Motor Winding Machine Selection Guide: Tailored for Different Winding Methods

The winding pattern of a stator significantly influences an electric motor's performance, efficiency, and reliability. Parallel, helical, and cross-winding are common patterns. To achieve the best motor performance and production rates, motor winding machines must be tailored to these specific patterns. Following HONEST to explore these things.

1.?Parallel?Wire?Arrangement

Arrange the wires neatly in the stator slots so that the wires of each turn of the coil are parallel to each other. First, the winding uniformity must be ensured. This feature makes the magnetic field distribution more uniform, greatly reducing the fluctuation of the magnetic field, and reducing the noise and vibration of the motor. Secondly, the parallel wires should have a certain gap to facilitate air circulation, effectively improve the heat dissipation effect, and extend the service life of the motor. Equipment requirements:

(1) High precision: It is required to be equipped with precision guide rails, ball screws, and high-precision sensors to accurately control the position and spacing of the wire arrangement.

(2)?Tension?control:?It?can?be?equipped?with?an?automatic?tension?control?system,?which?can?automatically?adjust?the?tension?according?to?the?wire?material,?wire?diameter,?and?winding?speed?to?ensure?that?the?tension?is?always?within?the?appropriate?range.

(3)?Wire?arrangement?speed:?It?should?be?adjustable?and?able?to?maintain?stable?operation?at?low?speed.?At?the?same?time,?the?main?shaft?speed?of?the?winding?machine?should?match?the?wire?arrangement?speed?to?ensure?the?uniformity?of?the?winding.

2.?Helical?Winding

The?wire?is?wound?in?a?helical?shape?in?the?stator?slot.?This winding method can not only wind more coils in a limited space, increasing the output power of the motor, but also make the spiral winding structure make the coils more compact, and the mutual support between the wires enhances the overall mechanical strength of the coils, which can better withstand various forces during the operation of the motor. Equipment?requirements:

(1) High-speed winding: Helical winding should usually be equipped with a high-power motor and a high-speed spindle to complete a large number of winding tasks in a short time. At the same time, the winding mechanism in the winding machine should be able to adapt to the requirements of high-speed winding to ensure that the wire will not be loose or poorly wound.

(2)?Space?adaptability:?A?winding?machine?with?a?small?size?and?compact?structure?can?be?selected?to?operate?in?a?small?space.

(3)?Automation?level:?Helical?winding?usually?requires?a?high?degree?of?automation?to?improve?overall?production?efficiency.

3.?Cross Wiring

Arrange the wires in the stator slots in a cross-shaped manner. It can make the magnetic field more evenly distributed in the stator, reduce the local concentration of the magnetic field, and improve the efficiency and performance of the motor. It can effectively reduce the electromagnetic coupling between coils and improve the electromagnetic compatibility of the motor. Equipment requirements:

(1) Complex wire arrangement control: Cross-wiring requires complex wire arrangement control to achieve cross-wiring arrangement of wires. It should be equipped with a programmable controller PLC or industrial computer that can implement complex wire arrangement algorithms and motion control.

(2)?Tension?uniformity:?To?ensure?the?uniformity?of?wire?tension?at?the?intersection?to?prevent?wire?breakage?or?loosening,?a?winding?machine?equipped?with?a?tension?compensation?device?can?be?selected.

(3) Compatibility: Since cross-wiring is more complicated, the winding machine should have good compatibility and be able to adapt to motor stators of different specifications and models. It should also have adjustable parameters and universal fixtures to facilitate rapid switching between different production tasks.

Whether it is parallel wiring, helical wiring, or cross-wiring, they all have their advantages in the motor stator. When choosing motor winding machines, it is necessary to comprehensively consider factors such as accuracy, space, adaptability, degree of automation, wiring control, and compatibility of the winding equipment.

HONEST Intelligent has focused on motor winding and assembly equipment for over 18 years. We provide high-precision winding machines. The equipment is suitable for the fields of automotive motor production, new energy vehicles, rail transit, aviation, home appliances, industries, etc. Consult now to get a free quote and customized scheme.