What are the winding difficulties of brushless motor stator winder?

In the manufacturing process of brushless motor, stator winding is a crucial link, however, the winding process often encounter some difficulties, these difficulties may be from the equipment configuration, operation technology, material characteristics and other aspects. The following Nuoyuan will analyze these difficulties in detail, and put forward the corresponding solutions, in order to improve the quality of winding and production efficiency, I hope to help you!
 

1. Analysis of winding difficulties

‌1. Cable routing ‌

Difficulty: the wiring is not tight, bloated, can not achieve precision wiring.

Cause: The equipment configuration of the winding machine is low or the debugging is not in place, resulting in poor wiring effect.

2.‌ multiple lines and round ‌

Difficulty: When the line diameter is thick, it is difficult to achieve multiple lines and winding.

Reason: limited by space, and easily lead to uneven tension between wires, thus affecting the quality of winding.

‌3. Injury line ‌

Difficulty: It is easy to hurt the line when winding the thick wire.

Reason: the diameter of the thick line is large, the friction is large when winding, and it is easy to wear or break.

‌4. Disconnection ‌

Difficulty: Easy to break when winding thin wire.

Reason: thin wire diameter is small, winding speed is easy to break due to excessive tension.

‌5. Device stability ‌

Difficulty: Unstable operation of the machine, resulting in reduced winding quality.

Cause: Aging, wear, or improper configuration of the device affects the winding accuracy and stability.

‌6. Mold and stator frame problem ‌

Difficulty: Mold and stator frame processing does not meet the requirements, resulting in wire scraping, firing needle and other problems during winding.

Reason: mold and stator frame processing accuracy is not enough or installation positioning is not accurate.

Second, the solution

1.‌ Improve device configuration and commissioning ‌

The use of better configuration of wire winder equipment, such as high accuracy wire winder, to improve wire accuracy and efficiency.

Professional debugging of the equipment to ensure that the wiring is neat and tight to meet the production requirements.

‌2. Optimize multiple lines and wrap the technique ‌

Select the appropriate number of parallel winding according to the wire diameter to avoid the problem of multiple parallel winding caused by too thick wire diameter.

Adopt advanced winding process and technology, such as multi-station winding machine, to improve winding efficiency and accuracy.

‌3. Injury prevention ‌

Special treatment of thick lines, such as the use of wear-resistant materials or increased lubrication, to reduce the friction when winding.

Adjust the machine to ensure that the tension is moderate during the winding process to avoid excessive wear and tear.

‌4. Prevent disconnection ‌

Reduce winding speed when winding thin wire to reduce excessive tension.

Check and maintain the equipment regularly to ensure that the parts such as the wire wheel and the wire nozzle are free of foreign substances and maintain a smooth winding environment.

‌5. Improve device stability ‌

Regular maintenance and maintenance of the equipment to ensure that the equipment is in good condition.

Using advanced control system and sensor technology, real-time monitoring of equipment operating status, timely discovery and solution of problems.

‌6. Ensure mold and stator frame quality ‌

The mold and stator frame are produced in strict accordance with the drawings to ensure the machining accuracy and installation positioning.
 

The mold and stator frame are polished and polished to avoid problems such as wire scraping and firing needle, and improve the quality of wire winding and production efficiency.
To sum up, there are many difficulties in the winding process of the brushless motor stator winding machine. However, by improving the equipment configuration, optimizing the winding process, preventing wire damage and breakage, improving the stability of the equipment, and ensuring the quality of the mold and stator frame, we can effectively solve these problems and improve the winding quality and production efficiency. This will provide a better guarantee for the manufacture of brushless motors and help the sustainable development of the motor manufacturing industry.