![\"Vacuz](\"https:\/\/vacuz.com\/wp-content\/uploads\/2023\/08\/Vacuz-High-Precision-Automatic-0.2mm-1314T-Drone-Motor-BLDC-Brushless-Outer-Stator-Coil-Winding-Machine-Sample-2.jpg\" "\\"How")
<\/p>\nThe winding of the external rotor of a brushless motor is generally done using a fly fork winding machine. However, many people encounter wire breakage and damage during the winding process due to various problems during debugging, which is quite troublesome. So, how can a fly fork automatic stator winding machine avoid wire breakage and damage? What are some debugging tips? Vacuz will give you a brief introduction below!<\/p>\n
<\/p>\n
Common causes of wire breakage:<\/p>\n
1. Improper tension setting: Too high tension \u2192 wire breakage; Too low tension \u2192 floating wire \u2192 broken after crossing.<\/p>\n
2. Excessive speed, especially at bending points and when changing slots, causing wire breakage.<\/p>\n
3. Burrs on the die\/nozzle, scratching the insulation layer of the enameled wire \u2192 inter-turn short circuit (hidden wire damage).<\/p>\n
4. Friction in the wire path, guide wheel jamming, nozzle misalignment, causing the wire to be “rubbed” and broken.<\/p>\n
5. Excessive acceleration, the inertial impact at the moment of starting\/sudden stop breaks the wire.<\/p>\n
Hata Ay\u0131klama Noktalar\u0131:<\/p>\n
1. Use a servo tensioner (accuracy \u00b10.1%), not a regular magnetic powder tensioner for thin wire.<\/p>\n
2. When hooking the wire, it should hang naturally to the bottom; it should not be too loose or too tight.<\/p>\n
3. After powering on, check the tension curve. If the fluctuation exceeds \u00b15%, readjust.<\/p>\n
Step 1: Starting winding speed \u2264 200 RPM (ensure the wire end is securely hooked).<\/p>\n
Step 2: During the constant speed phase, gradually increase to the target speed.<\/p>\n
Step 3: At slot change\/bending points, automatically reduce speed by 10%\u201320%.<\/p>\n
Step 4: Before an emergency stop, reduce speed in advance (soft stop).<\/p>\n
It is recommended to reduce the winding speed of thick wire by more than 20% compared to thin wire!<\/p>\n
Distance between hook sleeve and guide die:<\/p>\n
The distance between the hook sleeve and guide die should be 2-3mm (the thicker the line, the greater the distance should be). Too far a distance means the line won’t catch on the bottom of the hook, leading to line breakage during swinging. The distance from the point where the fly fork exits the line to the guide die should be as close as possible, with the copper wire forming a diagonal line. A large distance will stretch the line at a large angle, causing sudden tension changes and line breakage.<\/p>\n
Adjustment method:<\/p>\n
The fly fork should not be too far from the hook sleeve; otherwise, the line will catch on the outer corner of the hook and break during swinging.<\/p>\n
Die and line guide:<\/p>\n
Line guide (line guide wheel): Hardness \u2265 HRC90 (hard alloy) or ceramic coating, inner hole Ra \u2264 0.2\u03bcm.<\/p>\n
Line guide inner diameter = line diameter \u00d7 1.1-1.3 times. The line guide must be replaced when changing the line diameter.<\/p>\n
The guard plate should be mirror polished with a friction coefficient \u2264 0.1. Wear will result in uneven line distribution, damaging the line.<\/p>\n
The die head\/tongue is CNC machined, burr-free, with an elastic die tongue that adapts to the slot. Inspection is performed after each changeover.<\/p>\n
![\"Vacuz](\"https:\/\/vacuz.com\/wp-content\/uploads\/2023\/06\/Vacuz-Double-Stations-Automatic-BLDC-Brushless-Drone-Motor-Stator-Coil-Flying-Fork-Winding-Machine-And-Paper-Insertion-Machine-Packing-4.jpg\" "\\"How")
<\/p>\n
The secret to uninterrupted thread production = appropriate tension + graded acceleration + smooth path + matched speed. Always remember during debugging: start slowly, then increase speed; start with tension, then increase speed; start with the path, then increase output. A good machine can run at 5000 RPM without breaking threads, but you must first find the “speed point” for your specific thread type\u2014that’s the true measure of efficiency.<\/p>","protected":false},"excerpt":{"rendered":"
The winding of the external rotor of a brushless motor is generally done using a fly fork winding machine. However, many people encounter wire breakage and damage during the winding process due to various problems during debugging, which is quite troublesome. So, how can a fly fork automatic stator winding machine avoid wire breakage and […]<\/p>\n","protected":false},"author":1,"featured_media":0,"comment_status":"closed","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_gspb_post_css":"","_joinchat":[],"footnotes":""},"categories":[63],"tags":[],"class_list":["post-14700","post","type-post","status-publish","format-standard","hentry","category-technology"],"blocksy_meta":[],"_links":{"self":[{"href":"https:\/\/vacuz.com\/tr\/wp-json\/wp\/v2\/posts\/14700","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/vacuz.com\/tr\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/vacuz.com\/tr\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/vacuz.com\/tr\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/vacuz.com\/tr\/wp-json\/wp\/v2\/comments?post=14700"}],"version-history":[{"count":2,"href":"https:\/\/vacuz.com\/tr\/wp-json\/wp\/v2\/posts\/14700\/revisions"}],"predecessor-version":[{"id":14705,"href":"https:\/\/vacuz.com\/tr\/wp-json\/wp\/v2\/posts\/14700\/revisions\/14705"}],"wp:attachment":[{"href":"https:\/\/vacuz.com\/tr\/wp-json\/wp\/v2\/media?parent=14700"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/vacuz.com\/tr\/wp-json\/wp\/v2\/categories?post=14700"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/vacuz.com\/tr\/wp-json\/wp\/v2\/tags?post=14700"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}