What are the working processes of the fully automatic brushless stator winding machine?

The fully automatic brushless motor stator winding machine is mainly used for stator winding work. Its working processes all have standards. So, what are the working processes of the fully automatic brushless stator winding machine? How can the winding process be optimized? Now, Nuoyuan will give you a brief introduction!
 

I. Core Workflow

Youdaoplaceholder0 1. Stator positioning and mold installation ‌

Fix the stator of the motor to ensure stability. Select and install the winding die according to the specifications.

Youdaoplaceholder0 2. Parameter configuration and program invocation ‌

Input key parameters such as wire diameter, winding speed and tension. Call the preset program to adapt to the production of multiple models.
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3. Winding startup and process control ‌

The electric main drive unit rotates the turntable. The winding head guides the wire to the stator slot, and the clamping device fixes and cuts the wire tail. Adjust the tension between the wires in real time to avoid wire breakage or loose wiring.

Youdaoplaceholder0 4. Automatic shutdown and quality inspection ‌

It will automatically stop when the preset number of turns is reached. Sensor monitoring parameters, combined with electrical tests, ensure the performance of the windings.

Ii. Optimization Strategies for Winding Process
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1. Equipment selection and maintenance ‌

Select high-precision equipment to enhance the accuracy of winding actions and the lifespan of the equipment. Establish a maintenance database, predict faults and replace worn parts.

Youdaoplaceholder0 2. Dynamic parameter adjustment ‌

Adjust the tension in real time according to the wire specifications. When the wire diameter is thick or multiple strands are wound in parallel, reduce the speed to minimize the risk of wire loss and breakage.

Youdaoplaceholder0 3. Improvement in cable layout accuracy ‌

Introduce machine vision technology to achieve tight wiring. Adopting 3D printed molds shortens the development cycle and reduces costs.

Youdaoplaceholder0 4. Intelligent and automated upgrade ‌

The intelligent parameter setting system automatically generates winding schemes and optimizes historical data. Remote monitoring and fault early warning, rapid response to abnormal situations.

Youdaoplaceholder0 5. Process flow innovation ‌

The wear-resistant enhancement process reduces wear during winding. Multi-wire parallel winding solution, balancing efficiency and quality.
 

The fully automatic brushless stator winding machine achieves efficient and stable winding production through precise positioning, dynamic parameter control and intelligent technology. Optimizing the process requires the coordinated advancement of four aspects: equipment precision, parameter adjustment, wire arrangement technology upgrade, and intelligent management. By formulating targeted plans in combination with specific application scenarios, the winding quality and production efficiency can be significantly improved.