Vibration during operation of a brushless motor stator winding machine may stem from multiple factors, including the mechanical structure, electrical control, operating parameters, and external environment. Vacuz will detail the specific causes and corresponding solutions, hoping to be helpful!

1. Mechanical Structure

1. Frame Configuration Issues

For high-speed winding machines with four or six stations, if the frame is lightweight or made of instable materials, vibration can easily occur during operation, negatively impacting the stator winding process.

Solution: Build the frame from highly stable materials. The base can be made of sheet metal, which is durable and can withstand high pressure. The chassis can be welded and cast from square tubes for enhanced stability. The work surface can be made of stainless steel, which is corrosion-resistant and has a smooth surface. The frame can be made of aluminum alloy, which ensures strength while reducing weight. This combination of materials ensures a stable and reliable overall frame structure.

2. Component Quality Issues

Poor quality of components such as the servo drive motor, guide rails, lead screws, and cylinders can easily cause vibration during high-speed operation. For example, poor-quality guide rails may experience jamming during sliding, causing the winding machine to operate unsteadily.

Solution: Prioritize high-quality or imported servo motors and spare parts. These products undergo rigorous quality testing, offering higher precision and reliability, and can effectively reduce vibration during high-speed operation.

3. Rotor Balance Issues

Misalignment in the placement of the permanent magnets on the rotor, or inadequate machining of the rotor shaft, can lead to uneven mass distribution across the rotor, causing vibration.

Solution: Use a professional dynamic balancing machine to inspect and calibrate the rotor.

4. Bearing Issues

Severe bearing wear, poor lubrication, or improper installation can increase friction and resistance during motor rotation, causing the rotor to rotate unsmoothly and cause vibration.

Solution: Regularly inspect bearing wear and replace bearings promptly if significant wear is detected. Ensure the bearings are properly installed and add the appropriate amount of lubricant to reduce friction and resistance.

II. Electrical Control Level

1. Motor Controller Issues

The speed and direction of a brushless motor are controlled by the motor controller. If the controller parameters are incorrectly set or there is a fault, motor jitter may occur during startup.

Solution: Optimize the motor controller parameters. You can appropriately increase the motor controller’s acceleration and deceleration, or adjust the PID parameters to enable the motor controller to more accurately control speed and direction, thereby reducing jitter.

2. Phase Sequence Error

The three-phase windings of a brushless motor have a specific phase sequence. If the phase sequence is incorrect during wiring, the magnetic fields generated by each phase will not switch in the correct order during motor startup, resulting in uneven torque and jitter.

Solution: Carefully check the connections between the motor’s three-phase windings and the drive circuit to ensure the correct phase sequence. Refer to the motor’s wiring diagram or use a professional phase sequence detection tool to verify this to avoid jitter caused by incorrect phase sequence.

3. Sensor Fault

Brushless motors typically rely on position sensors such as Hall sensors to provide rotor position information. If a sensor malfunctions, such as damage, displacement, or external interference, the position information fed back to the drive circuit will be inaccurate, causing torque fluctuations and jitter during motor startup.

Solution: Use a professional testing instrument, such as a multimeter, to check the sensor’s electrical performance for open circuits, short circuits, and other faults. Also, check that the sensor is correctly and securely installed, and that it is not loose or displaced. If the sensor is damaged, replace it with a sensor of the same model that meets the required specifications.

4. Electromagnetic Interference

Electromagnetic interference may exist around the driver circuit. For example, electromagnetic fields from other high-power electrical devices or high-frequency signal sources can interfere with the driver circuit’s normal operating signals. Alternatively, improper wiring within the driver circuit itself, such as inadequate isolation between the power and signal lines, can cause signal transmission interference.

Solution: Shield the driver circuit with a metal shield to reduce external electromagnetic interference. Also, arrange the circuit wiring appropriately, separating the power and signal lines. If necessary, use shielded cables for signal transmission and ensure proper grounding to ensure stable signal transmission.

III. Operating Parameters

1. Excessive Operating Speed

Different stator products have different speed limits, generally within which they can be reached. Exceeding this operating range can not only damage or break the wires, but also cause jitter.

Solution: According to the specifications and requirements of the stator product, set the winding machine’s operating speed appropriately to ensure it operates within a stable range. Control system parameters can be adjusted to limit the operating speed to avoid jitter caused by excessive speed.

2. Unstable Tension Control

Improper tensioner settings or a malfunction in the tension control system can lead to uneven tension during the winding process, causing jitter. For example, if the tensioner setting is too high, the wire will be overly tight and prone to breakage; if it is too low, the wire will sag, resulting in uneven winding.

Solution: Optimize the tension control system to ensure stable and adjustable tension. Regularly check the tensioner settings and status, and adjust or replace any faulty components promptly. Install a tension sensor to monitor tension changes in real time and make adjustments based on the results.

IV. External Environment

1. Floor Factors

When installing the winding machine, if the floor is uneven or has height differences, the machine can easily become unbalanced, causing jitter. For example, if a winding machine is installed on uneven ground, all four legs won’t touch the ground simultaneously, causing the machine to wobble.

Solution: During installation, be sure to adjust the height properly to ensure the machine is balanced and stable. You can use a level or other tool to assist with adjustments, ensuring that each leg bears evenly, thus preventing vibration caused by uneven ground.

2. Other Vibration Sources

In addition to winding machines, motor manufacturers typically have a variety of other equipment. Some large equipment vibrates violently, and if placed too close to the winding machine, it can easily cause vibration, affecting its operational stability.

Solution: Try to move the winding machine away from the work site with high vibration sources. If this is not possible, install vibration-damping pads on the large equipment to reduce the impact on the winding machine.

What causes vibration in brushless motor stator winding machines? How can this vibration problem be resolved? Vacuz has provided a brief explanation above. We hope this information is helpful!

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