What are the stators and configurations of brushless motor winding machines? How to evaluate equipment prices

The use of brushless motor winding machines greatly improves the stator winding efficiency and also improves the winding quality. Of course, the use of professional winding machine equipment is also critical to the configuration of the stator and machine. So what are the stators and configurations of brushless motor winding machines? How to evaluate the price of equipment? Let Vacuz briefly introduce it to you!

1. The influence of stator core parameters on winding machine configuration

1. Notch direction

Notch facing inward: You need to choose an inner winding machine (such as a precision needle winding machine), which has high wiring precision and is suitable for complex winding requirements such as brushless motors.

Notch outward: Flying fork outer winding machine is preferred, which has low cost and high efficiency. It is suitable for brush motors or simple structure stators.

2.Outer diameter and inner diameter dimensions

Outer diameter range: Micro and small equipment usually requires the stator outer diameter to be between Φ20~Φ130mm. If it exceeds the stator outer diameter, non-standard customization is required.

Inner diameter range: The inner diameter of the stator is generally Φ12~Φ100mm, and the size directly affects the selection of the number of stations for the winding machine (such as two stations, four stations). The larger the outer diameter, the larger the winding space required, and the number of stations may be reduced.

3. Stack thickness (height)

The stack thickness range of ordinary equipment is 5~80mm. If it exceeds 150mm, customized equipment is required to avoid wire breakage caused by excessive needle swing.

4. Enameled wire diameter and material

Wire diameter range: Thin wires (such as 0.1mm) require a high-speed winding machine to improve efficiency; thick wires (such as >1.0mm) require a tension control system to ensure the tightness of the coil.

Material differences: Different materials such as copper wire and aluminum wire have different requirements for tension control of the winding machine and need to be configured accordingly.

5. Wrapping method

Single wire winding: suitable for stators with large wire diameter or low precision requirements, and low configuration requirements.

Multi-wire parallel winding: Synchronized winding functions and complex wiring systems are required to prevent wire entanglement and improve motor performance density.

2. Core configuration requirements of winding machine

1. High-precision winding mechanism

A servo motor is used to drive the precision winding head, and a tension control system is used to ensure stable winding of the wire.

The wire diameter has a wide adaptable range (such as 0.02~1.2mm) and supports multi-station structure (dual-station, four-station) to improve efficiency.

2.Automated loading and unloading system

Integrated mechanical arms or special fixtures realize automatic grabbing, positioning and clamping of the stator core, with a positioning accuracy of ±0.02mm.

Seamlessly connects with the logistics line to reduce manual intervention.

3. Intelligent detection system

Equipped with 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 detect appearance defects such as broken wires, jumpers, abnormal number of turns, etc.

4. Efficient cable arrangement and cable trimming mechanism

The servo-driven cable arrangement mechanism ensures that wires are arranged neatly and avoids overlapping.

The automatic thread trimming device supports automatic cutting and processing of thread ends after winding is completed.

5. Industrial grade control system

High-performance PLC and multi-axis motion controller are used to realize coordinated control of winding, wiring, and loading and unloading.

Supports industrial bus protocols to ensure high real-time and stability of the system.

Brushless motor winding machine price evaluation and influencing factors

1. Price range and typical configuration

1. Economical equipment: The price is about tens of thousands of yuan, suitable for simple winding requirements (such as single station, basic functions).

2. Mid-to-high-end equipment: The price ranges from 100,000 yuan to hundreds of thousands of yuan. It is equipped with multi-station, high-precision tension control, intelligent detection system, etc., and is suitable for complex stator winding.

3. Customized equipment: customized according to special needs (such as ultra-thick stack height, special-shaped notch), the price may be higher.

2. Factors affecting price

1. Stator parameter complexity

When the notch direction, outer diameter/inner diameter size, stack thickness and other parameters exceed the standard range, non-standard customization is required, which increases the cost.

High-precision requirements such as multi-wire parallel winding and fine wire winding require more complex equipment configurations.

2. Number of workstations and efficiency

The price of four-station and six-station equipment is higher than that of single-station equipment, but the production efficiency is increased by 3 to 5 times, making it suitable for large-scale production.

3. Degree of automation

Equipment that integrates automatic loading and unloading, intelligent detection, remote monitoring and other functions are more expensive, but can reduce labor costs and defective rates.

4. Brand and after-sales service

Well-known brand equipment is usually more expensive, but provides more stable performance and complete after-sales services (such as 24-hour response, regular maintenance).

3. Price evaluation suggestions

1. Clarify demand priorities: Balance equipment performance and cost based on production scale, accuracy requirements, budget and other factors.

2. Compare multiple suppliers: Comprehensive evaluation based on equipment configuration, price, and after-sales service to avoid simply pursuing low or high prices.

3. Pay attention to non-standard customization capabilities: If the stator parameters are special, you need to choose a manufacturer with non-standard design capabilities to ensure the applicability of the equipment.

What are the stators and configurations of brushless motor winding machines? How to evaluate the price of equipment? Vacuz has given a brief explanation above. I hope this knowledge can help everyone!