What are the debugging requirements for motor fully automatic stator winding machine? How to ensure accurate and stable debugging

After the assembly of the fully automatic motor stator winding machine is completed, further professional debugging needs to be completed. Generally speaking, it must be carried out in accordance with the requirements to ensure stable debugging. So what are the specific debugging requirements for the fully automatic motor stator winding machine? How to ensure that debugging is accurate and stable? Let Vacuz briefly introduce it to you!

1. Core requirements for debugging: accurate adaptation and dynamic balance

1. Adaptation of wire diameter and tension

Wire diameter matching: Adjust the tensioner range according to the enameled wire diameter to ensure that thin wires are continuous and thick wires are tight. For example, the tension range of copper wire is usually 0.5-5N, and that of aluminum wire is 0.3-3N. The fluctuation needs to be ≤±0.5N.

Dynamic tension adjustment: real-time monitoring of tension through a closed-loop feedback system, automatically optimizing the curve to prevent breakage or looseness.

2. Groove shape and path optimization

Groove shape adaptation: Adjust the winding path algorithm for different groove shapes (such as trapezoid, rectangle), optimize the needle bar movement trajectory, and prevent wire scratches.

Cable arrangement accuracy control: Forced cable arrangement must ensure that the cable arrangement mechanism steps by a preset distance (usually the wire diameter) for each turn, and the error is controlled within ±0.01mm.

3. Speed and load balancing

Lightweight design: Reduce the inertial impact of the equipment and match the winding speed and load capacity. For example, the spindle speed and wire arrangement speed need to be accurately synchronized to avoid wire breakage due to excessive load during high-speed operation.

Vibration suppression: Through the closed-loop servo system and vibration suppression algorithm, the jitter amplitude during high-speed winding is controlled within ±0.01mm.

4.Environment and safety control

Temperature management: Keep the workshop temperature at 20±2℃ to avoid overheating or overcooling of electronic components.

Humidity control: relative humidity is controlled at 50±5% to prevent circuit board short circuit or electrostatic breakdown.

Shock absorption measures: Fix the equipment on a shock-proof platform to reduce the impact of vibration on winding accuracy.

2. Phased implementation strategy to ensure accurate and stable debugging

1. Preparation before debugging: details determine success or failure

Component inspection: Confirm that key components (such as spindle, winding head, clamp) are installed in place and the screws are not loose to avoid transportation damage.

Electrical connection verification: Check that the power cord and signal cable are connected correctly and there are no short circuits or open circuits to ensure the safety of the electrical system.

Safety mechanism test: Verify that emergency shutdown, overload protection and other devices are sensitive and reliable to ensure safe operation.

2. Mechanical debugging: a solid foundation is the key

Debugging of spindle and winding head:

Check the smoothness of the spindle rotation and adjust the concentricity to ensure the uniformity of the coil.

Optimize the movement trajectory of the winding head, eliminate jitter or offset, and adjust the distance from the main axis to control the winding tension.

Fixture and mold positioning:

Make sure the clamp has a moderate clamping force to secure the wire and avoid damage.

The width and height of the mold need to match the winding rod. Too tight will affect loading and unloading, and too loose will cause shaking.

3. Electrical and parameter settings: the core of accurate control

Tensioner settings:

Adjust the tension value according to the wire material (copper/aluminum) and wire diameter. The tension of aluminum wire needs to be smaller than that of copper wire of the same diameter.

Real-time monitoring of tension fluctuations ensures uniformity and avoids broken wires or loose coils.

Program parameter input:

Set the number of winding coils, direction, speed, cable spacing and other parameters to ensure that they match production needs.

Adjust the movement trajectory of the wire arrangement head to achieve synchronization with the spindle and optimize the order of coil arrangement.

4. Trial operation and optimization: progressive verification from low speed to high speed

Low speed start observation:

Run the device without loading wires and check that all components are operating normally and there is no abnormal noise or vibration.

After loading the wire, wind it at low speed and observe whether the wire enters the slot smoothly and there are no jumpers or jammed wires.

Gradual speed-up and parameter optimization:

Monitor tension fluctuations and adjust tensioner PID parameters to ensure that the wire is tight and continuous.

Use a laser distance meter to detect the distance between wires and verify that the wiring accuracy error is within the allowable range.

Salt water test and insulation testing:

Test the insulation performance of windings to ensure compliance with safety standards.

Test DC resistance and withstand voltage.

5. Preventive maintenance and intelligent monitoring: guarantee of long-term stability

Regular cleaning and lubrication:

Clean the dust on the surface of the equipment and add lubricating oil to reduce wear and extend the life of the equipment.

Check the wear of tensioner springs, needle rods and other components, and replace aging components in a timely manner.

Intelligent monitoring system:

Install a tension sensor to feedback the tension value in real time, and automatically stop and alarm when abnormality occurs.

Monitor the vibration frequency of equipment through acceleration sensors to detect potential faults in advance.

Data recording and analysis:

Record winding parameters, fault codes and other data, and optimize the process through big data analysis to improve production efficiency.

Establish a process database to support fast parameter matching and reduce debugging time.

What are the debugging requirements for a fully automatic motor winding machine? How to ensure accurate and stable debugging? Vacuz has given a brief explanation above. I hope this knowledge can help everyone!