To achieve high-volume winding on both internal and external winding machines while ensuring winding quality and stability, it is essential to systematically identify key influencing factors and implement targeted measures.
I. Internal Winding Machines: Focus on Stator Adaptation and Precise Process Control
The core to enhancing winding efficiency on internal winding machines lies in “stator characteristic matching” and “precise control of process parameters.” This requires a layered approach across three dimensions: stator adaptation, process optimization, and equipment configuration:
1. Precise Control of Stator Characteristics
As the fundamental carrier for winding, stator characteristics directly determine winding smoothness and quality:
Stator Slot Orientation: Internal winding machines are specifically designed for stator slots facing inward. This structural feature ensures smooth wire insertion into stator slots and uniform slot filling, preventing wire jamming or uneven filling caused by mismatched slot orientations.
Stator dimensional accuracy: Both the outer and inner diameters of the stator must be strictly controlled within preset tolerances to guarantee precise mechanical compatibility with standard winding equipment. For non-standard stator dimensions, custom equipment must be procured in advance to prevent winding misalignment, efficiency loss, and other issues caused by dimensional deviations.
Stacking Thickness and Slot Pitch: Precise control of stator stacking thickness must be achieved through process means (e.g., precision press-fitting), while ensuring consistent slot pitch. These parameters directly impact winding threading accuracy and are critical prerequisites for reducing winding deviations and enhancing overall efficiency.
2. Optimizing and Upgrading Winding Processes
Process optimization is central to improving the operational yield of internal winding machines, requiring enhancements across four dimensions: workflow, control, tension, and automation.
Workflow Simplification and Efficiency Enhancement: Streamline existing winding operations by eliminating redundant steps (e.g., repeated positioning, manual verification) to reduce cycle time per winding. Standardize operational procedures to minimize human error caused by complex processes.
Advanced Control System Integration: Implement a solution deeply integrating PLC motion controllers with servo systems to achieve precise regulation of winding trajectories, rotational speeds, and start/stop timing. This reduces mechanical motion deviations and ensures consistent wire positioning for each winding layer.
Dynamic Wire Tension Management: Equipped with tension sensors and a closed-loop control system, this feature continuously monitors wire tension changes and dynamically adjusts feed force. This prevents both excessive tension causing wire stretching/deformation and insufficient tension leading to wire loosening, ensuring winding process stability.
Automation Implementation: Features include touchscreen visual programming (simplifying parameter setup) and automatic corner wrapping (replacing manual operations), reducing manual intervention. This not only lowers operator workload but also shortens production cycles, making it particularly suitable for batch production scenarios.
3. Ensuring Equipment Configuration Stability
Hardware forms the foundational support for high-volume winding. This requires attention to both component selection and condition monitoring:
Core Component Optimization: Prioritize industry-leading brands for critical parts like motors and transmission gears. This minimizes component failure rates at the source, safeguards long-term operational stability, and reduces downtime caused by part damage.
Real-Time Operational Monitoring: Install equipment condition monitoring modules to track core parameters like rotational speed, temperature, and load in real time. Upon detecting anomalies (e.g., excessive temperature or speed fluctuations), the system issues immediate alerts, enabling operators to proactively address potential faults while maintaining production efficiency.
II. External Winding Machines: Emphasizing Structural Compatibility and Technical Application, Strengthening Maintenance Management
Unlike internal winding machines, external winding machines with high-pin winding focus more on “stator structure alignment” and “core technology application.” Simultaneously, standardized maintenance is required to extend the stable operation cycle of the equipment:
1. Stator Compatibility and Winding Technology Core
External winding machines primarily serve stator structures with external rotors (slots facing outward), demanding critical attention to adaptability and technical precision:
Precise Stator Structural Alignment: During model selection, match the specific stator shape (e.g., circular, irregular) and dimensional parameters (outer diameter, number of slots) with the corresponding external winding machine model. This ensures mechanical alignment accuracy between the winding mechanism and stator, preventing wire displacement caused by improper adaptation.
Application of Flying-Fork Winding Technology: Core implementation utilizes flying-fork winding technology. Pre-programmed settings for fork trajectory, rotational speed, and wire spacing achieve precise wire arrangement. For multi-slot stators, optimized programming prevents fork movement interference, ensuring uniform winding quality.
2. Standardized Equipment Maintenance Management
Sustained high-performance operation of external winding machines requires standardized maintenance protocols: Establish standardized periodic maintenance procedures covering:
- Cleaning of equipment surfaces and internal components (removing wire debris and dust)
- Lubrication of critical transmission points (e.g., flying shuttle shafts, wire feed rollers) using specialized lubricants to prevent wear
- Performance inspections of core components (e.g., sensors, motors) Timely replacement of aged components (e.g., seals, drive belts) ensures the equipment remains in optimal operating condition, preventing unexpected failures that could disrupt production schedules.
III. Common Optimization Directions for Internal and External Winding Machines
Beyond equipment-specific differences, both internal and external winding machines require implementing shared measures in areas such as “intelligent operation, modular design, and user-friendly operation” to further enhance overall winding efficiency and stability:
1. Deep Upgrade in Intelligence and Automation
Promote the development and application of fully automated winding systems, integrating functions such as automatic material feeding (replacing manual stator placement), automatic wire arrangement, and automatic inspection (e.g., winding turn count verification, wire damage detection). Simultaneously introduce machine vision and AI image recognition technologies—machine vision enables automatic correction of stator positioning deviations, while AI image recognition performs real-time quality inspection of winding. The combination of these technologies enhances production efficiency and reduces defect rates.
2. Implementation of Modular Structural Design
Adopting a modular design philosophy, the winding machine's wire feeding, threading, tension control, and inspection functions are decomposed into independent modules. Each module can be individually upgraded (e.g., replacing with higher-precision tension control modules) or swapped (e.g., adapting threading modules for different stators). This enables rapid adaptation to various stator specifications and types without replacing the entire equipment, significantly reducing modification costs and adaptation cycles.
3. Continuous Enhancement of Operational Ease
Optimized human-machine interface design employs intuitive icon-based operation, simplifying parameter settings (e.g., winding turns, speed) and troubleshooting procedures. Detailed illustrated manuals and video tutorials (covering routine operations and common fault resolution) assist new operators in rapid proficiency. Voice interaction capabilities (e.g., voice-activated parameter settings, fault consultation) can be added in certain scenarios to further lower the operational threshold.
4. Strict Full-Process Hardware Quality Control
Core components (e.g., servo motors, PLCs, sensors) prioritize high-performance products from internationally renowned brands to ensure fundamental hardware reliability. Enhanced quality inspections during production and assembly (e.g., component installation precision checks, full-system trial runs) prevent operational deviations caused by assembly errors. Strict hardware quality control extends equipment lifespan and reduces long-term maintenance costs.
5. Comprehensive After-Sales Service and Maintenance System
A dedicated technical support team provides 24/7 online assistance (including remote troubleshooting and video-guided repairs) to promptly address production site needs. Emphasize “easy disassembly and assembly” in mechanical design (e.g., quick-release covers, standardized interfaces) to facilitate maintenance operations. Provide detailed maintenance manuals and repair video tutorials, while establishing rapid spare parts supply channels (e.g., regional spare parts warehouses) to minimize equipment downtime.
Achieving high-sales winding for both internal and external winding machines requires targeted breakthroughs based on equipment characteristics: internal winding machines focus on stator adaptation and precise process control, while external winding machines emphasize structural integration and flying crossbar technology application. Concurrently, common optimizations are implemented across intelligent features, modularity, operational convenience, hardware quality, and after-sales service. Only by comprehensively covering the entire core chain—“stator, process, equipment, and service”—can we effectively ensure winding process stability and efficiency, thereby achieving dual improvements in product quality and production efficiency.
