As a precision manufacturing equipment, the quality control of the motor stator winding machine is crucial. To ensure the excellent performance of the equipment, the manufacturer needs to start from the five key links of hardware configuration, control system, process design, production details and quality inspection, strictly follow the technical specifications and continuously optimize. Vacuz will introduce it to you!

1. Hardware configuration: Lay a solid foundation

High precision and stability of core components ‌

1. Drive system ‌: Select high-performance servo motors and high-precision drivers, with bus-type PLC motion controllers, to achieve multi-axis collaborative control and reduce motion errors to the lowest point. The application of high-precision ball screws and linear guides ensures the repeatable positioning accuracy of the cable arrangement mechanism and effectively prevents winding deviation.

2. Tensioner ‌: Using hysteresis or servo tensioners, support real-time monitoring and dynamic adjustment of tension, and strictly control the fluctuation range within ±2%, effectively avoiding wire breakage or loose coil problems.

3. Molds and fixtures ‌: The mold processing accuracy is as high as ±0.01mm, and wear is regularly detected and replaced in time to ensure that the winding is neat and undamaged. The design of the quick-change fixture greatly shortens the changeover time, while ensuring that the stator clamping force is moderate to avoid deformation.

2. Control system: a model of intelligence and high coordination

‌Multi-axis coordination and real-time response‌

‌1. Motion control‌: The advanced multi-axis motion controller is used to achieve seamless coordination of the winding head, the wire arrangement mechanism, and the loading and unloading system to ensure the accuracy of the winding path. Supporting industrial bus protocols improves the real-time and anti-interference capabilities of the system.

‌2. Human-computer interaction‌: Equipped with a touch screen operation terminal, intuitively set and monitor process parameters such as winding speed, tension value, number of turns, etc. At the same time, it provides production data statistics functions to provide strong support for optimizing the production process.

‌3. Remote maintenance‌: Through industrial Ethernet or 4G/5G networks, remote monitoring and fault diagnosis are realized, and predictive maintenance functions are integrated to warn equipment failures in advance to ensure production continuity.

3. Process design: a combination of customization and refinement

‌Personalized customization of winding solutions‌

‌1. Winding path optimization‌: According to the stator structure and specifications, a detailed winding path is formulated to optimize the wire bending radius to ensure that the wire is not damaged during the winding process. Support multi-wire winding process, configure multi-channel pay-off device and synchronous tension control to ensure that multiple wires are stably fed into the slot.

‌2. Refined tension control‌: According to the wire material and wire diameter, set a reasonable tension range to avoid excessive tension causing wire breakage or too little tension causing loose coils. Use a closed-loop tension control system to monitor and adjust the tension value in real time to ensure that the whole process fluctuation is controlled within ±3%.

‌3. Accurate wire arrangement and wire cutting‌: Use a servo-driven wire arrangement mechanism to ensure that the wires are arranged neatly to avoid crossing or overlapping. Configure an automatic wire cutting device to achieve automatic cutting and processing of the wire ends after winding, and the wire cutting error is small.

IV. Production details: strict control, excellence

‌Strict control of key links‌

‌1. Equipment installation and commissioning‌: Ensure that the equipment installation environment is suitable, away from vibration sources and electronic interference equipment. Carry out no-load testing and wire operation commissioning, observe the mold positioning, needle bar and wire nozzle coordination, and adjust parameters in time to avoid needle or stator slot misalignment problems.

‌2. Refined wire management‌: Select high-quality enameled wire and regularly test the wire resistance and insulation performance. Pre-treat the wire, such as straightening and deburring, to reduce resistance and damage during winding.

3.‌Operator training‌: Regularly organize operation skills training to ensure that personnel are proficient in equipment operation procedures, safety specifications and troubleshooting methods. Formulate standardized operation instructions, standardize operation steps, and improve production efficiency and product quality.

5. Quality inspection: Full process monitoring to ensure excellent quality

‌Double guarantee of online inspection and finished product inspection‌

‌1. Online inspection‌: Configure coil turns detection, wire diameter detection, insulation performance detection and other modules to monitor the winding quality in real time. Introduce machine vision technology to accurately detect surface defects of winding, such as broken wires, jumpers, abnormal turns, etc.

‌2. Finished product inspection‌: After the winding is completed, electrical tests such as resistance test, insulation resistance test, and withstand voltage test are carried out to ensure that the electrical performance meets the standards. Samples are randomly inspected for high temperature aging tests to verify the stability of the coil under adverse conditions.

‌3. Data traceability‌: Establish a production data file to record the winding parameters, test results and fault information of each device in detail, so as to facilitate quality traceability and process optimization.

In summary, motor stator winding machine manufacturers need to start from the five dimensions of hardware configuration, control system, process design, production details and quality inspection, strictly control the quality of equipment, and ensure that the equipment performance is excellent, stable and reliable. Vacuz hopes that this knowledge can help everyone!

Email: sales@vacuz.com