Whether winding by hand or using a winding machine, the coil slot rate of the motor stator has always been a concern for everyone. In a reasonable design and winding method, it is necessary to improve the slot rate. So what is the relationship between the number of turns of the fully automatic motor winding machine and the slot rate? How to improve the slot rate space? Let Vacuz briefly introduce it to you below!

1. The intrinsic connection between the number of turns of the coil and the slot rate

‌1. The direct impact of the number of turns on the slot rate‌:

The increase in the number of turns of the coil will occupy more space in the slot, but in this process, special attention should be paid to the tightness and uniformity of the conductor arrangement. Using the accurate control ability of the fully automatic winding machine, the wire can be evenly distributed in the slot, thereby reducing the space waste caused by uneven arrangement.

‌2. Definition and limitation of slot rate‌:

In addition to the conventional slot rate control range, you can also consider fine-tuning according to the specific application scenario of the motor. For example, in situations where high power density is required, the upper limit of the slot rate can be appropriately increased, but full preparations must be made in terms of heat dissipation and insulation.

2. Core strategies for improving slot fill rate

‌1. Optimize conductor design:

‌Material selection: In addition to high-conductivity copper wire, superconducting materials or new alloy materials can be explored to further reduce the conductor cross-sectional area and improve the current carrying capacity.

‌Shape optimization: In addition to rectangular, trapezoidal and elliptical conductors, conductors with customized shapes can also be considered to better adapt to the slot type and improve space utilization.

‌2. Improve slot design:

‌Slot selection: Optimize slot design to find a balance between the appropriate slot fill rate and processing difficulty.

‌Size optimization: Through precise measurement and simulation analysis, the slot depth, slot width and slot shoulder width can be fine-tuned to optimize the available space in the slot and reduce conductor waste.

‌3. Insulation treatment:

The use of nano-insulating materials or self-healing insulating materials can reduce the thickness of the insulation layer while ensuring insulation performance, further improving the slot fill rate.

4. Improve the level of manufacturing process:

Wire winding technology: Using AI algorithm to optimize the winding path planning can achieve a more efficient winding process and reduce wire crossing.

Wire embedding process: Combining machine vision and automation technology can achieve a more accurate wire embedding process, reduce human errors and improve the slot fill rate.

5. Introduce advanced technology:

Digital manufacturing: Using digital technology to simulate the motor manufacturing process can detect and solve potential problems in advance and optimize the manufacturing process.

Internet of Things technology: Real-time monitoring of the motor operating status through the Internet of Things technology can collect data for subsequent design and optimization.

III. Key considerations

1. Heat dissipation and insulation balance:

In addition to optimizing the cooling system and adjusting the thickness of the insulation material, high-efficiency heat dissipation technologies such as heat pipes or liquid cooling can also be considered to better balance the heat dissipation challenges brought by high slot fill rates.

2. Manufacturing feasibility:

In the slot fill rate design, the limitations and cost constraints of the existing manufacturing process must be fully considered to avoid unnecessary waste caused by over-design.

‌3. Performance Verification‌:

In addition to simulation and experimental verification, long-term operation tests can also be considered in actual application scenarios to evaluate the impact of slot fill rate improvement on motor performance and service life.

The balance between the number of coil turns and slot fill rate of the fully automatic motor winding machine is a complex and critical design issue. Through systematic design optimization, innovative materials and technology applications, and comprehensive consideration of key factors, we can effectively improve the slot fill rate and optimize motor performance. In the future, with the continuous development of intelligent manufacturing and Internet of Things technologies, we are expected to achieve more breakthroughs and progress in this field.

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