wire layer.

Key Points: The flying fork’s dynamic balancing design reduces high-speed vibration. Regular calibration of the rotating shaft concentricity (tolerance ≤ ±0.01mm) is recommended.

2. Die Positioning and Slot Switching

A servo motor drives the die head for precise positioning, the spring tongue adapts to different slots, and an indexing motor enables continuous winding of multiple slots.

Optimization Directions: Laser-assisted positioning technology is used to improve slot switching efficiency (target: single slot switching time ≤ 0.3 seconds).

3. Automated Control Process

A PLC coordinates the lifting and lowering of the flying fork, the trimming of the wires, and other actions, while an induction switch controls the wire length, enabling an entirely unmanned process.

Intelligent Upgrade: Machine vision is introduced to monitor wire routing quality in real time, automatically correcting offsets or overlaps.

II. Technical Features

1. High Accuracy and Efficiency

The servo system ensures positioning accuracy of ±0.02mm and a slot fill rate exceeding 98%. The multi-station design increases efficiency by 3-5 times.

Case Study: In the production of new energy vehicle motors, a dual-station machine can produce 800-1000 stators per day.

2. Wide Adaptability

Supports wire diameters from 0.1mm to 1.3mm, and modular fixtures enable quick changeovers in 10 minutes.

Special Needs: Model aircraft motors require custom micro-wire nozzles (aperture ≤ 0.15mm) to avoid scratching the fine wire.

3. Intelligence and Reliability

The human-machine interface supports parameter customization, and key components (such as guide rails) have a lifespan of over 100,000 hours.

Maintenance Tips: Replace the nozzle and guard plate every 500 hours to prevent uneven wire routing due to wear.

III. Stability Control Strategy

1. Equipment Accuracy

A high-precision lead screw (±0.005mm) and laser dynamic compensation technology offset temperature drift and wear.

Recommendation: Calibrate the fork trajectory using a laser interferometer quarterly. Adjustments are required if the deviation exceeds 0.01mm.

2. Tension Control Optimization

The electromagnetic tensioner, combined with a PID algorithm, maintains a fluctuation of ≤±0.5N. The speed of thick wire is reduced by 20%, and the tension of thin wire is 0.3-0.8N.

Risk Control: Sudden changes in tension must be monitored during thin wire winding to prevent wire breakage.

3. Environmental and Process Control

A constant temperature and humidity workshop (±2°C, ≤60% humidity) and shock-absorbing pads (≥90% vibration isolation) are essential.

Data Support: Statistics from one manufacturer show that uncontrolled environments can increase the failure rate by 40%.

4. Intelligent Monitoring

A sensor network monitors parameters such as vibration and tension in real time, and big data predicts maintenance cycles.

Case Study: A factory reduced unplanned downtime by 60% through predictive maintenance.

IV. Common Problems and Solutions

Problem 1: High-speed vibration of the flying fork

Cause: Unbalanced rotating shaft or worn coupling.

Solution: Dynamic balancing and replacement of high-rigidity couplings.

Problem 2: High breakage rate of thin wires

Cause: Excessive tension or burrs on the wire nozzle.

Solution: Enable low-tension mode and regularly polish the wire nozzle (Ra ≤ 0.2μm).

Problem 3: Insufficient Slot Fill Rate

Cause: Unoptimized wire routing algorithm or worn guard plate.

Solution: Update the wire routing algorithm and check the guard plate flatness.

V. Future Development Trends

In-depth Application of AI: Optimize winding paths through machine learning to reduce trial-and-error costs.

Flexible Manufacturing: Develop adaptive fixtures to support small-batch, high-variety production.

Green Manufacturing: Develop low-energy drive systems to reduce power consumption per unit of production by over 20%.

How do you control the stability of a fully automatic flying fork stator winding machine? What are its operating principles and features? Vacuz has provided a brief explanation above. We hope this information is helpful!

Электронная почта: sales@vacuz.com