How does a brushless fan stator winding machine achieve winding automation?

The brushless fan stator winding machine, as a key equipment in modern motor manufacturing, has successfully achieved the automation of the winding process with its precise mechanical structure, advanced control system and intelligent software algorithm. This not only enhances production efficiency but also provides a solid guarantee for the quality and stability of the products. Next, Nuoyuan will conduct an in-depth analysis of the fan stator winding equipment from three aspects: implementation methods, core functions, and main features.
 

I. Ways to Achieve Winding Automation

1. Mechanical structure automation ‌ : The brushless fan stator winding machine adopts multi-axis linkage control technology. Through the servo motor driving the X, Y, and Z axes to work in coordination, and in combination with the rotating main shaft, it can accurately draw the winding trajectory in three-dimensional space. For instance, the needle-type internal winding machine is an outstanding representative of this technology. It uses a servo motor to drive the needle rod to move at high speed, while the mold moves left and right, accurately winding the enameled wire into the stator slot. In addition, the modular fixture design adds great flexibility to the equipment, allowing for quick replacement to adapt to different stator models and significantly reducing the changeover time.

2. Intelligent control system ‌ : The integration of PLC and servo drive enables real-time adjustment of winding parameters such as speed, tension, and number of turns, ensuring the consistency and stability of the winding process. The introduction of the human-machine interface (HMI) has made the operation simpler and more intuitive, supporting multiple functions such as parameter setting, program invocation, and fault diagnosis, providing convenience for operators.

3. Software algorithm optimization ‌ : The built-in intelligent wiring algorithm can automatically generate winding paths based on parameters such as the number of stator slots and wire diameter, effectively avoiding problems such as skipped wires and broken wires. Meanwhile, the application of the closed-loop tension control system enables real-time monitoring and adjustment of the tension of the enameled wire, ensuring the tightness of the winding and the integrity of the wire material.

Ii. Core Functions of Brushless Fan Stator Winding Machine

1. Youdaoplaceholder0 Automatic winding and wire arrangement ‌ : The brushless fan stator winding machine can automatically feed, wind, cut and arrange enameled wires. The entire process does not require manual intervention, greatly improving production efficiency.

2. Multi-station parallel operation ‌ : Supports simultaneous operation of two or more stations. For instance, a dual-station flyfork winding machine can handle two stators at the same time, further shortening the production cycle and enhancing production capacity.

3. Parametric programming ‌ : The equipment can store multiple winding programs. By calling preset parameters, different stator production models can be quickly switched, perfectly meeting the production requirements of multiple varieties and small batches.

4. Real-time monitoring and fault diagnosis ‌ : Equipped with sensors to monitor the winding status in real time. Once problems such as abnormal tension or broken wires are detected, the equipment will automatically shut down and sound an alarm, effectively reducing the scrap rate.

Iii. Main Features of Brushless Fan Stator Winding Machine

Youdaoplaceholder0 1. High accuracy ‌ : By using high-accuracy servo motors and guide rails, the winding accuracy can reach ±0.01mm, ensuring the uniformity and consistency of the stator winding and providing a solid guarantee for the performance and quality of the product.

2. High efficiency ‌ : The winding speed can reach over 1000 revolutions per minute. Combined with a multi-station design, the production efficiency is increased by more than 10 times compared to traditional manual winding, enhancing the economic benefits for enterprises.

3. Strong compatibility ‌ : It can be adapted to brushless fan stators of different wire diameters (0.05mm-1.5mm) and different slot numbers, and is widely used in household appliances, power tools, new energy vehicles and other fields, demonstrating strong market adaptability.

4. High stability ‌ : Key components are made of imported brands, ensuring the long-term stable operation of the equipment, reducing maintenance costs, and saving precious time and resources for the enterprise.

5. Easy operation ‌ : The human-machine interface is friendly and intuitive. Operators can start operating after simple training, reducing the reliance on skilled workers and improving the overall operational efficiency of the enterprise.
 

In conclusion, the brushless fan stator winding machine, with its outstanding performance and broad application prospects, has become an indispensable important equipment in modern manufacturing. We believe that in the future development, it will continue to play a greater role and contribute to the transformation and upgrading as well as high-quality development of enterprises.