The control system for a brushless motor stator winding machine is crucial, impacting the stability and operational performance of the entire machine. So, what are the control technologies and requirements for brushless motor stator winding machines? How can we make the equipment more stable and efficient? Vacuz will briefly introduce them below!

I. Core Control Technology: A Deep Breakthrough in Accurate Adaptation and Dynamic Balancing

1. Accurate Adaptation of Wire Diameter and Tension: Tension Balancing Strategy for Multi-Wire Parallel Winding

Dynamic Tension Compensation Algorithm: For multi-wire parallel winding (e.g., 30 0.2mm enameled wires), this algorithm utilizes time-segmented tension control technology. Initially, low tension (0.3N) is used to guide the wire into the groove, gradually increasing it to the target tension (1.5N) in the middle, and finally finishing with a low tension (0.8N) to minimize wire breakage.

2. Groove and Winding Path Optimization: Algorithm-Driven Intelligent Wire Route

Inner-Groove Wire Route Algorithm: Generates needle bar motion trajectories based on B-spline curves, and uses force control sensors to adjust needle bar pressure in real time to ensure the wire is tightly inserted into complex grooves (such as double V-grooves).

External-Groove Flying Fork Winding Technology: Utilizes five-axis linkage control (X/Y/Z axes + flying fork rotation axis + wire tracing axis). A high-speed camera (1000fps) captures the moment the wire enters the groove, dynamically correcting the flying fork angle (±2°), reducing the wire traverse misalignment rate from 3% to 0.5%.

3. Dynamic Speed ​​and Load Balancing: Lightweight Design and Motion Profile Optimization

High-Stack Stator Winding Strategy: For stators with a height greater than 200mm, a “segmented acceleration-constant speed-deceleration” motion profile is employed to reduce acceleration from 5m/s² to 2m/s², minimizing the winding oscillation radius (from 15mm to 5mm).

II. Improving Equipment Stability: Intelligent Upgrades to Full-Process Control and Preventive Maintenance

1. Commissioning Phase: Digital Twin Technology Accelerates Parameter Calibration

Virtual Commissioning Platform: Using a digital twin model to simulate the winding process, tension and speed parameters can be optimized in advance (for example, reducing commissioning time from 4 hours to 1 hour).

2. Operation Phase: Real-Time Monitoring Using Multi-Sensor Fusion

Triple Tension-Vibration-Temperature Monitoring:

Tension sensor (range 0.1-5N, accuracy ±0.01N)

Triaxial accelerometer (monitors vibration frequency, threshold 5mm/s²)

Infrared temperature sensor (monitors motor temperature, threshold 80°C)

Early Warning Mechanism: When any parameter exceeds its limit, the system automatically triggers “speed reduction” or “emergency shutdown” and sends a fault diagnosis report to the mobile device.

3. Maintenance Phase: Predictive Maintenance and SOP Optimization

Data-Driven Maintenance Strategy:

Data such as winding times, tension fluctuations, and vibration peaks are collected to predict bearing life using a machine learning model (with >90% accuracy).

III. Efficient Production Practices: Collaborative Innovation in Process Optimization and Automation Upgrades

1. Multi-Wire Parallel Winding Technology: Co-design of Materials and Equipment

Wire Pretreatment: Ultrasonic cleaning is used to remove the oxide layer on the wire surface, improving friction consistency during multi-wire parallel winding (friction coefficient fluctuation <±5%).

Equipment Adaptation: Customized tensioners (such as 30-channel independent tension control) ensure uniform tension for each wire (with an error of <±0.02N).

2. Automation Function Integration: Upgrading from a single machine to a production line

Automatic Wrapping + Automatic Wire Trimming: Pneumatic grippers and a laser positioning system enable precise control of wrap angle (e.g., 45° ± 2°) and trimming length (e.g., 5mm ± 0.5mm).

Production Line Collaboration: Connecting with post-process varnishing and assembly equipment through the MES system enables full automation of the “winding-varnishing-assembly” process (reducing cycle time from 120 seconds per unit to 80 seconds per unit).

3. Environmental Control: Refined Management from Workshop to Equipment

Zoned Temperature and Humidity Control: The workshop is divided into a winding area (20-25°C, <60%RH) and a varnishing area (30-35°C, <50%RH) to prevent cross-influence.

Active Vibration Isolation Technology: Using an air spring damping platform (natural frequency <2Hz), the impact of equipment vibration on wire routing accuracy is reduced from ±0.1mm to ±0.03mm.

IV. Industry Trends and Creative Suggestions

Trend Insights: Explore the impact of “windingless motors” (such as axial flux motors) on traditional winding technology and how winding machine manufacturers can adapt to these new motors through “modular design.”

What are the control technologies and requirements for brushless motor stator winding machines? How can we make our equipment more stable and efficient? Vacuz has provided a brief introduction to this topic above. We hope this little knowledge can help you!

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