What are the criteria for choosing a brushless motor stator winding machine?

The winding of the stator of a brushless motor is a very important process. The quality and speed of the winding will affect the production situation of the manufacturer. Therefore, choosing a winding machine and the manufacturer becomes much more crucial. So, what are the criteria for selecting a brushless motor stator winding machine? How to measure the price and quality requirements? Let NOYU introduce it briefly for you!
 

 

I. Selection Criteria 
Stator parameter compatibility 
Slot direction: For stators with inward-facing slots, choose needle-type inner winding machines (such as four-position or six-position inner winding machines) to ensure the accuracy of the wiring; for stators with outward-facing slots, fly-screw outer winding machines are suitable, with lower costs and higher efficiency. 
Outer diameter and inner diameter: Small stators (10-70mm) can be selected with multi-station equipment (such as four-station), while large stators (>120mm) require single-station equipment or custom models to avoid insufficient winding space. 
Stack thickness (height): If the stack thickness exceeds 70mm, custom equipment is required to prevent excessive swing from causing thread breakage; if it exceeds 150mm, non-standard customization is necessary, as ordinary equipment cannot meet the requirements. 
Number of slots and slot spacing: If the number of slots is large and the slot spacing is small (e.g. < 0.5mm), high-precision equipment (with an error of ≤ ±0.01mm) is required to avoid scratching the wire. 
2. Wire diameter and winding method 
Wire diameter range: For fine wires (less than 0.1mm), precise tension control is required and the speed can be appropriately increased; for thick wires (more than 0.8mm), the speed should be reduced and the tension increased to ensure the tightness of the coil. 
Multi-line winding: Requires synchronous winding function and complex wiring system to prevent wire entanglement, suitable for high power density motors. 
Number of coil turns: When the number of turns is large, choose a high-speed multi-station external winding machine (such as a six-station machine) to improve efficiency; when the number of turns is small but high precision is required, select a precise single-station equipment. 
3. Equipment Performance and Configuration 
Core components: Preferentially select professional servo motors, precise guide rails, and high-stiffness screws to ensure the stability and lifespan of the equipment. 
Control system: Utilizes PLC or touch screen to preset parameters, supports multi-station collaborative control, and enhances the level of automation. 
Winding system: Equipped with high-precision tensioners and steel needles, etc., to ensure the flatness of the winding ≤ 0.05mm, avoiding broken or damaged wires. 
Mold accuracy: The mold error should be controlled within ±0.01mm, and its wear resistance and hardness must meet the requirements for long-term use. 
4. Production Efficiency and Flexibility 
Number of workstations: The more workstations there are (for example, six workstations), the higher the production efficiency will be, but the cost will also increase accordingly; it needs to be balanced based on the production volume requirements. 
Customization capability for non-standard products: For special-shaped slots or extremely thick and high-dense stators, select manufacturers with non-standard design capabilities to ensure the equipment's compatibility. 
Parameter flexibility: Supports rapid adjustment of parameters such as winding speed and tension through the control system, meeting the production needs of multiple varieties. 
5. After-sales Service and Technical Support 
Response time: Choose manufacturers that offer 24-hour response and on-site repair within 48 hours to minimize downtime losses. 
Training and Maintenance: The manufacturer is required to provide operation training, regular maintenance (such as cleaning and lubrication of key components) and spare parts supply services. 
Industry reputation: Prioritize choosing manufacturers with good market reputation and a rich case history to reduce the risk of equipment failures. 
II. Methods for Measuring Price and Quality 
Price range 
Standard equipment: The flywheel external wrapping machine costs around 40,000 to 80,000 yuan. It is suitable for small-scale production or applications with low precision requirements. 
High-end equipment: The price of the needle-type inner winding machine ranges from 100,000 to 150,000 yuan. Especially the six-station or eight-station high-speed inner winding machines are suitable for large-scale or high-precision production. 
Customized equipment: The price of non-standard customized models needs to be negotiated based on specific requirements. Generally, it is 20% to 50% higher than that of standard models. 
2. Quality Evaluation Dimension 
Wire winding accuracy: Check the accuracy of the coil turns, wiring precision, and the flatness of the wire arrangement. The error should be controlled within ±0.05mm. 
Equipment stability: Verified through no-load operation tests (to observe speed stability and bearing heat conditions) and long-term operation tests (lasting for more than 8 hours). 
Applicability: Confirm whether the equipment supports the winding of multiple specifications of stator windings, and whether the mold replacement is convenient (such as with a quick-change structure). 
Maintenance cost: Assess the replacement frequency and cost of vulnerable components (such as tensioners and steel needles), and prioritize the selection of modular design equipment to reduce long-term costs. 
3. Cost-performance Optimization Strategy 
Clarify requirements: Determine the type of equipment (such as single station vs. multi-station) based on production scale, product specifications, and precision requirements. 
Comparison of configurations: Within the same price range, prefer to choose equipment with better brands for core components such as servo motors and guide rails. 
Reference case: Request application cases from the manufacturer in the same industry, and conduct on-site inspections to evaluate the equipment performance and collect user feedback. 
Negotiation skills: Utilize competition among multiple manufacturers' quotations. 
 

What are the criteria for choosing a brushless motor stator winding machine? How to measure the relationship between price and quality requirements? The above has provided a brief explanation. We hope these knowledge can be helpful to everyone!