Brushless micromotor stator winding technology requires a combination of parameter adaptation, process control, and equipment selection to provide reliable implementation recommendations. Vacuz will share these solutions! We hope they are helpful!

I. Core Winding Process Optimization Directions

1. Dynamic Tension Compensation Strategy

For wire diameters between Φ0.08 and Φ1.3 mm, a dual closed-loop tension control system is recommended. For example, in model aircraft motor winding, this system automatically adjusts the baseline tension by monitoring wire diameter changes in real time (such as the cumulative effect of wire diameters when winding multiple strands). This prevents tension loss due to inertia during high-speed winding.

2. Wire Traversing Accuracy Improvement Solution

A linear encoder + servo motor directly connected to the traversing shaft is recommended, replacing traditional belt drives to eliminate mechanical backlash.

Key Parameters: The servo motor response frequency must be ≥2 kHz, and the guideway positioning repeatability must be ±0.005 mm.

3. Special-Shaped Stator Winding Technology

For special-shaped stators, we recommend using a six-axis robot combined with a flexible winding head. Using offline programming to generate a spatial curved trajectory, we optimize the winding path, increasing winding efficiency by 30% while also preventing wire scratches.

II. Recommended Equipment Configurations by Scenario

1. Stator with Outward Slots (External Winding)

Economical Solution: Flying Fork Winding Machine + Stepper Motor Wire Trapping

Applicable Applications: Model Aircraft Motors, Toy Motors (Accuracy Required ≤ 0.2mm)

Cost Advantage: Equipment price reduced by 40%, but winding speed must be limited to ≤ 800rpm to avoid vibration.

High-Precision Solution: Flying Fork Winding Machine + Servo Motor Wire Trapping (EtherCAT Bus)

Applicable Applications: Ventilator Turbine Motors, Industrial Servo Motors

Performance Improvement: Wire Trapping accuracy reaches ±0.08mm, and slot fill rate increases by 10%-12%.

2. Stator with Inward Slots (Inner Winding)

Standard Solution: Needle-type inner winding machine + single servo motor

Applicable Applications: Air conditioning compressor motors, water pump motors

Efficiency Optimization: A four-station rotary table design reduces winding time per unit to 6-8 seconds.

High-Speed ​​Solution: Dual servo-driven inner winding machine

Applicable Applications: Brushless electric drill motors, brushless angle grinder motors

Key Improvement: Indexing time reduced to 0.2 seconds, supporting high-speed winding at 1200 rpm.

3. Customization

Modular Platform Expansion:

Basic Configuration: 6-axis servo system (B&R ACOPOSmulti) + force sensor (range 0-50N).

Extended Functions: Visual inspection (wire break detection), automatic loading and unloading (compatible with different stator sizes).

III. Equipment Selection Pitfalls

1. Servo System Selection Pitfalls

Avoid selecting a driver with a response frequency less than 1kHz. Otherwise, vibration will occur during high-speed starts and stops (e.g., 1200 rpm → 0 rpm), causing the wire to loosen.

2. Tensioner Accuracy Verification Method

Require the supplier to provide a tension fluctuation test report (must be ≤ ±0.05N). Use the hanging weight method to simulate actual winding tension and verify the linearity of the magnetic powder brake.

3. Key Points for Software Functionality Testing

Programming Flexibility: Test the efficiency of switching between G-code and dedicated winding languages ​​to ensure process adjustment time is ≤ 15 minutes.

Data Traceability: Verify that the MES interface supports real-time upload of parameters such as tension, speed, and number of turns, and generates traceable reports.

What are the requirements for winding small stators for brushless micromotors? How should winding machine equipment be configured? Vacuz has provided a brief overview above. We hope this information is helpful!

Электронная почта: sales@vacuz.com