The stator winding machine is the key equipment in the motor manufacturing process, and its performance directly determines the quality of the motor winding. Effective control of winding accuracy, slot full rate and line damage is the key to ensure stable operation of motor performance. Hehui Intelligence will discuss with you how the stator winding machine can achieve these control objectives.

Control of winding accuracy

stator winding machineThe winding accuracy refers to the ability to accurately control the various parameters of the coil (such as the number of turns, the number of layers, the line spacing, the position, etc.) during the winding process. The winding accuracy directly affects the performance and stability of the motor. When the winding accuracy is insufficient, it may cause the performance of the product to decrease, affect the stability and efficiency of the product, and even cause the uneven distribution of the internal stress of the coil, which may cause fracture, short circuit and other faults during use.

In order to ensure the winding accuracy, the stator winding machine usually takes the following measures:

1.tension control system: Through the tension control system, it is ensured that the tension can respond to the action of the equipment mechanism to ensure that the stable tension is continuously output during the winding process. This helps to avoid loosening or deformation of the coil due to tension fluctuations.

2.Process monitoring: In the winding process, sensors and monitoring equipment are used to monitor key parameters in real time, such as position, tension, speed, etc., to ensure the stability and consistency of winding accuracy. This real-time monitoring helps to detect and correct deviations in time to ensure product quality.

3.servo control system: As the brain center of the winding machine, the servo control system is responsible for performing all actions. The selection of high precision and good quality servo control system is an important prerequisite to ensure the accuracy of winding.

4.Cable arranging device: The cable arrangement device is mainly composed of tension device, steel needle and other spare parts, which is directly related to the winding accuracy. The control of the tensioner should be reasonable, and the tightness should be adjusted according to the wire diameter and wire during debugging to ensure the consistency and tightness of the winding.

Control of tank full rate

The slot fill rate is an important index to measure the filling degree of winding in the stator slot of the motor. If the slot full rate is insufficient, it means that the cross-sectional area of the conductor in the slot is relatively small, which easily leads to an increase in resistance, which increases the power loss of the motor and reduces the efficiency.

In order to ensure that the slot full rate is up to standard, the stator winding machine usually takes the following measures:

1.precision manufacturing process: In the winding process, use a high-precision automatic winding machine to properly control the winding tension to avoid wire slack or excessive tension, and ensure the tightness and consistency of the winding.

2.Quality Inspection: Using an automatic detection system to perform electrical tests on the windings, such as resistance test, insulation resistance test and withstand voltage test, real-time monitoring of the winding process to ensure that the electrical performance of the windings meets the requirements.

3.Mold device: The precision control of the mold is very important to the groove full rate. The mold needs special treatment, wear resistance and hardness must meet the requirements to ensure that there will be no deviation in the winding process.

Control of Line Injury

Wire injury is one of the common problems in the winding process. If the wire is damaged or broken, it will not only affect the performance and quality of the product, but also increase the production cost and maintenance difficulty.

In order to control line damage, the stator winding machine usually takes the following measures:

1.Optimize process flow: Design a reasonable wiring path to ensure that the wires are evenly distributed in the winding slots and avoid friction between the wires and sharp edges or other parts during the winding process.

2.Tension adjustment: Set the tension reasonably to avoid wire breakage caused by excessive tension or wire relaxation caused by excessive tension. The collocation of the spring on the tension mechanism should be appropriate to ensure the stability of the tension during the winding process.

3.Regular maintenance: Regularly check and maintain the winding equipment to ensure that all parts of the equipment (such as winding nozzle, wire wheel, tension device, etc.) are in good condition. This helps to find and repair potential failure points in time to avoid line injuries.

4.Program parameter settingReasonably set the program parameters of the winding machine, such as acceleration, hook speed, etc., to ensure that the winding process is stable and continuous, and to reduce line injuries caused by unreasonable parameter settings.

In summary, the stator winding machine through the use of tension control system, process monitoring, servo control system, precision manufacturing process, quality testing, mold device optimization, process optimization, tension adjustment, regular maintenance and program parameter settings and other measures, effective control of winding accuracy, slot full rate and line damage, to ensure stable operation of motor performance.