What is the multi-wire parallel winding process and principle of the motor stator?

In the field of motor manufacturing, to enhance the efficiency of motors, reduce resistance losses and improve heat dissipation performance, the multi-wire parallel winding process has emerged. This process optimizes the motor winding structure by simultaneously winding multiple enameled wires in the stator slots. The following is a detailed explanation of the core steps of this process by NOYU:
 

1. Wire preparation ‌ : According to the specific design requirements of the motor, carefully select the appropriate specification of enameled wire, which includes the choice of wire diameter and the determination of insulation grade. Subsequently, the wire is pre-treated, such as straightening and deburring, to ensure that its quality meets the winding requirements.

2. Wiring and positioning ‌ : With the help of a precise wiring mechanism, multiple wires are neatly arranged at the preset intervals and accurately fed into the stator slots. During this process, it is necessary to ensure that the wires remain parallel to avoid any crossing.

3. Synchronous winding ‌ : Start the main shaft of the winding machine to drive the wire to wind synchronously into the stator slots. During the winding process, the tension must be strictly controlled to ensure it remains constant, so as to prevent the wire from breaking due to excessive tension or loosening due to insufficient tension.

4. Interlayer insulation ‌ : When multiple layers of coils need to be wound, insulating materials such as insulating paper or film must be inserted between adjacent coil layers to prevent inter-turn short circuits and ensure the safe operation of the motor.

5. End shaping ‌ : After winding is completed, the ends of the coil are shaped, such as binding and varnishing, to fix the wire and enhance the mechanical strength of the coil, providing a strong guarantee for the stable operation of the motor.

The reason why the multi-wire parallel winding process can effectively enhance the performance of motors is mainly based on the skin effect and proximity effect in electromagnetism:

1. Skin effect ‌ : Under the influence of high-frequency current, the current tends to flow on the surface of the conductor, resulting in a significant reduction in the current density in the central part of the conductor. By adopting a multi-wire parallel winding method, the equivalent cross-sectional area of a single wire can be reduced, making the current distribution on the wire surface more uniform, thereby reducing resistance losses and improving motor efficiency.

2. proximity effect ‌ : The currents in adjacent wires will influence each other, resulting in an uneven current distribution. To reduce this impact, the multi-wire parallel winding process rationally designs the spacing and arrangement of the wires, making the distribution of current in the conductors more reasonable and thereby enhancing the winding efficiency.

3. Heat dissipation optimization ‌ : Multi-wire parallel winding not only optimizes the current distribution but also increases the surface area of the windings, thereby enhancing the heat dissipation efficiency. This enables the motor to operate stably at a higher power density, further enhancing its performance.

To meet the requirements of the multi-wire concurrent winding process, the winding machine equipment needs to have the following functions and make corresponding parameter adjustments:

Equipment structure and function ‌ :

1. Multi-wire parallel winding mechanism ‌ : It includes a multi-channel wire laying device, wire laying guide wheels and tension control system, ensuring that multiple wires can be synchronously and stably fed into the stator slots.

2. High-precision positioning system ‌ : Utilizing servo motors and precision guide rails, it accurately aligns the stator slots and precisely controls the winding path.

3. Tension control system ‌ : It monitors and adjusts the tension of the wire in real time to ensure it remains constant and prevent wire breakage or uneven winding.

4. Automatic control system ‌ : Integrated with PLC or numerical control system, it realizes the automatic adjustment of winding parameters and fault diagnosis functions, improving production efficiency and quality stability.

Equipment parameter adjustment ‌ :

1. Wire diameter matching ‌ : Select the appropriate wire release wheel and guide wheel according to the wire specification to ensure that the wire can pass smoothly through the winding machine equipment.

2. Tension setting ‌ : Adjust the tension value according to the material and diameter of the wire to ensure that the tension fluctuates within a reasonable range and avoid adverse effects on the winding quality.

3. Winding speed ‌ : Optimize the winding speed to balance production efficiency and winding quality. Due to the relatively complex multi-wire parallel winding process, the winding speed is usually about 10% to 20% lower than that of single-wire winding.

4. Slot alignment ‌ : Advanced technologies such as visual systems or laser calibration are used to ensure that the wire is accurately aligned with the stator slots, preventing winding offset.
 

Equipment maintenance and optimization ‌ :

1. Cleaning and lubrication ‌ : Regularly clean and lubricate key components such as the release wheel, guide wheel and tension sensor to reduce the possibility of wear and failure.

2. Calibration and debugging ‌ : Regularly calibrate and debug key components such as tension sensors and positioning systems to ensure their accuracy and stability meet production requirements.

3. Process optimization ‌ : Continuously adjust winding parameters (such as tension curve, winding speed, etc.) based on actual production data and accumulated experience to enhance winding quality and efficiency.