How does the motor stator winding machine achieve fully automated production?

When discussing the fully automated production of motor stator winding machines, we do indeed need to conduct a detailed analysis from multiple dimensions such as equipment configuration, process design, control system, auxiliary functions, key technical indicators, and application cases. The following is a detailed elaboration by NOYU on these aspects. We hope it can be helpful to everyone!
 

I. Equipment configuration requirements ‌

1. High-precision winding mechanism ‌ : It adopts a precision winding head driven by a servo motor and is equipped with a tension control system to ensure the stable winding of the wire. The wire diameter adaptability range is wide, and stable winding can be achieved for wires from 0.02mm to 1.2mm. In addition, multi-station structures (such as dual-station, four-station, and six-station) are configured to support multi-line parallel winding, thereby enhancing production efficiency.

2. Automated loading and unloading system ‌ : Integrated with mechanical arms or dedicated fixtures, it enables automatic grasping, positioning and clamping of stator cores, and seamlessly connects with the logistics line. Visual recognition technology is adopted to ensure the accurate positioning of the stator core, with a positioning accuracy of ±0.02mm.

3. Intelligent detection system ‌ : Equipped with modules such as coil turns detection, wire diameter detection, and insulation performance detection, it can monitor the winding quality in real time. Introduce machine vision technology to conduct appearance defect detection on the stator after winding, such as broken wires, skipped wires, and abnormal number of turns.

4. High-efficiency wire arrangement and cutting mechanism ‌ : A servo-driven wire arrangement mechanism is adopted to ensure that the wires are neatly arranged and avoid crossing or overlapping. It is equipped with an automatic wire cutting device to support the automatic cutting and processing of wire ends after winding is completed.

II. Process design requirements ‌

1. Winding process parameterization ‌ : Supports flexible setting of parameters such as the number of coil turns, winding speed, and winding tension to meet the winding requirements of stators of different specifications. Equipped with a process database, it can store the winding process parameters of various stators, enabling rapid model changing.

2. Mold and fixture design ‌ : Design dedicated winding molds for different stator models to ensure the shape and dimensional accuracy of the coils. The fixture should have a quick changeover function to reduce the changeover time.

3. wire processing technology ‌ : Integrates pre-treatment functions such as wire preheating, coating, and drying to enhance the insulation performance and winding quality of the wire. Supports special process requirements such as parallel winding of multiple strands of wire.

III. Requirements for the control system ‌

1. Industrial-grade PLC and motion control ‌ : High-performance PLC is adopted in combination with a multi-axis motion controller to achieve coordinated control of the winding mechanism, wire arrangement mechanism, and loading and unloading system. Support industrial bus protocols to ensure the high real-time performance and stability of the system.

2. Human-machine interface: Equipped with a touch screen operation terminal, it supports intuitive setting and monitoring of process parameters. It provides production data statistics and analysis functions, such as yield rate, production efficiency, etc.

3. Remote monitoring and maintenance ‌ : Supports remote monitoring and fault diagnosis of equipment via industrial Ethernet or 4G/5G networks. Integrate predictive maintenance functions to warn of equipment failures in advance through data analysis.

IV. Requirements for Auxiliary functions ‌

1. Safety protection design ‌ : Equipped with safety light curtains, emergency stop buttons and other safety devices, it complies with international safety standards such as CE and UL. A closed protective cover is adopted to prevent foreign objects from entering the interior of the equipment.

2. Environmental adaptability ‌ : The equipment must have dust-proof and anti-static functions to meet the environmental requirements of the motor production workshop. Support real-time monitoring and adjustment of environmental parameters such as temperature and humidity.

3. Modularization and scalability ‌ : A modular design is adopted, facilitating the upgrade and maintenance of the equipment. Reserve interfaces to support the expansion of future functions (such as automatic rubber coating, varnish impregnation, etc.).

V. Key Technical indicators ‌

1. Winding accuracy ‌ : the error of the number of coil turns is ≤±1 turn, and the deviation of the wire diameter is ≤±0.01mm.

2. Production efficiency ‌ : The winding speed of a single station can reach 1000-3000 revolutions per minute, and the efficiency of multi-station equipment can be increased by 3-5 times.

4. Equipment stability ‌ : MTBF (Mean Time Between Failures) ≥5000 hours.

5. Mold change time ‌ : ≤15 minutes (including mold change and process parameter adjustment).
 

In conclusion, through the above configuration and design, the motor stator winding machine can achieve full-process automated production from stator core feeding to finished product offline, significantly improving production efficiency and product quality, while reducing labor costs and defect rates.