How do multi-head winding machines work, and what is the winding process

As the name suggests, a winding machine is used for winding—that is, winding wire products around a fixed object. However, in this context, we are primarily referring to the winding of stator and rotor products, with enamelled wire being the main material used.

The working principle of a winding machine is closely linked to the winding process. Once a stator or rotor winding diagram is available, a corresponding winding programme is created. After this is imported into the PLC system, control can be initiated. Once commissioning is complete, the process becomes fully automated: upon pressing the start button, the wire guide begins to operate, feeding the wire according to the winding programme. External winding machines typically employ a flying fork winding method, whilst internal winding machines generally use an up-and-down winding method. The entire process is completed automatically; should any issues arise during operation, the machine can be paused, and the speed can be adjusted within permissible limits. This is primarily manifested in three aspects: automatic wire feeding, automatic winding and automatic indexing. Once the winding is complete, the machine automatically cuts the wire, after which the product can be removed and the next stator product loaded. If other products need to be processed, the mould is removed and replaced with the appropriate one. By repeating this process, an assembly line model is established, enabling the mass production of stators and rotors.

With the continuous development and advancement of science and technology, coupled with expanding industrial demand, traditional winding methods can no longer meet the requirements for stator and rotor winding and are gradually being replaced. New fully automatic winding machines are now sweeping the market and are progressively being applied across various industries. Examples include: model aircraft motors, self-balancing scooter motors, electric scooter motors, new energy vehicle motors, rotary transformers, fan stators, twist-and-go scooter motors, cooling fan stators, crop protection machinery, and various types of externally wound stators; or brushless motor winding for power tools, water pumps, stepper motors, vacuum cleaner motors, barrier gates, and winches.

It is evident that winding machines have a very wide range of applications and are suitable for many industries. However, in order to meet further demands and facilitate mass production, winding machines still require continuous improvement and development. We are confident that in the future, winding machines will become even more powerful!