There are many common parts for brushless motor stator winding machines, and the nozzle is one of them. It is also a relatively key small accessory. It has high requirements for precision and material. So what are the specific common requirements? What are the commonly used nozzles and how to choose them? Vacuz will introduce them to you! I hope it can help you!

1. Core requirements for nozzles

The nozzle of the brushless motor stator automatic winding machine plays a vital role in the high-speed and precise winding process. The following are the key performance requirements that the nozzle must meet:

‌1. High wear resistance and impact resistance‌: The nozzle must be made of high-quality materials such as super-hard alloy (such as tungsten carbide), heat-treated carbon steel or ruby, with a hardness of HRC90 or above and a bending strength of ≥2300N/mm² to ensure that it will not deform or break during frequent friction and high-speed winding.

‌2. Surface treatment‌: The inner hole and key parts of the nozzle need to be finely ground through multiple processes to achieve mirror-grade finish (inner hole roughness Ra≤0.1, arc Ra≤0.025) to prevent the enameled wire from being scratched when passing at high speed.

‌3. Low friction and stability‌: The special structural design can effectively reduce the friction damping between the enameled wire and the nozzle, reduce the risk of wire breakage, and ensure the insulation performance of the coil. The nozzle also needs to accurately cooperate with the tensioner to adjust the tension fluctuation in real time (within ±0.5N) to avoid loose coils or wire breakage caused by sudden changes in tension.

‌4. High accuracy and compatibility‌: The inner hole diameter of the nozzle can be processed up to 0.15mm, and the wall thickness is ≥0.10mm to meet the needs of thin wire (such as 0.1mm) or multi-wire winding. At the same time, the nozzle must strictly match the model and stator parameters (such as slot direction, outer diameter, inner diameter) of the winding machine to ensure the smooth progress of the winding process.

‌5. Customization capability‌: To meet the winding requirements of non-standard stators, the nozzle should have customization capabilities, support processing according to drawings, and adjust the shape, curvature or size of the nozzle according to special needs.

2. Common nozzle types and characteristics

‌1. Tungsten carbide nozzle‌:

Advantages: extremely high hardness (HRA90 or above), strong wear resistance, suitable for high-speed winding (such as inner winding of brushless motor stator).

Application scenarios: multi-strand parallel winding coils, fully automatic winding machine wire passing system.

2.‌Ruby nozzle‌:

Advantages: high surface smoothness, low friction coefficient, suitable for ultra-fine wire (such as 0.05mm) or high-precision winding.

Application scenarios: micro motor, precision sensor coil winding.

‌3. Heat-treated carbon steel nozzle‌:

Advantages: low cost, with certain wear resistance and impact resistance, suitable for medium and low speed winding equipment.

Application scenarios: household appliance motor, fan stator winding.

‌4. Guide needle nozzle‌:

Structural features: The inner hole and the inlet and outlet are mirror-polished, the arc transition is natural, and the wire passing is smooth.

Application scenario: Fully automatic winding machine guide needle system, suitable for stator and rotor winding processes.

III. Selection of nozzles

‌1. Select according to winding process requirements‌:

High-speed winding: Tungsten carbide or ruby nozzles are preferred to ensure wear resistance and low friction.

Multi-wire winding: Select nozzles with high dimensional accuracy (such as aperture tolerance ±0.01mm) to avoid interference between wires.

Fine wire winding: Mirror-grade surface treatment (Ra≤0.05) nozzles are required to prevent scratching of enameled wires.

‌2. Verify equipment compatibility‌:

Model matching: Confirm that the nozzle is compatible with the brand and model of the winding machine to ensure the smooth progress of the winding process.

Parameter calibration: Adjust the nozzle position through full winding debugging to ensure accurate coordination with the mold and wire arrangement device.

‌3. Evaluate the supplier’s strength‌:

Production capacity: Choose suppliers that support small-batch customization to meet non-standard needs.

Quality control: Require suppliers to provide full inspection reports of electron microscopes to ensure that the surface finish of the nozzle meets the standards.

4.‌Field testing and feedback‌:

Trial winding verification: Before formal purchase, conduct small-batch trial winding to observe indicators such as wire breakage rate and coil consistency.

After-sales support: Give priority to suppliers who provide technical guidance (such as tension adjustment training) and fast replacement services.

In summary, the nozzle of the brushless motor stator automatic winding machine plays a vital role in the winding process. When selecting the nozzle, it is necessary to comprehensively consider factors such as winding process requirements, equipment compatibility, supplier strength, and field testing and feedback to ensure winding quality and efficiency.

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